KSR-SK-DB
In-Line Splice Kit
KSR Snow Melting Cable
INSTALLATION PROCEDURES
KSR-SK-DB
The following installation procedures are suggested guidelines for
the installation of in-line cable splices. They are not intended to
preclude the use of other methods and good engineering or field
construction practices.
Receiving, Storing and Handling . . .
1. Inspect materials for damage incurred during shipping.
2. Report damages to the carrier for settlement.
3. Identify parts against the packing list to ensure the proper
type and quantity has been received.
4. Store in a dry location.
KSR-SK-DB In-Line Splice Kit
Kit Contents . . .
1
2
6 7
3
3
4
5
8
9
Installation Precautions . . .
• To minimize the potential for arcing and fire caused by product
damage or improper installation use ground-fault protection. The
National Electrical Code (NEC) and Canadian Electrical Code (CEC)
require ground-fault protection of equipment for each branch
circuit supplying electric heat tracing.
• Installation must comply with Thermon requirements and be installed in accordance with the NEC, CEC, or any other applicable
national and local codes.
• Power connections and end termination must be located in NEMA 4
or 4X enclosures (Thermon KSR-JB or UL Listed equivalent) located
above moisture line.
• De-energize all power sources before opening enclosure.
• Keep ends of heating cable and kit components dry before and
during installation.
• Do not locate the splice in an expansion joint area, where a bend
occurs in the cable, or within a conduit entering or exiting a slab.
• Do not splice cables that have different catalog numbers and/or
voltage ratings.
• Component approvals and performance rating are based on use
of Thermon specified parts only.
• The kit instructions should be used in conjunction with the
installation instruction for the heating cable and other accessary
items.
Canadian Standard Association
Certified Snow Melting Equipment
for Applications Having a Type
Designation of 2B
Underwriters Laboratories Inc.
5N23 De-Icing and Snow Melting
Equipment (KOBQ)
Item Quantity Description
1 1 Heat Shrink 28mm X 325mm (1.10” X 12.80”)
2 1 Heat Shrink 20mm X 120mm (.79” X 4.72”)
3 & 4 1
5 1 RTV Tube
6 2 Small Lug (14-16 AWG)
7 1 Large Lug (10-12AWG)
8 2 Power Connection Boot
9 1 Mastic Tape 25 mm X 150MM (.98” X 5.91”)
Heat Shrink 10mm X 125mm (.39” X 4.92”)
Cut heat shrink into 3 pieces per step 11
Tools Required . . .
2
In-Line Splice Instructions
76 mm
(3”)
INSTALLATION PROCEDURES
70mm
(2.75”)
1. Cut and remove heating cable overjacket as
shown.
Do not cut metallic braid.
40 mm
(1.57”)
4. Skive outside edges of primary insulation and
black matrix 40mm (1.57”) as shown.
Do not cut bus wire strands.
2. Separate braid strands at edge of overjacket and
pull cable through opening in braid.
5. Cut V-notch in matrix and pull wires from matrix.
3. Twist braid into a pigtail. Cut end of cable 70mm
(2.75”) as shown.
Do not cut braid.
6. Cut and remove remaining center core of matrix.
7. Apply a liberal amount of RTV sealant to cable.
9.5 mm
(.38”)
8. Slide boot onto the end of the cable.
3
Ground Braid
Boot
9. Crimp small lugs on end of bus wires.
Small Lug
KSR-SR-DB
Ground Braid
Heat Shrink 2
20mm x 120mm
(.79” X 4.72”)
Heat Shrink 1
28mm X 325mm
(1.10 X 12.80”)
Small Lug
Boot
Cable
10. Slide heat shrink 1 28mm x 325mm (1.10” x 12.80”)
then heat shrink 2 20mm x 120mm (.79” X 4.72”)
onto cable as shown.
Heat Shrink 3
Heat Shrink 2
Heat Shrink 3
10mm X 35mm
(.39” X 1.38”)
Heat Shrink 1
11. Cut 10mm X 125mm (.39” X 5”) into 3 pieces : 3 2
pieces @ 35mm (1.38”) 4 1 piece @ 55mm (2.16”).
Slide heat shrink 3 10mm X 35mm (.39” X 1.38”) over
small lugs on each splice connection boot legs.
Heat Shrink 3
Heat Shrink 2
Mastic Tape
Heat Shrink 3
Small Lug
Crimped
12. Repeat steps 1-8 for second cable to be spliced.
Crimp the small lugs to the second cable.
Heat Shrink 2
13. Center heat shrink 3 over crimped small lugs. Using
heat gun, heat until heat shrinks firmly set.
Heat Shrink 2
Large Lug
Heat Shrink 4
10mm x 55mm
(.39” X 2.17”)
16. Crimp large lug on one of the braid as shown. Slide
heat shrink 4 over the braid with large lug.
Heat Shrink 1
14. Cut 2 pieces of mastic tape about 25mm (1”) long.
Stretch mastic tape to cover the end of each splice
connection boot and cable primary insulation jacket
up to metallic braid.
Heat Shrink 4
17. Crimp large lug to the end of the other braid.
15. Center shrink 2 over splice connection area. Using
heat gun, heat until heat shrink firmly sets.
Heat Shrink 4
18. Center heat shrink 4 over crimped lug. Using heat
gun, heat until heat shrink firmly sets.
4
Mastic Tape
Heat Shrink 1
Heat Shrink 1
19. Cut two pieces of mastic tape about 25mm (1”) long.
Stretch mastic tape to cover the yellow cable jacket
on each cable.
20. Center heat shrink 1 over the splice connection area.
Using heat gun, heat until heat shrink firmly sets.
21. Completed splice.
5
10
20
30
40
INSTALLATION PROCEDURES
Cable Take-Off
mm
0
inches
0
1
50
60
70
80
90
100
110
120
130
140
150
2
3
4
5
6
160
170
180
190
For In-Line Splice
THERMON . . . The Heat Tracing Specialists
100 Thermon Dr. • PO Box 609 • San Marcos, TX 78667-0609
Phone: 512-396-5801 • Facsimile: 512-396-3627 • 1-800-820-HEAT
www.thermon.com In Canada call 1-800-563-8461
®
6
7
Form 50252-0707
Specifications and information are subject to change without notice.
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