Product SPecificationS

SYSTEM ACCESSORIESHeat tracinG caBLeS

THERMON The Heat Tracing Specialists european Headquarters: Boezemweg 25 Po Box 205 2640 ae Pijnacker the netherlands Phone: +31 (0) 15-36 15 37 corporate Headquarters:100 thermon dr Po Box 609 San Marcos, tX 78667-0609 Phone: 512-396-5801 1-800-820-4328 FortheThermonofficenearestyouvisitusat... www.thermon.com

FormTEP0010U-0113ThermonManufacturingCo.PrintedinU.S.A.Informationsubjecttochange.

Terminator ZP...isdesignedtofabricatepowerconnections, in-line/t-splice connections or formakingend terminations.TheTerminatorZP-XP issuitable foruse inhazardousareas (ExeT6/T4),harshindustrialenvironmentsandhasa IP66 rating.Theupfrontpositioningofthe terminalblockpermitseasyaccessduringassemblyandforfutureroutinemaintenance.

the terminator ZP kit includes; Pipe-mounted expediterwithsuitablegrommet,JunctionboxwithtwoM25entriesandoneM25-B-Exeblindplug, four 6-mm2 line/load terminals, two 6-mm2 earth terminals, terminals rated to 22 amps (t6 85C)or46amps(T4135C),Maximumvoltageratingof750Vac.Wallmountversionisavailable.

Product Reference Legend:ZP-XP and ZP-WP......rSX, VSX, BSX, HtSX,

KSX, fP, HPt

ZP-R-XP and ZP-R-WP............................teSH

Terminator ZL... isdesignedtoprovidevisualindicationofanenergizedheatingcircuit.Thekitmaybeutilizedasapowerconnectionoranendterminationkit.Electricalconnectionsaremadeinterminalblocksutilizingnickel-platedcopperterminals to ensure corrosion-free electrical integrity.

the terminator ZL kit includes; iP66 rated junction box,yellowLEDindicatinglamp,four6-mm2 line/load terminals, two 6-mm2 earth terminal, pipe-mountedfitting,heatercablegrommet.

Product Reference Legend:ZL-XP and ZL-WP......rSX, VSX, BSX, HtSX,

KSX, fP, HPt

Terminator Beacon... end-of-circuit light kits aredesignedspecificallyforrapid,trouble-freeinstallation of thermon self-regulating and power-limiting,parallel resistancepolymer insulatedheatingcables.TheTerminatorBeaconutilizesahighintensitygreenLEDassemblyforsuperiordayornightvisibility.

Product Reference Legend:ZE-B....BSX, rSX, HtSX, KSX, VSX, fP, HPt

Pipe Mount Wall Mount Wall Mount

PETK...circuit fabricationkitsare required forusewithallThermonParallelHeatingCablesConnectionKits.KitsforterminationofSXcablesincludeapowerconnectionboot,endcap,RTVadhesiveandacautionlabel.KitsforterminationofHPTandFPcablesalsoincludetapestripandadistinctgrommet.

Product Reference Legend:PETK-1....................................BSX, rSX, VSXPETK-2...........................................KSX, HtSXPETK-3 ................................................fP, HPtPETK-3-ECM .......................................fP, HPtPETK-3-ZT ..........................................fP, HPtPETK-4 ........................................HPt > 240c

Terminator ZS/ZE...designed to fabricateaccessible outside-the-insulation splices orend terminationsofThermonHeatingCables.electrical connections are made using wire fasteners (for applications requiring terminations tobemadewithterminalblockconnections,theTerminatorZPkitmaybeused).

Product Reference Legend:ZS/ZE-XP..........BSX, rSX, HtSX, KSX, VSX,

fP, HPt

SCTK...splice connection termination kits are required when preparing outside-the-insulation splices with all thermon Parallel Heating CablesConnectionKits.Kits for terminationsofSXcablesinclude2spliceconnectionboots,assortedwirenutsandRTVadhesive.KitsforterminationofHPTandFPcablesalsoincludeadistinctgrommet.

Product Reference Legend:SCTK-1....................................BSX, rSX, VSXSCTK-2...........................................KSX, HtSXSCTK-3.................................................fP, HPt

Pipe Mount

APPLiCATion FREEZE PRoTECTion And PRoCESS TEMPERATuRE MAinTEnAnCEThe following information relates to power connection kits, end termination kits and common installation accessories used with Thermon BSX, RSX, KSX, HTSX, VSX, FP and HPT heating cables.

CABLE End TERMinATion KiTS, ATTAChMEnT TAPES And MiSCELLAnEouS iTEMS

M25-PWR-Exe, M25-B-Exe...Ex e approved nonmetallic gland and plug for use with Terminator.

M25-PWR-Exe...power gland is suitable for securing power cables with diameters between 8 and 17 mm.

M25-B-Exe...blind plug.

M25-PWR-IND, M25-B-IND, M25-LN-IND...non-metallic gland and plug for use in threaded openings of junction boxes.

M25-PWR-IND...power gland is suitable for securing power cables with diameters between 11 and 18 mm.

M25-B-IND...blind plug and sealing washer.

M25-LN-IND...locknut for securing M25 glands in JB-K-1 and JB-K-2 boxes.

SK-SX-OJ...Ex e approved under-the-insulation repair and splice kit for overjacketed SX cables. Kit includes stainless steel shells, screws, grommets, RTV adhesive/sealant, insulation tape and the neces-sary wire pins/lugs.

FT-1L, FT-1H...fixing tape for attaching heating cable to piping every 300 mm or as required by code or specification.

AL-20H, AL-30H...aluminium tapes for continu-ous (longitudinal) covering cable to piping and/or equipment. Item Max. Temp. Min. Temp. Size Number (Exposure) (Installation) (mm x m)

FT-1L 93 C 5 C 12 x 33 FT-1H 260 C -40 C 12 x 33 AL-20H 150 C -5 C 50 x 55 AL-30H 150 C -5 C 76 x 55

CL...vinyl-based peel-and-stick caution labels are intended for direct exposure to industrial environ-ments. Electrically heated pipelines and vessels should be clearly identified at frequent intervals along the pipeline or vessel. Caution labels should be placed at 3 to 6-m intervals or as required by code or specification. Additional languages or other texts are available; contact Thermon.

IEK-SX...Insulation entry kit for use in (non) hazardous locations that protects and seals the heating cable while penetrating insulation cladding.

BSX .......................................................... IEK-SXMKSX, HTSX, FP, HPT .................................. IEK-SXSRSX, VSX ................................................... IEK-SXLTESH ..........................................................IEK-TES

M25-SX.-Ex....Ex e approved nonmetallic gland for use with M25 junction boxes.

M25-SX.-IND....nonmetallic gland for use with JB-K-0-M25 junction boxes

BSX ....................................................M25-SXM-...KSX, HTSX, FP, HPT ............................M25-SXS-...RSX, VSX .............................................M25-SXL-...TESH ................................................. M20-PWR-...

XP-1-...predrilled stainless steel (type 304) mounting bracket designed for mounting Thermon junction boxes and thermostats directly to the pipework. The bracket is easily secured to the pipe using B-4, B-10 or B-21 attachment bands. The XP-1 utilises a 110-mm standoff.

XP-1-140X140 ................... JB-K-0, JB-K-1, JB-K-2XP-1-WP ........................................ Terminator WP

B-4, B-10, B-21...stainless steel attachment bands for securing Thermon nonmetallic kits to pipes.B-4...for pipes up to 100 mm diameterB-10...for pipes up to 250 mm diameterB-21...for pipes up to 530 mm diameterABA-25...for pipes up to 25 mm diameterABA-40... for pipes up to 40 mm diameterTerminator-LN-Tool...for tightening the locknuts of the Terminator kits. Tool is recommended to ensure enclosure is properly secured to the pipe-mounted expediter.

CS-L-*-Ex. Circuit switch with lamp to be used as an in-line isolation switch for single phase, phase-phase and 3-phase heat tracing circuits. Available in 16 A, 25 A and 40 A versions.

Product SPecificationS

SYSTEM ACCESSORIESHeat tracinG caBLeS

ETS-05

1 / 4INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemETS05-DS-DOC2210-Rev1

SURFACE SENSING ELECTRONIC THERMOSTAT

PRODUCT OVERVIEW

The Raychem ETS-05 electronic surface sensing thermostat provides accurate temperature control for heating cables.

The ETS-05 is available in two versions. The ETS-05-L2-E is for temperatures up to 199C, while the ETS-05-H2-E can be used for temperatures up to 499C. The maximum nominal load is 32 A for both thermostats. Temperature setting is accurate via digital rotary switches inside the enclosure.

The ETS-05 has a LED indicator which indicates the status of the thermostat (powered on/off), the status of the heat-tracing cable (powered on/off) and the status of the sensor. In case of sensor failure the thermostat can switch to an on or off state, depending upon the users requirement.

PRODUCT CHARACTERISTICS

ETS-05-L2-E ETS-05-H2-E

Application Surface sensing Surface sensing

Area of use Hazardous area: Zone 1 or Zone 2 (Gas) or Zone 21 or Zone 22 (Dust) Ordinary

APPROVALS CERTIFICATION

Raychem ETS-05 Electronic Thermostat II 2(1)G II 2D Ex e ia mb (Ga) IIC T5 Gb Ex tb IIIC T100C Db Ta40 to +60C Supply = 99-121V (ETS-05-x1-x) or 195-230V (ETS-05-x2-x) Maximum switched current 32A Resistive IECEx BAS 13.0071 Baseefa13ATEX0137 Um=253V Max. Current = 0.5A Prospective short circuit current 1500A

PRODUCT SPECIFICATION

Temperature setpoint range 0C to 199C 0C to 499C

Temperature measurement range 55C to 260C 55C to 585C

Maximum sensor lead resistance 20 Ohm 20 Ohm

Ingress protection IP66 IP66

Switching accuracy 1 K at 5C 1 K at 5C, 2C at 499C

Switching differential (Hysteresis) 3C 3C

Output relay Single Pole change over type (SPST) Single Pole change over type (SPST)

Switching capacity 32 A resistive load 32 A resistive load

Ambient temperature range 40C to + 60C 40C to + 60C

Supply voltage 230 V +10% / -15% 50/60 Hz 230 V +10% / 15% 50/60 Hz

Internal power consumption 3 VA 3 VA

Terminal size max. 6 mm2 max. 6 mm2

Cable entries 2 x M25: 1 x M25 gland for power cable in 1 x M25 rain plug for heating cable out

2 x M25: 1 x M25 gland for power cable in 1 x M25 rain plug for heating cable out

Sensor M16 gland with 3 wire PT100 flexible sensor, 2 m long

M16 gland with 3 wire PT100, stainless steel sensor, 2 m long,

ETS-05

INDUSTRIAL HEAT TRACING SOLUTIONSEN-RaychemETS05-DS-DOC2210-Rev12 / 4

LED STATUS INDICATIONS

Green: ETS-05 powered on, heat-tracing cable off

Green: ETS-05 powered on, heat-tracing cable off

Yellow: ETS-05 powered on, heat-tracing cable on

Yellow: ETS-05 powered on, heat-tracing cable on

Red flashing: Sensor failure - controller in fail safe mode

Red flashing: Sensor failure - controller in fail safe mode

DIMENSIONS (IN MM)

123456789

0 123401234

00 1 0 1

Power Terminals

1

Line Out

2

NeutralOut

3

NeutralSupply

4

230V Supply

5

Earth

6

Earth

7

Earth

Terminals 2 and 3 are joined electricallyTerminals 5, 6 and 7 are joined electrically

Sensor/Failure Mode Select Terminals

4321

Link 3-4 removed = Output OFFLink 3-4 fitted = Output ON

Terminals 1 to 3 allow for the connection of a three wire PT100 sensor.

Terminals 3 to 4 allow the user to select the default heating status on sensor error.Without a link fitted the heating will turn OFF if a sensor error is detected (default)With a link fitted the heating will turn ON if a sensor error is detected

ETS-05

3 / 43 / 4INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemETS05-DS-DOC2210-Rev1

TYPICAL WIRING DIAGRAM FOR DIRECT SWITCHING

PE 1 2 3PE PE

PE

L1out

Fail-Safeoption

32 AMP

30 mA

MAX*

ETS-05

in 4

Link 3-4 removed = Output OFFLink 3-4 fitted = Output ON

MOUNTING METHOD

Support bracket SB-100, SB-101, SB-110, SB-111, SB-130 or surface mounting with 4 fixing holes on 106 x 82mm centres

Support bracket SB-100, or SB-101, SB-110, SB-111, SB-130 or surface mounting with 4 fixing holes on 106 x 82mm centres

ORDERING DETAILS

Product Name ETS-05-L2-E ETS-05-H2-E

Part number 1244-014367 1244-014368

* Circuit breaker configurations may vary according to local standards/requirements

1 / 4EN-RaychemHIQ-DS-DOC2210 Rev3

HIQMINERAL INSULATED (MI) INCONEL SHEATHED HEATING CABLE

INDUSTRIAL HEAT TRACING SOLUTIONS

TYPICAL CABLE CONSTRUCTIONS

Raychem HIQ mineral insulated (MI) Inconel 600 series heating cables are suited for use in hazardous areas. The Inconel 600 sheath offers excellent corrosive properties against a wide range of organic acids and alkalis, as well as chloride stress-corrosion cracking, in combination with a high temperature withstand capability. HIQ cables are typically used in bitumen plants, gas plants, oil refineries, reactors and vessels, sodium loops and a wide variety of other heat-tracing applications where temperature resistance, power output and durability are required and exceed the limitations of stainless steel sheathed MI heating cables. The heating cables can be used for exposure temperatures up to 700C and a typical power output up to 300 W/m. Higher temperatures and power outputs can be achieved, contact Pentair Thermal Management for assistance. The heating cables are offered as bulk cables as well as factory-terminated heating units employing brazing or laser welding techniques to ensure optimum quality of the connections. The offering is completed with a full range of components for installation, connection and splicing of the heating cables.

Nichrome conductor

Magnesium oxide insulation

Inconel sheath

APPLICATIONArea classification Hazardous areas, Zone 1 or Zone 2 (Gas) or Zone 21 or zone 22 (Dust)

Ordinary areas

APPROVALSSystem (heating units) Baseefa02ATEX0046X

II 2GD Ex e II T6 to T1 Ex tD A21 IP6XActual T class temperature determined by design

Bulk cable Baseefa02ATEX0045U II 2G Ex e II

Heating units are also approved for Dust environments.This product also has all required approvals for use in Kazakhstan, Russia and other countries. Contact your local Pentair Thermal Management representative for more details.

HIQ

2 / 4 EN-RaychemHIQ-DS-DOC2210 Rev3 INDUSTRIAL HEAT TRACING SOLUTIONS

TECHNICAL DATACable sheath material Inconel 600Conductor material NichromeMax. exposure temperature 700C* (heating cables)

450C (brazed heating units)700C* (laser welded heating units)*Higher temperatures can be realized, contact Pentair Thermal Management

=Min. installation temperature 60CMin. bending radius 6 x outer diameter at 60CMax. supply voltage and power Voltage (U0/U) Max. power output*

300/500 Vac460/800 Vac (laser welded heating units)

300 W/m*typical value, depending on application

Earth leakage 3 mA/100 m (nominal at 20C)Min. cable spacing 25 mm for hazardous areas

MI SERIES HEATING CABLES HIQ

Order Reference Nominal resistance (/km @ 20C)Outer diameter

(mm)Temp. coefficient

(x 10-3/K)Max. coil

length [m]Nom.weight

(kg/km)HIQ1M10K 10000 3.2 0.09 772 39HIQ1M6300 6300 3.2 0.09 774 39HIQ1M4000 4000 3.2 0.09 776 39HIQ1M2500 2500 3.4 0.09 689 46HIQ1M1600 1600 3.6 0.09 617 52HIQ1M1000 1000 3.9 0.09 528 62HIQ1M630 630 4.3 0.09 437 78HIQ1M400 400 4.7 0.09 368 96HIQ1M250 250 5.3 0.09 292 127HIQ1M160 160 6.5 0.09 194 191

Resistance tolerance: 10%

RECOMMENDED COLD LEADS FOR HIQ MI SERIES HEATING CABLES

Nom. cross section [mm2]

Order reference

Max. current (design B)

Outer diameter (mm)

Standard gland size

2.5 IC1H2.5 34 5.3 M206 IC1H6 57 6.4 M20

Brass glands are standard on all heating units. Other materials are possible, contact Pentair Thermal Management for more information.Delivery length of bulk cable on coil depends on type of resistance and is limited by max. coil length as indicated in the table on top. Factory terminated elements are limited by a max. weight of 50kg, however to ensure practical and safe on-site handling, it is strongly recommended to limit element lengths to 25 - 30kg. Not all resistances are standard items and as such may not be in stock. Contact Pentair Thermal Management to confirm lead time. Pentair Thermal Management requires the use of a 30 mA residual current device to provide maximum safety and protection from fire.Where design results in higher leakage current, the preferred trip level for adjustable devices is 30 mA above any inherent capacitive leakage characteristic of the heater as specified by the trace heater supplier or alternatively, the next common available trip level for non adjustable devices, with a maximum of 300 mA. All safety aspects need to be proven.Also refer to the components section for more details on heating units, accessories and nomenclatures. Page 118.

1 / 4

JUNCTION BOX FOR MODULAR SYSTEMJBU-100

INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemJBU100-DS-DOC2210 Rev3

The JBU-100 kit is designed to connect pow er to up to three Raychem BTV, QTVR, XTV, KTV or VPL industrial parallel heating cables and is approved by PTB for use in hazardous locations.

Innovative Spring-type terminals provide fast installation and safe, reliable, main te nance-free operation.

The box is part of the modular component system, it al lows for max i mum flexibility and can be ei ther wall or pipe mounted.

Connection kits (M25) and insulation en try kits have to be ordered separately. The box is offered in two basic versions customised to local installation practices.

All kits are also available as a lighted ver sion (-L). These include a unique light mod ule with a superbright green LED that sim ply plugs into the terminals, and a lens in the lid. This provides indication that pow er is available in the box.

DESCRIPTION JBU-100-E JBU-100-L-E

JBU-100-EP JBU-100-L-EP

This box is for use in Europe and pro vides four M25 threaded entries, stopping plugs and one plastic power cable gland.

This box is for use in Europe and provides four M25 threaded entries, an earthing plate and an external earth stud. It is designed for use with armoured power cables.

KIT CONTENTS1 junction box with terminals 1 light module (for -L only)1 M25 gland for 8-17 mm diameter

power cable2 M25 stopping plugs

1 junction box with terminals with earth plate and external earth stud

1 light module (for -L only) 2 M25 stopping plugs

(JBU-100-L-E shown with light)

JBU-100

2 / 4 INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemJBU100-DS-DOC2210 Rev3

APPROVALS

PTB 09 ATEX 1061 U II 2G Ex e (e mb) II II 2D Ex tD (tD mbD) A21 IP66

IECEx PTB 09.0039UEx e (e mb) IIEx tD (tD mbD) A21 IP 66

PTB 09 ATEX 1061 U II 2G Ex e (e mb) II II 2D Ex tD (tD mbD) A21 IP66

IECEx PTB 09.0039UEx e (e mb) IIEx tD (tD mbD) A21 IP 66

Ex e II T*Ex em II T* (for -L only)

ex e II T*Ex em II T* (for -L only)

DNV approvalDNV Certificates No. E-11564 and No. E-11565

DNV approvalDNV Certificates No. E-11564 and No. E-11565

*For T-rating, see heating cable or design documentationThis product also has all required approvals for use in Kazachstan, Russia and other countries. Contact your local Pentair Thermal Management representative for more details.

DIMENSIONS (NOMINAL) JBU-100-E JBU-100-L-E

JBU-100-EP JBU-100-L-EP

PRODUCT SPECIFICATIONSIngress protection IP66 IP66Entries 4 x M25 4 x M25Ambient temperature range 50C to +56C* (JBU-100-E)

40C to +40C (JBU-100-L-E)50C to +56C* (JBU-100-EP)40C to +40C (JBU-100-L-EP)

*Extra conditions for safe use apply for ambient temperatures above +40C. Please refer to the the summary on page 170, the certificate or installation instructions for full details.

Terminals Spring-type terminals Spring-type terminals2 phase, 2 neutral, 2 ground 2 phase, 2 neutral, 2 ground

Max. conductor size 10 mm2 stranded, 10 mm2 solid 10 mm2 stranded, 10 mm2 solidMax. operation voltage 480 Vac 480 VacMax. current rating 40 A 40 A

Hazardous locations

160

90

160 110

140

160

140

90

160 110

JBU-100

3 / 4INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemJBU100-DS-DOC2210 Rev3

MATERIALS OF CONSTRUCTIONEnclosure, lid Electrostatic charge-resistant

glass-filled engineered polymer, blackElectrostatic charge-resistant glass-filled engineered polymer, black

Lid screws Stainless steel Stainless steelLid gasket Silicone rubber Silicone rubberEarth continuity plate N/A Steel, zinc plated, and blue chromated

OPTIONAL LED INDICATOR LIGHTColour Green GreenVoltage rating 100-254 Vac 100-254 Vac Power consumption < 1 W < 1 W

Ordering details

JUNCTION BOXPart Description JBU-100-E JBU-100-EPPN (Weight) 051976-000 (1.7 kg) 243948-000 (1.8 kg)

JUNCTION BOX WITH LIGHTPart Description JBU-100-L-E JBU-100-L-EPPN (Weight) 069262-000 (2.1 kg) 113974-000 (2.2 kg)

ACCESSORIESHeating cable connection kits C25-100, C25-21, CCON25-100 C25-100, C25-21, CCON25-100,

C25-100-METALInsulation entry kit IEK-25-04 or IEK-25-PIPE IEK-25-04 or IEK-25-PIPEPower cable gland GL-36-M25 (included) GL-38-M25-METAL (optional)Junction box support bracket (optional)

SB-100, SB-101 SB-100, SB-101

1 / 3EN-RaychemRAYSTATEX0304-DS-DOC2210 Rev3

RAYSTAT-EX-03 AND RAYSTAT-EX-04 SURFACE AND AMBIENT SENSING, ELECTRONIC

INDUSTRIAL HEAT TRACING SOLUTIONS

These electronic surface sensing and ambient thermostats provide accurate temperature control for heating cables.

The units can be supplied at nominal voltages of either 110 V 50/60 Hz or 230 V 50/60 Hz and have a double pole switch rated at 16 A. The switch contacts can be arranged to be volt free. Temperature setting is accurate via digital thumb wheel switches inside the enclosure.

The surface sensing version is supplied with a Pt 100 sensor and a 2 m long stainless steel sheathed extension cable giving freedom to locate the electronics remote from the sensor. The ambient version is supplied with a local Pt 100 sensor and a wind shield.

The enclosure is manufactured from high impact resistant glass filled polyester offering IP66 protection.

For pipe temperatures up to 215C, the units can be mounted on the pipe using a support bracket.

APPLICATION RAYSTAT-EX-03 RAYSTAT-EX-04Surface sensing Ambient sensing

THERMOSTATArea of use Hazardous area: Zone 1 or Zone 2 (Gas) or Zone 21 or Zone 22 (Dust) Ordinary

APPROVALS CERTIFICATIONBaseefa11ATEX0071X IECEx BAS 11.0036X

II 2 GDWhen the unit is powered with a supply voltage 99 and 230 Va.c. Ex e mb ia IIC T6 Ta 50C to +60C GbEx tb IIIC T85C Ta 55C to +60C Db IP66When the unit is powered with a supply voltage > 230 253 Va.c. Ex e mb ia IIC T5 Ta 50C to +60C GbEx tb IIIC T100C Ta 55C to +60C Db IP66

PRODUCT SPECIFICATIONTemperature range 0C to 499C 0C to 49CIngress protection IP66 IP66Deluge testing Passed Shell UK requirements Passed Shell UK requirementsSwitching accuracy 1 K at 5C

1% of setpoint above 100C1 K at 5C

Switching differential (Hysteresis) 1C at 100C 2C at 200C 5C at 499C

1C

Output relay Dual pole change overtype (DPDT)(optional volt free)

Dual pole change over type (DPDT)(optional volt free)

RAYSTAT-EX-03 AND RAYSTAT-EX-04

EN-RaychemRAYSTATEX0304-DS-DOC2210 Rev32 / 3 INDUSTRIAL HEAT TRACING SOLUTIONS

PRODUCT SPECIFICATION (continued)Switching capacity 16 A 110 Vac 10% 50/60 Hz

16 A 230/253 Vac 10% 50/60 Hzresistive load

16 A 110 Vac 10% 50/60 Hz16 A 230/253 Vac 10% 50/60 Hzresistive load

Ambient temperature range 50C to +60C 50C to +60CSupply voltage 110 Vac 10% 50/60 Hz

230/253 Vac 10% 50/60 Hz110 Vac 10% 50/60 Hz230/253 Vac 10% 50/60 Hz

Internal power consumption 110 Vac ~ 4 VA, 230/253 Vac ~ 3 VATerminal size max. 4 mm2 max. 4 mm2

DIMENSIONS (IN MM) RAYSTAT-EX-03 RAYSTAT-EX-04

TYPICAL WIRING DIAGRAM FOR DIRECT SWITCHING

Cable entries 2 x M20 glands (cable 7.5 13 mm)1 x M25 with M25(M)/M20(F) adaptor and (M20) plug

2 x M20 glands (cable 7.5 13 mm) 1 x M25 with M25(M)/M20(F) adaptor and (M20) plug

Sensor 2 wire Pt 100, stainless steel sensor, 2 m long 2 wire Pt 100, stainless steel sensor, complete with wind shield

MOUNTING METHODRaychem support bracket SB-100 or SB-101, SB125 or surface mounting with 4 fixing holes on 110x140mm centres

Raychem support bracket SB-100 or SB-101, SB125 or surface mounting with 4 fixing holes on 110x140mm centres

ORDERING DETAILSPart Description RAYSTAT-EX-03 RAYSTAT-EX-04PN (Weight) 333472-000 (3.0 kg) 462834-000 (3.1 kg)

160

90

160

3

110

140

160

140

110

523

90

160 110

0

160

90

160

3

110

140

160

140

110

523

90

160 110

0

*

230 V / 50 HzNPE

L1

max.16 A/C

1 2 3 126 98754

RAYST AT-EX-03/04

Pt 100

NO C NC CNO

1 2 3 126 98754

RAYST AT-EX-03/04

Pt 100

NO C NC CNO

N

PE

L1

max.16 A/C

400 V / 50 HzL2L3

*

**

***

***

NC

*

Sensor

Sensor

**

Heating system

Sensor

* Circuit breaker configurations may vary according to local standards/requirements

** Link 1-8 and/or 3-5 can be removed to provide potential-free contacts

*** Terminal 2: 110 Vac input terminal

1 / 8INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemXMIA-DS-H56870 09/14

PRODUCT OVERVIEW

Raychem XMI-A heating cables provide solutions for industrial freeze protection and process- temperature maintenance applications up to 1022F (550C) and maximum exposure temperatures up to 1200F (650C).

They are available as 300 V and 600 V rated heating cables and are approved for applications up to 61 watts per foot (200 watts per meter) of power output, and can be used for pipe and vessel tracing in both hazardous and nonhazardous area applications.

XMI-A heating cables are constructed using an Alloy 825 sheath and are ideally suited for heating applications where high power output, high exposure temperatures, or extreme resistance to environmental corrosives is needed.

For additional information, contact your Pentair Thermal Management representative or call (800) 545-6258.

TEMPERATURE RATING

Maximum continuous exposuretemperature for heating cable*

1200F (650C)

Maximum continuous exposure temperature for brazed components such as hot/cold joints and end cap*

1022F (550C)

* Higher temperature/power capabilities may also be available depending on the application; contact Pentair Thermal Management for additional information.

TEMPERATURE ID NUMBER (T-RATING)

To be established by calculating the maximum sheath temperature. Use TraceCalc Pro design software or contact Pentair Thermal Management for assistance.

APPROVALS

Class I, Div. 1 and 2, Groups A, B, C, DClass II, Div. 1 and 2, Groups E, F, GClass III

Nonhazardous and Hazardous Locations

Class I, Div. 1 and 2, Groups A, B, C, DClass II, Div. 1 and 2, Groups E, F, GClass IIIFor use in Zone 1 and Zone 2 locations

Ex e IIC T* Gb

XMI-A (Alloy 825 sheath)

Heating cable construction

Insulation(magnesium oxide)

Heating conductor(single)

Heating conductors(dual)

Alloy 825sheath

XMI-A (ALLOY 825)HIGH TEMPERATURE CONSTANT WATTAGE MINERAL INSULATED HEATING CABLES

XMI-A (ALLOY 825) HEATING CABLE

EN-RaychemXMIA-DS-H56870 09/142 / 8 INDUSTRIAL HEAT TRACING SOLUTIONS

SPECIFICATIONS

Product Family

Sheath Material

Product Code

Voltage Rating

Number of Conductors Max. Power Output** Bending Radius

XMI-A Alloy 825 XMI-A61 600 V 1 61 W/ft; 200 W/m 6 times heating cable diameterXMI-A Alloy 825 XMI-A32 300 V 2 60 W/ft; 197 W/m 6 times heating cable diameterXMI-A Alloy 825 XMI-A62 600 V 2 61 W/ft; 200 W/m 6 times heating cable diameter** Actual power output values are application specific and may be lower, particularly for designs in hazardous locations. Use TraceCalc Pro

design software or contact Pentair Thermal Management for design assistance.

BASIC HEATING CABLE DESIGN CONFIGURATIONS

XMI-A heating cables are designed as engineered heating units according to your specific application. An engineered heating unit consists of a length of heating cable (Heated length) joined to a length of non-heating cold lead (Cold lead length). Engineered heating units are designed using our TraceCalc Pro software. This section describes the available XMI-A engineered heating unit design configurations.

Various quick connector options are available for the XMI-A cold lead (Canada only). Refer to data sheet H59126 for further details.

Design A

Design B

Design D

Cold lead lengthHeated length

Heated lengthCold lead length

Heated length Cold lead length

Cold lead length

Cold lead lengthHeated lengthCold lead length

NPT glandconnector

NPT glandconnector

NPT glandconnector

NPT glandconnector

Design E

Single conductor cable (XMI-A61 series only)

Single conductor cable (XMI-A61 series only)

Dual conductor cable (XMI-A32 or XMI-A62 series only)

Dual conductor cable (XMI-A32 or XMI-A62 series only)

XMI-A (ALLOY 825) HEATING CABLE

3 / 8INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemXMIA-DS-H56870 09/14

HEATING CABLE CATALOG NUMBER

A Raychem XMI-A engineered heating unit is ordered by compiling the catalog number based on the design of the specific engineered heating unit required for your application. Typically, an engineered heating unit is designed using our TraceCalc Pro design software which provides the catalog number as part of the design output. An explanation of the catalog number follows:

Example: Engineered Heating Unit (Part No.: EHU) EHU: D/32SA2200/40/538/208/7/S25A/X/N12/RG1/PE/S

Position: 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

D / 32SA2200 / 40 / 538 / 208 / 7 / S25A / X / N12 / RG1 / PE / S

Position Characteristic Code Options Description1 Design

configurationA, B, D or E Designates the basic heating cable design configuration of the XMI-A engineered heating

unit.

2 Heating cable reference

See Tables 3, 4 and 5 Indicates the XMI-A heating cable reference used in the design.

3 Heated length Length of the heating cable in feet or meters

Default value is in feet; if in meters add "M" after the length.

4 Power Power output of the heating cable unit

Power output at maintain temperature, in Watts, for the total heated length of the engineered heating unit.

5 Voltage Effective voltage applied to a heating unit

This is the designed effective voltage that will be applied to the engineered heating unit (in the case of series connected heating units, it is the voltage across a single unit).

6 MI cold lead length

(length) or (length)(length)

Length of the MI cold lead in feet or meters

Default value is in feet; if in meters add "M" after the length.

Standard lengths for XMI-A engineered heating units are 4 feet (1.2 m) or 7 feet (2.1 m), however custom lengths can be designated here.

For E and B configurations, which have cold leads on each end, a single value (such as 7) indicates that both MI cold leads are to be 7 feet long. A hyphenated value (such as 5-7) indicates that the cold lead on one end is 5 feet long and the cold lead on the other end is 7 feet long.

7 MI cold lead code

Select the cold lead code from Table 2

Table 2 is used to select the appropriate MI cold lead based on the current and voltage rating required by the design.

8 Hot-cold joint type

X X type joint is used with all XMI-A engineered heating units.

9 Gland size reference

Refer to Table 2 Gland size depends on the cold lead code selected from Table 2.

10 Reverse gland RG12, RG34, RG1 Optional reversed gland added to the cold lead to make a water tight seal for design configurations A and D, when used for internal pipe tracing applications. Design A configuration: only 1" NPT (RG1) reversed gland available. Design D configuration: 1/2" NPT (RG12), 3/4" NPT (RG34) or 1" NPT (RG1)

reversed gland available.

11 Pulling eye PE Optional pulling eye to aid in pulling a cable inside a pipe or channel. Use with Design D configuration only.

12 Special feature S Indicates a special non-standard feature has been added to the heating cable.

XMI-A (ALLOY 825) HEATING CABLE

EN-RaychemXMIA-DS-H56870 09/144 / 8 INDUSTRIAL HEAT TRACING SOLUTIONS

Examples D/62SQ3100/200/9920/480/4/S25A/X/N12 Configuration is Design D XMI-A62 heating cable (600 V rated, dual conductor cable), resistance at 20C is 0.100 /ft

(0.328 /m) Heating cable length is 200 ft (61 m) Heating cable wattage is 9920 W at 480 V MI cold lead length is 4 ft (1.2 m) MI cold lead code is S25A (25 Amps) Hot-cold joint type is X for use with XMI-A Alloy 825 sheath cables Gland connector is 1/2 in NPT

E/32SQ3200/25M/870/120/2.1M/LS23A/X/N12 Configuration is Design E XMI-A32 heating cable (300 V rated, dual conductor cable), resistance at 20C is 0.200 /ft

(0.656 /m) Heating cable length is 25 m (82 ft) Heating cable wattage is 870 W at 120 V MI cold lead length is 2.1 m (7 ft) on both ends MI cold lead code is LS23A (23 Amps) Hot-cold joint type is X for use with XMI-A Alloy 825 sheath cables Gland connector is 1/2 in NPT

B/61SQ3118/250/6820/480/5-7/S29A/X/N12 Configuration is Design B XMI-A61 heating cable (600 V rated, single conductor cable), resistance at 20C is 0.118 /

ft (0.387 /m) Heating cable length is 250 ft (76 m) Heating cable wattage is 6820 W at 480 V MI cold lead length is 5 ft (1.5 m) on one end and 7 ft (2.1 m) on the other end MI cold lead code is S29A (29 Amps) Hot-cold joint type is X for use with XMI-A Alloy 825 sheath cables Gland connector is 1/2 in NPT

D/32SA2200/40/538/208/7/S25A/X/N12/RG1/PE Configuration is Design D XMI-A32 heating cable (300 V rated, dual conductor cable), resistance at 20C is 2.0 /ft

(6.56 /m) Heating cable length is 40 ft (12.2 m) Heating cable wattage is 538 W at 208 V MI cold lead length is 7 ft (2.1 m) MI cold lead code is S25A (25 Amps) Hot-cold joint type is X for use with XMI-A Alloy 825 sheath cables Gland connector is 1/2 in NPT Supplied with 1 NPT reversed gland Supplied with pulling eye

TABLE 1 HEATING CABLE REFERENCE DECODING

6 2 S A 2 2 0 01 2 3 4 5 6 7 8Position

Position Description1 Maximum voltage rating 3 = 300 V, 6 = 600 V2 Number of conductors 1 or 2

3 Sheath material S = Alloy 8254 Conductor material A, B, C, F, P, Q, or T5 Move decimal point to left

indicated number of places1, 2, 3, 4, 5, or 6 places

6 to 8 Cable resistance to 3 whole numbers (use with digit 5)

2200 = 2.00 /cable foot at 20C

XMI-A (ALLOY 825) HEATING CABLE

5 / 8INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemXMIA-DS-H56870 09/14

TABLE 2 ALLOY 825 SHEATHED COLD LEADS

The cold lead is supplied from the factory with a standard stainless steel National Pipe Thread (NPT) gland connector ready for assembly into the junction box or panel using the flexible wire tails extending from the MI cold lead. The cold lead is selected based on the voltage and current requirements of the XMI-A engineered heating unit. The standard tail length is 12 in (30 cm) unless otherwise specified, and the gauge size (AWG) for the tails is shown in the table below.

Cold lead code for catalog number

Maximum voltage (V)

Maximum current (A)

Cold lead diameter Gland size (NPT)

Gland size reference for catalog no.

Tail size (AWG)in mm

Design A, D, ES25A 600 25 0.355 9.0 1/2 in N12 14LS23A 300 23 0.319 8.1 1/2 in N12 14S34A 600 34 0.402 10.2 3/4 in N34 10S49A 600 49 0.496 12.6 3/4 in N34 8S65A 600 65 0.543 13.8 3/4 in N34 6

Design BS29A 600 29 0.215 5.5 1/2 in N12 12S40A 600 40 0.273 6.9 1/2 in N12 10S48A 600 48 0.253 6.4 1/2 in N12 8S66A 600 66 0.319 8.1 1/2 in N12 6S86A 600 86 0.355 9.0 1/2 in N12 4Note: MI cold lead minimum bending radius is 6 times the cable diameter.

TABLE 3 XMI-A61 SERIES MI HEATING CABLE SPECIFICATIONS (600 V, SINGLE CONDUCTOR)

Heating cable reference

Nominal cable resistance at 20C

Approximate cable diameter

Maximum unjointed cable length Nominal weight

/ft /m in mm ft m lb/1000 ft kg/1000 m61SA2200 2.00 6.56 0.146 3.7 1809 552 35 5261SA2160 1.60 5.25 0.163 4.1 1452 443 44 6661SA2130 1.30 4.27 0.160 4.1 1508 460 42 6361SA2100 1.00 3.28 0.160 4.1 1510 460 43 6461SA3850 0.850 2.79 0.170 4.3 1338 408 48 7261SA3700 0.700 2.30 0.160 4.1 1514 462 43 6461SA3500 0.500 1.64 0.170 4.3 1344 410 49 7361ST3280 0.280 0.919 0.170 4.3 1337 408 48 7261SB3200 0.200 0.656 0.180 4.6 1198 365 55 8261SB3150 0.150 0.492 0.170 4.3 1350 412 51 7661SQ3118 0.118 0.387 0.175 4.4 1260 384 50 75

61SQ4732 0.0732 0.240 0.170 4.3 1338 410 48 7261SQ4581 0.0581 0.191 0.172 4.4 1308 399 50 7561SP4467 0.0467 0.153 0.170 4.3 1337 408 48 7261SP4366 0.0366 0.120 0.173 4.4 1292 394 50 7561SP4290 0.0290 0.0951 0.177 4.5 1236 377 53 7961SP4231 0.0231 0.0758 0.174 4.4 1282 391 52 7861SP4183 0.0183 0.0600 0.170 4.3 1347 411 50 7561SP4145 0.0145 0.0476 0.170 4.3 1351 412 51 7661SP4113 0.0113 0.0371 0.186 4.7 1130 345 61 9161SC5651 0.00651 0.0214 0.187 4.7 1110 338 60 8961SC5409 0.00409 0.0134 0.191 4.9 1069 326 64 9561SC5258 0.00258 0.00846 0.215 5.5 848 259 83 12461SC5162 0.00162 0.00531 0.268 6.8 546 166 129 19261SC5102 0.00102 0.00335 0.253 6.4 622 190 124 18561SC6640 0.00064 0.00210 0.319 8.1 391 119 197 294

XMI-A (ALLOY 825) HEATING CABLE

EN-RaychemXMIA-DS-H56870 09/146 / 8 INDUSTRIAL HEAT TRACING SOLUTIONS

TABLE 4 XMI-A32 SERIES MI HEATING CABLE SPECIFICATIONS (300 V, DUAL CONDUCTOR)

Heating cable reference

Nominal cable resistance at 20C

Approximate cable diameter

Maximum unjointed cable length Nominal weight

/ft /m in mm ft m lb/1000 ft kg/1000 m32SF1110 11.0 36.1 0.130 3.3 2283 696 28 42

32SF2900 9.0 29.5 0.140 3.6 1969 600 32 4832SF2750 7.5 24.6 0.157 4.0 1565 477 41 6132SA2600 6.00 19.7 0.135 3.4 2121 647 30 4532SA2400 4.00 13.1 0.146 3.7 1816 554 36 5432SA2275 2.75 9.02 0.153 3.9 1657 505 40 6032SA2200 2.00 6.56 0.169 4.3 1359 414 49 7332SA2170 1.70 5.58 0.167 4.2 1395 425 48 7232SB2114 1.14 3.74 0.174 4.4 1279 390 51 7632SB3700 0.700 2.30 0.170 4.3 1347 411 50 7432SQ3472 0.472 1.55 0.177 4.5 1232 376 52 7832SQ3374 0.374 1.23 0.183 4.6 1153 352 55 8232SQ3293 0.293 0.961 0.179 4.5 1206 368 53 7932SQ3200 0.200 0.656 0.161 4.1 1498 457 44 6632SQ3150 0.150 0.492 0.168 4.3 1378 420 49 7332SQ3100 0.100 0.328 0.185 4.7 1140 348 60 8932SP4734 0.0734 0.241 0.174 4.4 1284 391 52 7832SP4583 0.0583 0.191 0.178 4.5 1230 375 55 8232SP4458 0.0458 0.150 0.188 4.8 1105 337 62 9232SC4324 0.0324 0.106 0.184 4.7 1145 349 57 85

TABLE 5 XMI-A62 SERIES 62 MI HEATING CABLE SPECIFICATIONS (600 V, DUAL CONDUCTOR)

Heating cable reference

Nominal cable resistance at 20C

Approximate cable diameter

Maximum unjointed cable length Nominal weight

/ft /m in mm ft m lb/1000 ft kg/1000 m62SF1110 11.0 36.1 0.194 4.9 1023 312 61 9162SF2900 9.00 29.5 0.194 4.9 1024 312 61 9162SF2600 6.00 19.7 0.194 4.9 1025 313 62 9262SA2414 4.14 13.6 0.209 5.3 883 269 76 11362SF2200 2.00 6.56 0.245 6.2 644 196 100 14962ST2115 1.15 3.77 0.215 5.5 834 254 76 11362SB3700 0.700 2.30 0.245 6.2 644 196 100 14962ST3505 0.505 1.66 0.215 5.5 837 255 77 11562SQ3286 0.286 0.938 0.222 5.6 783 239 81 12162SQ3200 0.200 0.656 0.227 5.8 750 229 86 12862SQ3150 0.150 0.492 0.227 5.8 751 229 86 12862SQ3100 0.100 0.328 0.257 6.5 586 179 111 16562SP4775 0.0775 0.254 0.250 6.4 618 188 104 15562SP4561 0.0561 0.184 0.263 6.7 560 171 116 17362SP4402 0.0402 0.132 0.277 7.0 505 154 130 19462SP4281 0.0281 0.0922 0.292 7.4 456 139 147 21962SC4200 0.0200 0.0656 0.285 7.2 476 145 135 20162SC4130 0.0130 0.0427 0.304 7.7 419 128 156 23362SC5818 0.00818 0.0268 0.331 8.4 354 108 187 27962SC5516 0.00516 0.0169 0.364 9.2 294 90 230 34362SC5324 0.00324 0.0106 0.402 10.2 242 74 290 43262SC5204 0.00204 0.00669 0.496 12.6 159 48 438 65362SC5128 0.00128 0.00420 0.543 13.8 469 143 516 769

XMI-A (ALLOY 825) HEATING CABLE

7 / 8INDUSTRIAL HEAT TRACING SOLUTIONS EN-RaychemXMIA-DS-H56870 09/14

RESISTANCE CORRECTION FACTOR

Various conductor materials behave differently. Use the graphs below for approximate adjustment of power and resistance as a function of temperature. For detailed design, use TraceCalc Pro design software or contact Pentair Thermal Management.

Pipe Temperature to be Maintained (F/C) Pipe Temperature (F/C)

Power On

CC

QP

TA,B,F

QP

TA,B,F

662350

752400

752400

572300

482250

392200

302150

212100

12250

320

662350

572300

482250

392200

302150

212100

12250

320

5850

1.0

1.5

2.0

2.5

3.0

0

0.5

1.0

1.5

2.0

2.5

3.0

0

0.5

Resistanc

e Multip

lier for

Cond

uctor Materials

Resistance Multip

lier for

Cond

uctor Materials

Power Off

ALLOY 825 QUICK REFERENCE GUIDE

Alloy

INCOLOYAlloy 825nickel-iron-chromium

Description Nick

el (+

Coba

lt)

70F

(20

C)

1500

F (8

15C

)

Oxid

atio

n

Carb

uriza

tion

Sulfu

ric ac

id

Hydr

ochl

oric

acid

Hydr

oflu

oric

acid

Phos

phor

ic ac

id

Nitri

c aci

d

Orga

nic a

cid

Alka

lis

Salts

Seaw

ater

Chlo

ride c

rack

ing

Iron

Chro

miu

m

Othe

r

Thermalconductivity

Btu-in/ft2-hr-F (W/m-C)

Nominal chemicalcomposition, %

(major elements)

Hightemperatureresistance+1000F(+540C)

Corrosion resistance

G-E = Good to excellentNR = Not recommended

A = AcceptableX = Check for specific data

Excellent resistance to a wide variety of corrosives. Resists pitting and intergranular type corrosion, reducing acids and oxidizing chemicals

42.0

*From Huntington Alloys Publication 78-348-2

30.0 21.5 Mo 3.0Cu 2.2

77(11.1)

164(23.6)

G-E G-E G-E G-E G-E G-E G-E G-E G-E G-E G-E G-E

GROUND-FAULT PROTECTION

To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed and to comply with the requirements of Pentair Thermal Management, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. Many Raychem control and monitoring systems meet the ground-fault protection requirement.

ConstruCtion1 Junction box, glass-reinforced polymer with DIN rail

mounted terminal blocks 2 Pipe-mount expediter, glass-reinforced polymer3 Stainless steel mounting bracket4 LED end of circuit light (available on Beacon only).

AppliCAtionTerminator nonmetallic heating cable termination kits are designed specifically for rapid, trouble-free installation of Thermon heating cables. The integral design of these nonmetallic kits combines the pipe-mounted fitting, heating cable grommet and cable strain relief into a single assembly. Screws for securing the covers of the kits have been eliminated to simplify cover installation

while providing additional security (a tool is required to remove the cover after installation).

Terminator kits are approved for use in ordinary (nonclassified) areas, and are certified to the ATEX directive for use in Category 2 and 3 (Zone 1 and 2) classified areas.

rAtingsEnclosure rating..................................................... IP66Maximum pipe exposure temperature 1 ...............250C Minimum installation temperature 1 ......................-60COperating ambient temperature.............-60C to +55CMaximum voltage rating 2 ................................. 750 Vac

notes1. Minimum and maximum temperatures may be further limited by the temperature

ratings for the heating cables. Consult appropriate specification sheets.

2. Terminator Beacon operating voltage rating is 100-277 Vac.3. Terminator ZP and ZL are shipped with an M25-B-Exe EEx e approved blind

plug that can be replaced with an EEx e approved gland to permit power or heating cable connection or an EEx e approved blind plug to permit In-Line T-Splice, End Termination Lighted Power Connection or End Termination.

ProduCT SPECifiCATionS

TerminatorHEATing CAblE TErminATion KiTS

THERMON The Heat Tracing Specialists European Headquarters: boezemweg 25 Po box 205 2640 AE Pijnacker The netherlands Phone: +31 (0) 15-36 15 37 Corporate Headquarters:100 Thermon dr Po box 609 San marcos, TX 78667-0609 Phone: 512-396-5801 1-800-820-4328 for the Thermon office nearest you visit us at . . . www.thermon.com

form TEP0088u-1013 Thermon manufacturing Co. Printed in u.S.A. information subject to change.

Kit typeP = Power ConnectionL = Lighted Power

Connection/End TerminationS = In-line or T-Splice E = End Termination

produCt referenCe legend

Area designationZ = Category 2 and 3

(Zone 1 and 2) Areas

Mounting optionsXP = Pipe-mount Expediter

WP = Wall Mount Bracket with Expediter

Zp-Xp

Kits for bSX, rSX, HTSX, KSX, TSX, VSX, HPT and fP Cables:

Zp-r = Power Connection Kit (ATEX only)Kits for TESH, TES Cables

Zp-M = Power Connection KitKits for TEK, HTEK Cables

4

1

2

3

terminator Zp (shown)

terminator Ze-B Beacon

Certificate fm10ATEX0058X in accordance with Eu ATEX directive 94/9/EC

Certificate dEmKo01ATEX0021995 in accordance with Eu ATEX directive 94/9/EC

International Electrotechnical Commission iEC Certification Scheme for Explosive Atmospheres fmg 10.0022X

fm Approvals ordinary and Hazardous (Classified) locations

Underwriters Laboratories Inc. ordinary and Hazardous (Classified) locations

CertifiCAtions/ApprovAls

Terminator has additional hazardous area approvals including: AbS CSA CQST dnA KoSHA lloyds Tr TC

terminator Zp is dsigned to fabricate power connections, in-line/T-splice connections or for making end terminations for heating circuits. Electrical connections are made using terminal blocks.

terminator Zl (not shown) is designed to provide visual indi-cation of an energized heating circuit. The kit may be utilized as a power connection or an end termination kit. Electrical con-nections are made using terminal blocks.

terminator Zs/Ze is de-signed to fabricate accessible outside-the-insulation splices or end terminat ions of Thermon Heating Cables. Electrical connections are made using wire fasteners. (For applications requiring terminations to be made with terminal block connections, the Terminator ZP kit may be used.)

petK circuit fabrication kits are required for use with all Thermon Parallel Heating Cables Connection Kits. Kits for termination of SX cables include a power connection boot, end cap, RTV adhesive and a caution label. Kits for termination of HPT and FP cables also include tape strip and a distinct grommet.sCtKspl ice connect ion termination kits are required when preparing outside-the-insulation splices with all Thermon Parallel Heating Cables Connection Kits. Kits for terminations of SX cables include 2 splice connection boots, assorted wire nuts and rTV adhesive. Kits for termination of HPT and FP cables also include a distinct grommet

Zp Zp-M Zp-r Ze-B Zl Zs/Ze

Enclosure Ratings IP66 IP66 IP66 IP66 IP66 IP66

Max. Pipe Exposure Temperature 250C 250C 250C 250C 250C 250C

Min. Installation Temperature -60C -60C -60C -60C -60C -60C

operating Ambient Temperature -60C to +55C -60C to +55C -60C to +55C -60C to +45C -60C to +55C -60C to +55C

Electrical Connection Terminal Blocks 3 Terminal Blocks 3 Terminal Blocks 3 Wire Fasteners Terminal Block 4 Wire Fasteners

Number of Power Connections 1 to 3 Cables 1 Cable 3 Cables (Max) 1 Cable 1 Cable n/A

Number of In-Line/ T-Splices 2 to 3 Cables 2 Cables n/a n/a n/a 1 Inline

Number of End Terminations 1 to 2 Cables on ZP 1 Cable 3 Phases Wye 1 Cable 1 Cable 1 to 2 Cables

5

Maximum Conductor Size 1 6 mm

2 16 mm2 6 mm2 6 mm2 6 mm2 n/A

Maximum Voltage Rating 750 Vac 750 Vac 750 Vac 277 Vac See Indicating Lamp 750 Vac

Maximum Rated Current 1 50 Amps 85 Amps 50 Amps 50 Amps 50 Amps n/A

T-rating, Ta2 = 40C T4 @ 46 Amps T6 @ 22 AmpsT4 @ 46 Amps T6 @ 22 Amps

T4 @ 46 Amps T6 @ 22 Amps T6

T4 @ 46 Amps T6 @ 22 Amps

T4 @ 46 Amps T6 @ 22 Amps

Indicating Lamp Service Life Rating n/a n/a n/a n/a 100,000 Hours n/A

Indicating Lamp Operating

Voltage Rangen/a n/a n/a 100 to 277 Vac 12 to 270 Vac n/A

terminator Zp or Zl with pipe Mount expediter

terminator Zp or Zl with Wall Mount Bracket

terminator Zs/Ze

notes1. Alternate terminal block configurations are available, contact factory.

2. Higher Ambient temperatures are possible. Consult Thermon for corresponding T-rating.

3. Terminator ZP kit includes four line terminal blocks and two ground terminal blocks.4. Terminator ZL kit includes four line terminal blocks and two ground terminal blocks.5. Terminator ZE kit allows up to 3 cables to be terminated; additional ET end caps may be ordered separately.

ProduCT SPECifiCATionS

TerminatorHEATing CAblE TErminATion KiTS

Self-regulating heating cable

1-3EN-VPL-DS-DOC2210www.tycothermal.com

HE

ATIN

G C

AB

LES

CO

MP

ON

EN

TSC

ON

RTR

OL

AN

D M

ON

ITO

RN

ING

AC

CE

SS

OR

IES

Heating cable construction

3.3 mm2 nickel plated copper conductors

High temperature fluoropolymer outer jacket

Nickel plated copper braid

High temperature fluoropolymer inner jacket

Power-limiting heating element

Conductor connection

White jacket

High temperature fluopolymer conductor insulation

ApplicationArea classification Hazardous, Zone 1, Zone 2 (Gas), Zone 21, Zone 22 (Dust) OrdinaryTraced surface type Carbon steel

Stainless steelPainted or unpainted metal

Chemical resistance Organics and corrosivesFor aggressive organics and corrosives consult your local Tyco Thermal Controls representative

Supply voltageVPL2: 208-277 Vac VPL4: 400-480 Vac

ApprovalsThe VPL heating cables are approved for use in hazardous areas by Baseefa Ltd.Baseefa06ATEX0188X & IECExBAS06.0048X

II 2GD & Exe II T* (see schedule) Ex tD A21 IP66 Ex e II T* (see schedule) Ex tD A21 IP66*By design. Temperature classification (T-rating) has to be established by using the principles of stabilized design or the use of a temperature limiting device. Use TraceCalc design software or contact Tyco Thermal Controls.

The VPL heating cables are approved by DNV for use on ships and mobile off-shore units. DNV Certificate No. E-8095.

The products also have the required approvals for use in Kazakhstan, Russia and many other countries. Contact your local Tyco Thermal Controls representative for more details.

VPL is a family of power limiting heating cables designed for pipe and equipment heat-tracing in industrial applications.

VPL can be used for frost protection and process temperature maintenance requiring high power output and/or high temperature exposure. VPL can provide process temperature maintenance up to 230C and can

withstand routine steam purges and temperature exposure to 260C with power off.

Power-limiting cables are parallel heaters formed by a coiled resistor alloy heating element wrapped around two parallel conductors. The distance between conductor contact points forms the heating zone length. This parallel construction allows it to be

cut-to-length and terminated on-site. The power output of VPL heating cables decreases with increasing temperature. VPL heating cables can be overlapped once. The relatively flat power temperature curve of VPL ensures a low start-up current and high output at elevated temperatures. VPL cables are approved for use in hazardous areas. Approvals are listed below.

VPL

High-temperature power-limiting heating cable

2-3 EN-VPL-DS-DOC2210 www.tycothermal.com

VPL

Specifications

Maximum maintain or continuous exposure temperature (power on)

Cable 208 V 230 V 254 V 277 V 400 V 480 V5VPL2-CT 235C 230C 225C 225C 10VPL2-CT 220C 210C 200C 195C 15VPL2-CT 200C 180C 145C 105C 20VPL2-CT 150C 150C 5VPL4-CT 230C 230C10VPL4-CT 215C 205C15VPL4-CT 195C 160C20VPL4-CT 150C 150C

Maximum intermittent exposure temperature (power off) 260C

Temperature classification To be established using the principles of stabilized design or the use of a temperature limiting device. Use TraceCalc design software or contact Tyco Thermal Controls for assistance.Minimum installation temperature 60C

Minimum bend radius at 60C: 20 mm | at +20C: 20 mm

Thermal output ratingNominal power output rating on insulated steel pipes at 240 V and 480 V (power output of VPL4 at 400 V will be lower)

To choose the correct heating cable for your application use the TraceCalc design soft ware.

A 20VPL-CTB 15VPL-CTC 10VPL-CTD 5VPL-CT

W/m

0 20 40 60 80 100 120 140 160

80

70

60

50

40

20

10

30

A

B

C

D

180 200 220 2400

Pipe temperature (C)

Adjustment Factors

5VPL2-CT 10VPL2-CT 15VPL2-CT 20VPL2-CT254 V Power output 1.20 1.19 1.19 Not allowed

Circuit length 1.05 1.04 1.04 Not allowed277 V Power output 1.30 1.28 1.26 Not allowed

Circuit length 1.13 1.11 1.09 Not allowed5VPL4-CT 10VPL4-CT 15VPL4-CT 20VPL4-CT

400 V Power output 0.72 0.73 0.74 0.75Circuit length 0.86 0.87 0.89 0.90

Nominal power output (W/m at 10C) 5VPLx-CT 10VPLx-CT 15VPLx-CT 20VPLx-CTVPL2 at 230 V 15 30 45 61VPL2 at 240 V/VPL4 at 480 V 16 33 49 65VPL4 at 400 V 12 24 36 49

Product dimensions (nominal) and weight

Thickness (mm) 7.9 7.9 7.9 7.9

Width (mm) 11.7 11.7 11.7 11.7

Nominal cold lead/ heatingzone length (m)

1.2 (VPL2) 0.9 (VPL2) 0.6 (VPL2) 0.5 (VPL2)2.4 (VPL4) 1.7 (VPL4) 1.3 (VPL4) 1.1 (VPL4)

Weight (g/m) 200 200 200 200

3-3EN-VPL-DS-DOC2210www.tycothermal.com

VPL

Maximum circuit length based on type C circuit breakers according to EN 60898

VPL2 at 230 V 5VPL2-CT 10VPL2-CT 15VPL2-CT 20VPL2-CT

Electrical protection sizing

Start-up temperature

Maximum heating cable length per circuit (m) at 230 Vac

16 A 20C 195 100 70 50+10C 215 110 75 55

25 A 20C 220* 155* 105 80+10C 220* 155* 115 85

32 A 20C 220* 155* 130* 100+10C 220* 155* 130* 110*

40 A 20C 220* 155* 130* 110*+10C 220* 155* 130* 110*

VPL4 at 480 V and 400 V 5VPL4-CT 10VPL4-CT 15VPL4-CT 20VPL4-CT

Electrical protection sizing

Start-up temperature

Maximum heating cable length per circuit (m) at 480 Vac and (at 400 Vac)

16 A 20C 390 (335) 195 (170) 130 (115) 100 (90)+10C 425 (365) 210 (185) 140 (125) 105 (95)

25 A 20C 450* (450) 310 (265) 205 (185) 155 (140)+10C 450* (450) 320* (290) 220 (195) 165 (150)

32 A 20C 450* (450) 320* (320) 260* (235) 200 (180)+10C 450* (450) 320* (320) 260* (250) 210 (190)

40 A 20C 450* (450) 320* (320) 260* (260) 225* (225)+10C 450* (450) 320* (320) 260* (260) 225* (225)

*The maximum heating cable length must not exceed these values, even when voltage adjustment factors are used.

The above numbers are for circuit length estimation only. For more detailed information please use the Tyco Thermal Controls TraceCalc software or contact your local Tyco Thermal Controls representative.

Tyco Thermal Controls requires the use of a 30 mA residual current device to provide maximum safety and protection from fire.

Where design results in higher leakage current, the preferred trip level for adjustable devices is 30 mA above any inherent capacitive leakage characteristic of the heater as specified by the trace heater supplier or alternatively, the next common available trip level for non adjustable devices, with a maximum of 300 mA. All safety aspects need to be proven.

Ordering details

Part description 5VPL2-CT 10VPL2-CT 15VPL2-CT 20VPL2-CTPart No. 451828-000 892652-000 068380-000 589252-000Part description 5VPL4-CT 10VPL4-CT 15VPL4-CT 20VPL4-CTPart No. P000000678 P000000679 P000000680 P000000681

ComponentsTyco Thermal Controls offers a full range of components for power connections, splices and end seals.

These components must be used to ensure proper functioning of the product and compliance with electrical requirements.

Trace-HeaTing remoTe moniToring module exTernes BeHeizungs-BerwacHungsmodul module de surveillance disTance pour Traage lecTrique

ML-RaychemRMM2E-IM-INSTALL061 R7IndustrIal Heat tracIng solutIons

RMM2-E

2InstallatIon InstructIons

description The Raychem Remote Monitoring Module (RMM2-E) is part of the Raychem NGC control and monitoring system. The RMM2-E accepts inputs from up to 8 RTDs (3 wire Pt 100 temperature sensors) measuring pipe or ambient temperature in a trace heating system. Up to 16 RMM2-E units communicate with a Raychem NGC-30 or NGC-40 controller using a single RS-485 cable.For technical assistance, call your local Pentair Thermal Management representative or the Pentair Thermal Management service center listed on the last page.

Parts (supplied)rMM2-e without enclosure RMM2-E Trace-heating Remote Monitoring

Module Replacement fuses Jumper for voltage selection Label

Hazardous area unit (rMM2-eX-e) RMM2-EX-E Trace-heating Remote

Monitoring Module Exn R II T6 glassfibre-reinforced polyester

enclosure 12 Ex e M20 glands for power cable

(6 to 12 mm cable diameter) with mushroom stopping plugs

Replacement fuses Jumper for voltage selection

WarnIng:This component is an electrical device. It must be installed correctly to ensure proper operation and to prevent frozen pipes, shock or fire. Read and carefully follow all the installation instructions.

approvalsHazardous areas

II 3 G/D T=70C EExn R II T6 (Ta 20C to +60C) Baseefa03ATEX0739

special conditions for safe use:All unused entry holes must be sealed using the scheduled cable gland and stopping plug.Consider the effects of direct heating on the exterior of the enclosure and the impact this may have on the internal temperature rise.

non-Hazardous areas RTD and RS-485 circuitry are isolated from power mains circuitry by protective separation.

tools required 7 mm flat-blade screwdriver 3 mm flat-blade screwdriver wire stripper/cutter 27 mm spanner (for M20 glands)

3specificationsSupply voltage (nominal): 115/230 Vac, 10%, jumper selectable, 50/60 HzPower consumption: 2,5 VAAmbient operating range: 40C to +60C 20C to +60C (Exn enclosure and glands) Relative humidity: 5 to 95%, noncondensingTemperature sensors: 3-wire RTD (Pt 100)Temperature coefficient: per IEC 751-1983 (100 at 0C)Sensor connections: Can be extended with a 3-core shielded cable of 20 max. per

conductor (e.g., 150 m with 3 x 1.5 mm2 cable)RS-485 connections: Shielded, single twisted pair, max. 1200 mReplaceable fuse: F 200 mA/250 V, Wickmann part number 19370-034-K (FAST BLOW)

Installation materials (not supplied)Fasteners4 screws for 6.5 mm holes for mounting enclosures

Pt 100 temperature sensors (rtds)MONI-PT100-NH Temperature sensor for non-hazardous areas with M20 cable glandMONI-PT100-EXE Temperature sensor for hazardous areas

remote Monitoring Module (rMM2-e)

1 Fuse (200 mA, 250V)2 Terminals for power input with provision

for daisy chaining

3 Voltage selector jumpers4 Terminals for RS-485 bus5 LEDs which indicate communications

activity

6 LED which indicates power to the RMM2-E unit

7 Rotary switch (16 position) to assign RS-485 address

8 Terminals for RTD lead wires9 Shorting block to select RS-485

termination mode

60 mm

42 mm

15mm

75 mm

125 mm

0

60 mm

42 mm

15mm

75 mm

125 mm

0

1

2 3 4

5

67

8

9

4overview of Installation Procedure for the rMM2-eX-eA. Mount RMM2-EX-E enclosure and install cables.B. Connect power and earth wiring and select voltage operating range.C. Connect RTD cables to the RMM2-EX-E.D. Select RS-485 address for the RMM2-EX-E and connect the RS-485 bus cables.note: Installation to be performed by suitable trained personnel.note: Keep the Remote Monitoring Module clean and dry prior to installation to avoid damage

to internal components.note: When RMM2-E is used for DIN-rail installation in a local customised panel or enclosure,

must be added 10 earth terminals for earthing of RTDs and power cables. Terminals should accept wires from 0.2 to 4 mm2.

a. Mount enclosure and Install cables1. select a suitable location for the

rMM2-eX-e enclosure.The enclosure is suitable for use in Zone 2 areas. Do not mount in Zone 1 or Zone 0 areas. For installations in Zone 1 areas, contact Pentair Thermal Management.Use the dimensions to locate mounting holes for the enclosure. Mount the enclosure using suitable screws (hole diameter 6 mm).

2. Install cablesInstall power cable(s), RS-485 cable(s) and RTD cables into enclosure using glands supplied. Keep stopping plugs in unused entries.

0

91

160 110

260

240 6.5

0

5B. connect Power and earth Wiring and select Voltage operating range

3. select the voltage operating rangeConnect the supplied wire jumpers to the appropriate terminals to select input voltage. The RMM2-E is supplied jumpered for 230 volts.

4. connect wiring from power source to designated terminals on rMM2-e.

Use only copper conductors. Connect power cable wires to the terminals marked L1 and L2 on the RMM2-E. If power is being daisy chained, be sure to maintain polarity of L1 and L2 wiring for incoming and outgoing wires. The terminals accept stranded wires from 0.2 2,5 mm2. (0,2 - 4 mm2 solid wire)

5. connect earth wiring.Connect the earth wire(s) to the earth terminals mounted on the DIN rail. The terminals accept 0,8 - 2,5 mm2 solid or stranded wires.

Jumpered for 115V

Jumpered for 230V

0

2

0

3

6c. connect rtd cables to the rMM2-eThe RMM2-E has terminals for 8 three-wire, RTDs (Pt 100 temperature sensors, to IEC 751); do not use other types of RTDs. Select RTDs appropriate for the usage:

MONI-PT100-NH Temperature sensor for non-hazardous areas

MONI-PT100-EXE Temperature sensor for hazardous areas

Install each RTD in accordance with the installation instructions shipped with it, and run the RTD lead wires to the RMM2-E.

note: Resistance of lead wires from each RTD must not exceed 20 (e.g. 150 m with 3 x 1,5 mm2 cable).

0

8

rMM2-e terminal no.

1

2

3

4

5

6

7

8

Piping drawing identification description or location

6. connect lead wires from each rtd to the selected rMM2-e terminal block

The RMM2-E has 8 terminal blocks to connect lead wires from 8 RTDs. Each RTD connection is numbered; the number identifies the RTD, and determines the order in which the Raychem NGC system displays the RTD measurement. Therefore, order the RTD connections in a manner that makes the Raychem NGC system display most meaningful.The RMM2-E cover shows the correct wiring arrangement for the RTD wires. With Raychem RTDs, connect the two RTD lead wires of the same colour to the terminals marked - and connect the RTD lead wire that is a different colour to the + terminal.

7. If rtd-shield is not earthed elsewhere, connect shield to earth terminal.

8. record the location/identification for each rtd.

Because the RMM2-E terminal connection number identifies the RTD in the Raychem NGC system, it is important to record the location of each RTD. Use the space below to record the connections, and label the RMM2-E or its enclosure with this RTD identification information.

7d. select rs-485 address and connect the rs-485 Bus cables

9. select the rs-485 address for the rMM2-e unit.

Each RMM2-E connected to a Raychem NGC control and monitoring system must have a unique address; if two RMM2-Es are assigned the same address, communication faults will result. To ensure that you assign a unique address to each RMM2-E unit, do the following:

Review the Raychem NGC system layout; if a layout document does not exist, create one. If it has not already been done, assign an RS-485 address to each RMM2-E (up to 16) connected to the Raychem NGC system.

If you are adding one or more RMM2-E units to an existing Raychem NGC network, confirm that the RS-485 addresses for existing RMM2-E units correspond to the system layout. See for details the programming guide of the Raychem NGC system.

By checking the RS-485 addresses on an existing system, you can avoid potential conflicts that would be confusing and time consuming to troubleshoot otherwise.Record the RS-485 address selected for the Remote Monitoring Module you are currently installing, and label the exterior of the enclosure with the address assigned to the RMM2-E. For reference, here are the 16 possible RS-485 addresses: (0 -15 HEXADECIMAL)

0 1 2 3 4 5 6 7

8 9 A B C D E F

10. set the rs-485 address for the rMM2-e unit using the rotary switch provided

Take of the lid and use a flat-blade screwdriver to rotate the RS-485 address switch to the desired position. The single character visible on the switch indicates the RS-485 address assigned.

0

7

6

0

11. connect the rs-485 busnote: Do not make connections to the RS-485 bus while it is connected to an operating Raychem NGC network. Damage and/or alarms could result.The RS-485 bus allows units with unique addresses to be connected together along a common bus. To add a new unit to the network, simply connect the RS-485 bus from the last unit to the new one, or insert the new unit between two existing units on the bus. The order in which units are attached to the RS-485 bus does not matter. There are just two constraints on the RS-485 network:

Each RMM2-E must be assigned a unique address

The RS-485 bus must be a continuous string from the first network device to the last RMM2-E in the system.

note: The RS-485 bus operates at 5 V, and equipment connected to it could be damaged by exposure to higher voltages. Take precautions to avoid exposing the RS-485 wiring to discharge of static electricity or other sources of high voltage potential; in particular, avoid contact with the power supply wiring.

8The RMM2-E has two sets of terminals for connections to the RS-485 bus. One terminal block allows the RMM2-E to connect to the RS-485 bus, the second allows a continuation of the bus to other RMM2-E units on the network. Observe polarity, which is indicated on the RMM2-E. Connect the incoming RS-485 bus to the set of terminals marked IN, observing the polarity noted on the cover of the RMM2-E; use the terminal marked S for the shield of the RS-485 cable. Connect the continuation of the RS-485 bus to the set of terminals marked OUT in the same manner (not required for the last RMM2-E in the network). Important: Do not connect the shield of the RS-485 cables to the enclosures grounding terminal. Connect the shield only to the RMM2-E terminals provided. To avoid the potential for spurious ground loops, the RS-485 cable shield should be connected to ground only in the Raychem unit. For the last RMM2-E in the network, terminate the RS-485 bus by removing the shorting block on jumper location J17 from 23 and placing it across pins 12.

OR

NGC-30 via UIT2 NGC-40 via Bridge module

PETK-1 for BSX, RSX, VSX PETK-2 for KSX, HTSX PETK-3 for HPT, FP PETK-3-ECM for HPT, FP PETK-3-ZT for HPT, FP Order separately to be used in conjunction

with Thermon connection kits

PETKPower & End Termination Kit

INSTALLATION PROCEDURES

2 FMG 10.0022X Ex eb IIC T4-T6, Ex tb IIIC T135C-T85C

1725 II 2 GD Ex eb IIC T4-T6, Ex tb IIIC T135C-T85C, FM 10ATEX0058X

PETK Power and End Termination Kits (per cable)PETK-1 for BSX, RSX, VSXPETK-2 for KSX, HTSXPETK-3 for HPT, FPPETK-3-ECM for HPT, FPPETK-3-ZT for HPT, FP

Receiving, Storing and Handling . . .1. Inspect materials for damage incurred during ship-

ping.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.

1 2

Item Qty. Description

1 1 RTV Tube

2 1 Power Connection Boot

3 1 End Cap

4 1 Tape Strip (PETK-3 Only)

5 1 End Termination Caution Label

6 1 Grommet (For PETK-3 Terminator kits only)

7 1 Ground Sleeve

3

54

NOTE: This label is to have been placed over the end termination of an electrical heat tracing circuit. Electrical lockout may be required before working on this line or removal of thermal insulation.

6

Kit Contents . . .

7

Tools Required . . .

Note:1. These sets have been evaluated as components of Thermons Approved con-

nection kits, such that the area use ratings depend on the rating of the connec-tion kits.

PETK Certifications/Approvals 1 . . .

PETK INSTALLATION PROCEDURESWarnings . . .

Due to the risk of electrical shock, arcing and firecaused by product damage or improper usage, installation or maintenance, a ground-fault protection device is required.

InstallationmustcomplywithThermonrequirements(including form PN 50207U for Ex systems) and be installed in accordance with the regulations as per the norm EN IEC 60079-14 for hazardous areas (where applicable), or any other applicable national and local codes.

Component approvals and performance ratings arebasedontheuseofThermonspecifiedpartsonly.

De-energize all power sources before openingenclosure.

Keependsofheatingcableandkitcomponentsdrybefore and during installation.

Minimumbending radiusofheatingcable is32mm(except HPT is 57 mm and FP is 19 mm).

Individuals installing theseproducts are responsiblefor complying with all applicable safety and health guidelines. Proper Personal Protective Equipment (PPE) should be utilized during installation. Contact Thermon if you have any additional questions.

The following installation procedures are guidelines for the installation of the Power and End Termination Kit. For translations other than English and local language translation provided here, please contact Thermon. The English language installation procedure shall govern.

Note:Wirepinsmayberequiredasperclient/projectspecification(orderseperately).

3Step 2: Matrix Removal for BSX, RSX, HTSX, KSX, and VSX Cables

2b. Cut a 4mm strip of conductive matrix between the conductors. Do not cut bus wire strands.

2c. Cut and remove the 4mm matrix strip.2a. Cut and remove primary insulation jacket (BSX and RSX cables only).

Step 1: Remove Heating Cable Overjacket and Separate Metallic Braid to Form Pigtail

1b. Separate braid strands at edge of over-jacket and pull cable through opening in braid.

1c. Twist braid into a pigtail. Trim ends of braid.

1a. Cut and remove heating cable overjacket. Do not cut metallic braid.

For HPT and FP cable exchange grommet supplied in Terminator kit with: GRW-G provided in PETK-3 GRW-GT2 provided in PETK-3-ECM GRW-G/Tstat provided in PETK-3-ZT

IMPORTANT!Hea t ing cab le mus t be proper ly insta l led wi th in expedi ter assembly and mounted to pipe prior to terminating with PETK kit.

See Terminator Installation Instructions for expediter mounting details.

152 mm(6)

PETK INSTALLATION PROCEDURES

4 mm(.15)4 mm

(.15)

Terminator: Route cable through base entry and mount expediter to pipe using pipe band. Do not band over cable.

GRW GRW-G GRW-GT2 GRW-G/Tstat

4Step 2: Heating Element Removal for HPT and FP Cables

2b. Cutand removefiberglassoverlayandheating element. Push any remaining heating element wire under the primary insulation jacket.

3a. Apply RTV sealant to cable to cover dis-tance of at least 3mm and slide boot onto the end of the cable.

3b. Slide boot onto the end of the cable and green/yellow ground sleeve over twisted braid. Expose 13mm (0.5) of bus wire.

2a. Cut and remove primary insulation jacket.NOTE: Bus connection must be no more than

50 mm (2) from pipe as addressed in connection kit instructions.

2c. Cut and remove pairing jacket. Do not cut bus wire insulation.

Step 3: Install Power Boot on Heating Cables

120 mm(4.75)

117 mm(4.62)

13 mm(.5)

3c. Crimp conductor wire pins on each con-ductor and on twisted braid if required asperclient/projectspecification(orderseparately).

PETK INSTALLATION PROCEDURES

54a. Cut and remove heating cable overjacket. 4b. Trim away exposed braid from cable. 4c. Fill the end cap with RTV sealant and apply a circumferential bead to cable [minimum of 3 mm (0.12) wide]. Slide end cap onto end of cable.

Step 4: End Termination for HPT and FP

4a. Trim the cable 75mm (3) from the bus connection.

4b. Cut and remove overjacket and trim away exposed braid from cable.

4c. Cut and remove primary insulation jacket.

4d. Cutand removefiberglassoverlayandheating element. Push any remaining heating element wire under the primary insulation jacket.

4e. Cut and remove pairing jacket. Stagger cut one of the bus wires.

4f. Tape bus wires individually and then together. Continue taping to cover over-jacket. Fill the end cap with RTV sealant and apply a circumferential bead to cable [minimum of 3 mm (0.12) wide]. Slide end cap onto end of cable.

Do not cut bus wire strands.

13 mm(.5)

75 mm(3)

Bus Connection

25 mm(1)

19 mm(.75)

6 mm(.25)

PETK INSTALLATION PROCEDURES

Step 4: End Termination for BSX, RSX, HTSX, KSX, and VSX Cables

6Cable Take-off for BSX, RSX, HTSX, KSX and VSX

For Power Connecton Boot Termination For End Cap Termination

NOTE: Images may not be printed to scale.

Cable Take-off for HPT and FP Heating Cables

For End Cap Termination

0

1

2

3

4

5

6

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

For Power Connection Boot Termination

0

1

2

3

4

5

6

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

mm inches mm inches

Specificationsandinformationsubjecttochangewithoutnotice.PN50136U-0514

THERMON . . . The Heat Tracing Specialistswww.thermon.com

Corporate Headquarters100 Thermon Dr. PO Box 609San Marcos, TX 78667-0609 USAPhone: +1 512-396-5801

European HeadquartersBoezemweg 25 PO Box 2052640 AE Pijnacker The NetherlandsPhone: +31 (0) 15-36 15 370

FortheThermonofficenearestyou visit us at . . .

www.thermon.com

NOTE: Bus connection must be no more than 50 mm (2) from pipe as ad-dressed in connection kit instruc-tions.

NOTE: Images may not be printed to scale.

CONSTRUCTION1 Nickel-plated copper bus wires (16 AWG)2 Radiation cross-linked semiconductive heating matrix3 Radiation cross-linked dielectric insulation4 Tinned copper braid5Polyolefinoverjacketprovidesadditionalprotectionfor

cable and braid where exposure to aqueous inorganic chemicals is expected.

OPTIONS6FOJFluoropolymeroverjacketovertinnedcopperbraid

provides additional protection to cable and braid where exposure to organic chemicals or corrosives is expected.

BASIC ACCESSORIES Thermonofferssystemaccessoriesdesignedspecificallyfor rapid, trouble-free installation of Thermon heatingcables.

All cables require a connection kit to comply with approval requirements. Information on accessories to completeaheatercircuit installationcanbefoundintheHeatingCableSystemsAccessoriesproductspecificationsheet(Form TEP0010).

APPLICATIONBSXself-regulatingheatingcablesaredesignedtoprovidefreeze protection or process temperaturemaintenancetometallicandnonmetallicpiping,tanksandequipment.TheheatoutputofBSXcablevaries inresponsetothesurroundingconditionsalongtheentirelengthofacircuit.Whenever the heat loss of the insulated pipe, tank orequipmentincreases(asambienttemperaturedrops),theheatoutputofthecableincreases.Conversely,whentheheat loss decreases (as the ambient temperature rises or productflows),thecablereactsbyreducingitsheatoutput.BSXcablesareapprovedforuseinordinary(nonclassified)areasandhazardous(classified)areas.

RATINGSAvailable watt densities ................ 3,5,8,10w/ft@50F

(10,16,26,33w/m@10C)Supply voltages ..........................110-120or208-277VacMax. maintenance temperature ...................150F(65C)Max. continuous exposure temperature Power-off .................................................185F(85C)Minimum installation temperature............... -60F(-51C)Minimum bend radius @5F(-15C) ........................................ 0.38(10mm) @-76F(-60C) ................................... 1.25 (32 mm)T-rating 1 3,5,8w/ft(10,16,26W/m) ...............T6185F(85C) 10w/ft(33W/m) ...............................T5212F(100C)

Notes1. T-rating per the National Electrical Code and Canadian Electrical Code.

PRODUCT SPECIFICATIONS

BSX SELF-REGULATINGHEATINGCABLE

1

2

3

4

56

THERMON The Heat Tracing Specialists CorporateHeadquarters:100ThermonDrPOBox609SanMarcos,TX78667-0609Phone:512-396-58011-800-820-4328 FortheThermonofficenearestyouvisitusat...www.thermon.com

FormTEP0067-0714ThermonManufacturingCo.PrintedinU.S.A.Informationsubjecttochange.

CERTIFICATIONS/APPROVALS FM Approvals Ordinary Locations Hazardous(Classified)Locations ClassI,Division2,GroupsB,CandD ClassII,Division2,GroupsFandG ClassIII,Divisions1and2 ClassI,Zones1and2,AExeII

Underwriters Laboratories Inc. Ordinary Locations Hazardous(Classified)Locations ClassI,Division2,GroupsA,B,CandD ClassII,Division2,GroupsFandG ClassIII,Divisions1and2

Canadian Standards Association Ordinary Locations Hazardous(Classified)Locations ClassI,Divisions1&2,GroupsA,B,CandD ClassII,Divisions1&2,GroupsE,FandG Ex e II

POWER OUTPUT CURVES 1The power outputs shown apply to cable installed on insulated metallic pipe (using the procedures outlined in IEEE 515) at the service voltages stated below. For use onotherservicevoltages,contactThermon.

CIRCUIT BREAKER SIZING 2Maximum circuit lengths for various circuit breakeramperagesare shownbelow.Breaker sizing shouldbebasedontheNationalElectricalCode,CanadianElectricalCode or any other applicable code. The National Electrical CodeandCanadianElectricalCoderequireground-faultprotectionofequipmentforeachbranchcircuitsupplyingelectricheatingequipment.Checklocalcodesforground-faultprotectionrequirements.

Catalog Number120 Vac Nominal

Catalog Number240 Vac Nominal

Power Outputat 50F (10C)

w/ft (m)

BSX 3-1 BSX 3-2 3 (10)

BSX 5-1 BSX 5-2 5 (16)

BSX8-1 BSX8-2 8(26)

BSX 10-1 BSX 10-2 10 (33)

Notes1.Formoreprecisepoweroutputvaluesasafunctionofpipetemperature,referto

CompuTrace.2.Basedon the tripcurrentcharacteristicofTypeQOBorTypeQOequipment

protectiondevices.Fordeviceswithother tripcurrentcharacteristics,contactThermon.

3.Themaximumcircuitlengthisforonecontinuouslengthofcable,notthesumofsegmentsofcable.RefertoCompuTracedesignsoftwareorcontactThermonforcurrentloadingofsegments.

WattsperFoo

t(w/m

)

4(13)

6(20)

PipeTemperatureF(C)

0

2(6)

8(26)

12(39)

10(33)

30(-1)

50(10)

70(21)

90(32)

110(43)

130(54)

150(66)

BSX 10

BSX8

BSX 3

BSX 5

120 Vac Service Voltage Max. Circuit Length 3 vs. Breaker Size ft (m)

Catalog Number

Start-Up Temperature

F (C) 20A 30A 40A

BSX 3-1

50 (10) 360 (110) 360 (110) 360 (110)

0(-18) 325(99) 360 (110) 360 (110)

-20(-29) 285(87) 360 (110) 360 (110)

-40 (-40) 260(79) 360 (110) 360 (110)

BSX 5-1

50 (10) 240(73) 300(91) 300(91)

0(-18) 205 (62) 300(91) 300(91)

-20(-29) 185(56) 275(84) 295(90)

-40 (-40) 165 (50) 250(76) 265(81)

BSX8-1

50 (10) 190(58) 240(73) 240(73)

0(-18) 150 (46) 225(69) 240(73)

-20(-29) 135 (41) 200 (61) 240(73)

-40 (-40) 120(37) 180(55) 215 (66)

BSX 10-1

50 (10) 160(49) 200 (61) 200 (61)

0(-18) 110 (34) 170(52) 200 (61)

-20(-29) 100 (30) 150 (46) 200 (61)

-40 (-40) 90(27) 135 (41) 180(55)

240 Vac Service Voltage Max. Circuit Length 3 vs. Breaker Size ft (m)

Catalog Number

Start-Up Temperature

F (C) 20A 30A 40A

BSX 3-2

50 (10) 725(221) 725(221) 725(221)

0(-18) 650(198) 725(221) 725(221)

-20(-29) 575(175) 725(221) 725(221)

-40 (-40) 515(157) 725(221) 725(221)

BSX 5-2

50 (10) 480(146) 600(183) 600(183)

0(-18) 395(120) 590(180) 600(183)

-20(-29) 350(107) 525 (160) 590(180)

-40 (-40) 315(96) 475(145) 530 (162)

BSX8-2

50 (10) 385(117) 480(146) 480(146)

0(-18) 285(87) 425 (130) 480(146)

-20(-29) 255(78) 380(122) 480(146)

-40 (-40) 230(70) 345 (116) 430 (131)

BSX 10-2

50 (10) 280(85) 400 (122) 400 (122)

0(-18) 225(69) 340 (104) 400 (122)

-20(-29) 200 (61) 300(91) 400 (122)

-40 (-40) 180(55) 275(84) 365 (111)

PRODUCT SPECIFICATIONS

BSX SELF-REGULATINGHEATINGCABLE

Power Connection KitInstallation Instructions

For Power Connection (1-3 Heating Cables), In-Line Splice Connection, T-Splice Connection, or End Termination (1-2 Heating Cables) Applications

Terminator ZP-L-XPfor use with RSX, TSX, VSX self-regulating heating cables

Terminator ZP-S-XPfor use with BSX, HTSX, KSX self-regulating, HPT power-limiting,

and FP constant watt heating cables

IP66 NEMA/Type 4X -60C Ta +55C Listed Heat Tracing Cable System 137MOrdinary & Hazardous LocationsClass I, Division 2, Groups A, B, C & DClass II, Division 2, Groups F & G, Class IIIClass I, Zone 1, AEx e II T4-T6Ex e II T4-T6

0539 II 2 G & D Ex e II T4-T6 DEMKO 06ATEX0622119

Kit Contents 1

Due to the risk of electrical shock, arcing and fire caused by product damage or improper usage, installation or maintenance, a ground-fault protection device is required.

Installation must comply with Thermon requirements (including form PN 50207U for Ex systems) and be installed in accordance with the regulations as per the norm EN IEC 60079-14 for hazardous areas (where applicable), or any other applicable national and local codes.

Component approvals and performance ratings are based on the use of Thermon specified parts only.

De-energize all power sources before opening enclosure.

Keep ends of heating cable and kit components dry before and during installation.

Minimum bending radius of heating cable is 32 mm (except HPT is 57 mm and FP is 19 mm).

Warnings

Certifications/Approvals

B-type banding - order separatelyB-4: for pipes up to 4B-10: for pipes up to 10B-21: for pipes up to 21 15

1312

11

10 14

1

2

3

4 5

6 7 8 9

2 1 Junction Box Lid

Item Qty Description

Support Cap w/ O-ringThreaded Grommet CompressorGrommetSupport Base w/ O-ring

1 1 Expediter Assembly

3 1 Junction Box Base w/ O-ring

4 1 Terminal Blocks w/ DIN Rail (Refer to terminal specifications for maximum allowable wire size)5 1 Junction Box Lid Cord

6 1 Nut

7 1 Banding Guide

8 1 Power Gland9 1 Blind Plug

10 2 Conductor Wire Pins (per cable)

11 1 Braid Wire Pin (per cable)

12 1 Power Connection Boot (per cable)

13 1 Ground Sleeve (per cable)

14 1 RTV Tube (per cable)

15 1 Banding

Tools Required

Terminator-LN-Tool(order separately)

PETK power termination components (per cable) - order separatelyPETK-1: for RSX, TSX, VSXPETK-2: for BSX, KSX, HTSXPETK-3: for HPT

3 mm8 mm 28 mm

29 mm33 mm

Installation Instructions 2

Locate bus connection (HPT and FP only) and cable as shown. Cut end of cable at angle to aid in piercing grommet. Leave additional cable for expansion loop. See page 4 for multiple cable installation tips.

1.

6.

5.

3.

4.

2.

7.

8.

Insert cable into expediter. If mounted on bottom or side of pipe, punch out weep hole.

Slide expediter toward pipe and route cable through support base entry.

Insert banding guide into expediter and snap into place.

Mount expediter to pipe using pipe band. Do not band over cable.

Cut off end of cable.

Terminate cable with appropriate PETK termination kit. Refer to PETK installation instructions.

Push excess cable back through expediter. Tighten cap securely. Tape cable expansion loop to pipe.

Installation Instructions 3

Mount junction box base on expediter. Make sure to align slots to properly orient junction box base. Tighten nut with Terminator-LN-Tool. If mounting horizontally, threaded gland holes must face downward.

Install M25 power gland and M25 blind plug. For in-line splice, T-splice, or end termination, install additional M25 blind plug (order M25-B-EXE separately) instead of M25 power gland.

Install quick mount terminal blocks and tighten screws (if necessary).

Complete system wiring. Terminal set screws shall be tightened to a torque value of 1.4 Nm (12.4 lb-in). See page 5 for wiring details.

Install junction box lid and twist hand tight. Insert screw-driver into ratchet slots located on side of junction box base.

Use screwdriver to ratchet on junction box lid. Lid will rotate 30 degrees.

Lid latch mechanism fully engaged. To remove lid, repeat steps 14 and 15 but in the opposite direction.

9.

10.

11.

13.

14.

15.

16.12.

Install power cable (if necessary). The insulation on the conductors is to be stripped back in accordance with the terminal block manufacturers recommendations.

TwoCableLayoutTips 4

A1.

B2.

B1.

B3.

A2.

Locate bus connection (HPT and FP only) and cable as shown. Cut end of cable at angle to aid in piercing grom-met. Leave additional cable for expansion loop.

Insert two cables into expediter.

Locate bus connection (HPT and FP only) and cable as shown. Cut end of cable at angle to aid in piercing grom-met. Leave additional cable for expansion loop.

Insert three cables into expediter.

Mount expediter wi