¤ JBS-100-A, A6 Single Entry Power Connection with Junction Box Installation Instructions Description The JBS-100-A is a NEMA 4X rated power connection kit. It is designed ® for use with Raychem BTV-CR, BTV-CT, QTVR-CT, XTV-CT, KTV-CT and VPL-CT industrial parallel heating cables. The JBS-100-A6 utilizes larger terminal blocks to accommodate up to 6AWG power wires. This kit may be installed at temperatures as low as –40°F (–40°C). For easier installation store above freezing until just before installation. For technical support call Tyco Thermal Controls at (800) 545-6258. Tools Required • Wire cutters • Pliers or adjustable wrench • Utility knife • 1/4" or smaller flat-blade screwdriver • Needle nose pliers • Large slotted screwdriver • Marker • Wire stripper (for VPL-CT) Additional Materials Required Approvals • Pipe strap • GT-66 or GS-54 glass cloth tape Hazardous Locations Class I, Div. 2, Groups A, B, C, D Optional Materials (1) CLI, ZN1, AEx e II* Class II, Div. 1 and 2, Groups E, F, G • Recommended conduit drain: JB-DRAIN-PLUG-3/4IN P/N 278621-000 Class III Ex e ll T* • Small pipe adapter for 1" (25 mm) and smaller pipes: Temp Code* Catalog number JBS-SPA P/N E90515-000 (1) Except VPL *For system Temperature Code, see heating cable or design documentation. Kit Contents Item Qty Description A1 Stand A B1 Core sealer G C1 Green/yellow tube D1 Cable lubricant B E1 Cable tie F1 Lid F G1 Box with terminal block C E D WARNING: CAUTION: This component is an electrical device that must be • Component approvals and performance are based Health Hazard: Prolonged or repeated contact with the installed correctly to ensure proper operation and to on the use of Tyco Thermal Controls -specified sealant in the core sealer may cause skin irritation. prevent shock or fire. Read these important warnings parts only. Do not use substitute parts or vinyl Wash hands thoroughly. Overheating or burning the and carefully follow all of the installation instructions. electrical tape. sealant will produce fumes that may cause polymer fume fever. Avoid contamination of cigarettes or •To minimize the danger of fire from sustained • The black heating cable core and fibers are tobacco. Consult MSDS RAY5510 for further electrical arcing if the heating cable is damaged or conductive and can short. They must be properly information. improperly installed, and to comply with the insulated and kept dry. CHEMTREC 24-hour emergency telephone: requirements of Tyco Thermal Controls, agency • Damaged bus wires can overheat or short. Do not break certifications, and national electrical codes, (800) 424-9300. bus wire strands when scoring the jacket or core. ground-fault equipment protection must be used. Non-emergency health and safety information: Arcing may not be stopped by conventional circuit • Keep components and heating cable ends dry (800) 545-6258. breakers. before and during installation. • Use only fire-resistant insulation materials, such as fiberglass wrap and flame-retardant foam. 2 JBS-100-A, A6 Installation Instructions Heating cable types Outer jacket Outer jacket Braid Outer Braid jacket Inner jacket Braid Heating element Inner jacket Inner jacket Conductive fiber Bus wire connection Clear jacket Conductive core Spacer Insulated bus wire Bus wire Bus wire BTV-CR, BTV-CT, QTVR-CT XTV-CT, KTV-CT VPL-CT 1 2 • Optional: If stand is to be • Allow approximately installed on bottom side of pipe, 24" (60 cm) of heating knock out drain hole prior to cable for installation. For inserting cable. VPL, cut cable 12" (30 cm) 18" •With label on stand facing from bus indentation. (45 cm) desired direction of box opening, • Cut off heating cable end push 18" (45 cm) of heating at about 45° for easier cable through stand. Use cable insertion. 12" lubricant if needed. (30 cm) Indentation (bus wire • Square off cable end with connection on VPL 90° cut. Label on stand heating cables only). indicates Drain hole direction of box opening. • Do not attach stand to pipe until step 12. 3 4 • Lightly score outer jacket around and down as shown. • Bend heating cable to break jacket at score, then peel off jacket. BTV and QTVR Go to Step 5a Do not cut braid. XTV and KTV Go to Step 5b 7 1/2" (190 mm) Go to Step 5c VPL mm 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 inches 1 2 3 4 5 6 7 3 JBS-100-A, A6 Installation Instructions 5a 5b BTV and QTVR XTV and KTV • Push braid back to create a pucker. • Push braid back to create a pucker. • At pucker use a screwdriver to • At pucker use a screwdriver to open braid. open braid. • Bend heating cable and work it • Bend heating cable and work it through opening in braid. through opening in braid. • Lightly score inner 6 1/2" (165 mm) jacket around and • Lightly score inner down as shown. jacket around and down as shown. 6 1/2" (165 mm) • Peel off inner jacket. • Peel off inner jacket. • Notch core. 1/4" (5 mm) • Peel bus wire from core. • Cut and remove all fiber strands. • Score and remove center spacer. • Score core between bus wires at inner jacket. • Remove any remaining • Bend and snap core. fiber material from bus wires. • Pull braid tight to • Peel core from bus wire. make pigtail. • Remove any remaining core material from bus wires. • Pull braid tight to make pigtail. Go to Step 6 Go to Step 6 mm 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 inches 1 2 3 4 5 6 7 4 JBS-100-A, A6 Installation Instructions 5c VPL • Push braid back and bunch as tight as possible. 6" • Lightly score inner (152 mm) jacket around and down as shown. • Peel off inner jacket. • Unwind heating element, cut and remove as shown. 6" • Lightly score clear (152 mm) jacket around and down as shown. • Bend heating cable to break jacket at the score then peel off jacket. • Push braid forward. Use a screwdriver to open braid as shown. • Bend heating cable and work it through opening in braid. • Remove insulation from ends of bus wires. • Pull braid tight to make pigtail. 1/2" Go to Step 6 (13 mm) mm 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 inches 1 2 3 4 5 6 7 5 JBS-100-A, A6 Installation Instructions 6 7 • Mark the jacket CAUTION: Health Hazard. as shown. Wash hands after contact with sealant. Consult material safety data sheet RAY5510. • If needed, re-twist and straighten bus wires, then insert into the guide tubes as shown. 5/8" (15 mm) Make sure all strands go into the tubes. Tubes 8 9 • Push core sealer onto • Remove the guide tubes and the heating cable to the dispose of them in a plastic bag. mark made in step 6. Note: Extra force may be required for larger cables or at lower temperatures. Make sure the bus wires do not kink, bunch, or crossover. 10 11 • Pull heating cable back into stand so 1" (25 mm) is • Slip the green/yellow tube onto the braid. exposed as shown. Use cable lubricant if needed. Heat-shrinking is not required. •Trim bus wires and braid. 1/2" (13 mm) 1/2" 1" (25 mm) (13 mm) mm 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 inches 1 2 3 4 5 6 7 6 JBS-100-A, A6 Installation Instructions 12 • Fasten stand to pipe with Note: For 1" (25 mm) label facing desired direction and smaller pipes use of box opening. Do not pinch adapter (purchased heating cable. separately) and install • Loop and tape extra heating between stand and pipe. cable to pipe. 1" (25 mm) JBS-SPA adapter for Position small pipes adapter this side Glass cloth tape up. Pipe strap (Optional) To change direction of box opening: 13 14 • Screw box onto stand until it stops. Do not overtighten. • Loosen locknut. • Lift box and rotate. Make sure tab on threaded piece fits into one of the four notches in box. •Tighten locknut. Notch 15 • Insert cable tie through slots on stand and box, and tighten firmly to prevent box rotation. Trim 7 JBS-100-A, A6 Installation Instructions 16 This kit uses spring clamp style terminals. Terminals use a steel spring to clamp the wire to provide improved vibration resistance, reduced maintenance and faster installation. To connect wires, firmly insert a slotted screwdriver into the square 1 hole ( ) to open the spring. When fully inserted, the screwdriver will lock into place, allowing you to remove your hand and insert the wire 2 into the round hole ( ). Remove the screwdriver to clamp the wire. 1 The wire is held securely against the bus bar for low contact resistance over time without the need to periodically retighten screws. 2 Wire Screwdriver slot Wire hole • Push screwdriver FIRMLY into square hole. • Insert wire into round hole. • Use green terminal for braid and ground wire. •Remove screwdriver. 8 JBS-100-A, A6 Installation Instructions 17 • Install conduit and fittings as 3/4" locknut shown. To minimize loosening Make sure due to pipe vibration, use flexible Water tight conductors are conduit. conduit seal not exposed. • Pull in power and ground wires, strip off 1/2" (13 mm) of insulation and terminate. Conduit Tyco Thermal Controls recommends drain the use of a conduit drain to prevent water condensation build-up. 18 • Install lid. • Apply insulation and cladding. •Weather-seal the stand entry. • Leave these instructions with the end user for future reference. Weather seal Tyco and Raychem are trademarks of Tyco Thermal Controls LLC or its affiliates. Worldwide Headquarters Important: All information, including illustrations, is believed to be reliable. Users, however, should Tyco Thermal Controls independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls 300 Constitution Drive makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding Menlo Park, CA 94025-1164 its use. Tyco Thermal Controls' only obligations are those in the Tyco Thermal Controls Standard Terms and USA Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for Tel(800) 545-6258 any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Fax (800) 527-5703 Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to info@tycothermal.com make changes—without notification to Buyer—to processing or materials that do not affect compliance with any www.tycothermal.com applicable specification. ©1997, 2000, 2002 Tyco Thermal Controls LLC Printed in USA PN 789781-000 H56046 11/02