PBM-200-A Multiple entry power junction box -...

PBM-200-A Multiple entry power junction box

Installation Instructions PBM-200-A Multiple entry power junction box with cold applied connection technology for use with BARTEC PSB / HSB trace heaters

Consignes d’installation Boîte de raccordement à plusieurs entrées PBM-200-A à technologie de connexion froide pour utilisation avec les câbles chauffants de type BARTEC PSB / HSB

Table of contents

Overview 2

Certifications / Approvals 2

Technical data 2

Safety 2

Kit contents 3

Accessories 4

Installation 5

Preparation 5

Heating circuit length (PSB trace heaters) 5

Heating circuit length (HSB trace heaters) 5

Required tools 6

Cautions and warnings 6

Unrolling the trace heater 6

Installation on pipes 6

Fastening 7

Preparation of the trace heaters 7

Installation of the mounting stand 12

Preparation of the power connection box 14

Wiring 18

Installation of the end seal 20

Troubleshooting 21

Installation Instructions PBM-200-A Multiple entry power junction box

21-54E1-6D0017 Reservation Technical data subject to change without notice. No claims for damages arising from alternations, errors or misprints shall be allowed.

Page 2 / 21

Overview

This manual introduces the installation and operation of the BARTEC PBM-200-A Multiple entry power junction box for connection of up to 3 trace heaters.

The trace heating system uses a self-regulating trace heater. It features a temperature-dependant resistive element between two parallel cop-per conductors, that regulates and limits the heat output of the trace heater according to the ambient temperature. If the ambient tempera-ture rises, the power output of the trace heater is reduced. This self-regulating property prevents overheating which would cause damage to the trace heater. Even crossing or overlapping with other trace heaters (or other portions of the same trace heater) are possible.

The heating system is set up as a fixed equipment heating system for pipes in ordinary and hazardous areas. Thanks to the parallel design the trace heater can be cut and installed to any required length.

The manual applies for the following trace heaters:

BARTEC PSB BARTEC HSB

The following terms describe the parts of the trace heater within these instructions:

Certifications / Approvals

PBM-200-A Multiple entry power junction box for BARTEC PSB / HSB trace heaters

Technical data

Ambient temperatures -67°F to 131 °F / -55°C to 55 °C

Operation temperatures

PSB

HSB

-40°F to 150 °F / -40°C to 65 °C -76°F to -250 °F / -60°C to -120 °C

Voltage 110 to 254 VAC

Heat output 3 to 20 W/ft

Resistance Grounding braid: < 18.2 Ω/km

Explosion protection

Class I, Div 2 Group A, B, C, D Class II, Div 2 Group E, F, G

Class III (for information on T-ratings see the design

guide of the trace heater)

Heater dimensions PSB

HSB

0.46” x 0.22” (11.6 x 5.6 mm) 0.40” x 0.19” (10.2 x 4.8 mm)

Minimum bending radius 1” (25 mm)

Do not bend on the narrow axis.

Maximum power conductor size

10 AWG (6 mm²)

Terminals Spring clamp EX e 4x2 lines, 3x2 PE

Safety

For safe installation and operation of the PBM-200-A Multiple entry power junction box the technical requirements and instructions given in this manual must be followed.

WARNING Risk of fire or electrical shock. Follow these guidelines to avoid per-sonal injury or material damage.

All electrical systems and installations must comply with BARTEC GmbH requirements and be installed in accordance with the relevant electrical codes and any other applicable national and local codes.

BARTEC GmbH, the US and Canadian electrical codes require ground fault protection to be provided for all trace heating circuits.

Install the connection kit, trace heaters and end seals carefully. Use the trace heater in accordance with the intended purpose and strictly

comply with the operational data specified in section Technical Data. The bending radius of the trace heater must be at least 1” (25 mm).

Do not bend on the narrow axis. Any defective component of the kit must be replaced before installa-

tion. To avoid short circuits, do not connect the trace heater bus wires

together. Keep all components and the trace heaters dry before and during

installation. During installation silicone adhesive is used. Follow the safety in-

structions given on the packaging. Keep these instructions for future reference. If applicable, leave them

with the end user. De-energize before installation or servicing. Use only original BARTEC accessories.

bus wire

heating element

insulation jacket

grounding braid

outer jacket


Page 3 / 21

Kit contents

The following table lists the kit contents of the PBM-200-A Multiple entry power junction box:

PBM-200-A Multiple entry power junction box with cold applied connection technology

2 x Silicone pants

2 x End cap

6 x Ferrule

1 x Silicone adhesive

1 x Safety datasheet for

silicone adhesive

2 x Green/yellow tube for grounding braid

1 x Cover for junction box incl. 4 fixing screws

1 x Junction box with connection terminals

incl. M20 blind plug

2 x Trace heater

grommet

1 x Blind plug

1 x Top unit of the mounting stand incl. sealing ring and lock nut

1 x Base unit of the mounting stand



Page 4 / 21

Accessories

The following accessories are available for the PBM-200-A Multiple entry power junction box.

Off pipe cable gland kit and end seal

spare parts kit for replacement of damaged or lost parts

Catalog No.: CAK-PH-A

On pipe cable gland kit and end seal

spare parts kit for replacement of damaged or lost parts

Catalog No.: CAK-D5-A

Adhesive tapes

for trace heater installation on pipes etc.

Catalog No.:

PT-164 (100706) (for up to 212 °F / 100 °C)

GT-108 (392328) (for up to 356 °F / 180 °C)

Aluminium adhesive tape

application under trace heaters for better heat distribution

Catalog No.: AT80-164 (for up to 176 °F / 80 °C)

AT150-164 (for up to 302 °F / 150 °C)

Pipe straps

for fixation of mounting stands on pipes etc.

Supplied upon request, contact your local BARTEC distributor

Insulation entry bush

An insulation entry bush is used to prevent the heating cable being damaged where it passes through the thermal insulation outer cladding.

Catalog No.: IEB-P (for PSB) IEB-H (for HSB)

Electrical warning label

warning label for trace heater circuits

Catalog No.: HTWL-DE (German) HTWL-US (English) HTWL-FR (French) HTWL-RU (Russian)

3x

3x


Page 5 / 21

Installation

Preparation

Before installing any electric trace heating, the person installing must check if the trace heating has been designed and planned correctly. It is particu-larly essential to verify the following points:

complete project planning documentation, operating instructions and installation instructions. correct selection of the trace heater and accessories with respect to:

calculation of heat losses max. permissible operating temperature max. permissible ambient temperature temperature class heating circuit length

Before installing, make sure that all piping and equipment is properly installed and pressure tested.

Heating circuit length (PSB trace heaters)

The following table shows the maximum circuit lengths in ft (m) for the different PSB trace heater types with standard circuit breaker amperages. Breaker sizing should be based on the National Electrical Code, Canadian Electrical Code or any other local or applicable code.

Power output

Trace heater type

Start-up temperature

°F (°C)

Maximum heating circuit length in ft. (m)

Operating Voltage: 120 VAC Operating Voltage: 208 VAC Operating Voltage: 240 VAC

20 A 30 A 40 A 20 A 30 A 40 A 20 A 30 A 40 A

3 PSB

07-5801-.10.

+50 (+10) 312 (95) 312 (95) 312 (95) 591 (180) 591 (180) 591 (180) 673 (205) 673 (205) 673 (205)

0 (-18) 295 (90) 312 (95) 312 (95) 551 (168) 591 (180) 591 (180) 597 (182) 640 (195) 640 (195)

-20 (-29) 246 (75) 312 (95) 312 (95) 476 (145) 591 (180) 591 (180) 505 (154) 623 (190) 640 (195)

-40 (-40) 240 (73) 312 (95) 312 (95) 420 (128) 558 (170) 591 (180) 479 (146) 623 (190) 640 (195)

5 PSB

07-5801-.15.

+50 (+10) 262 (80) 262 (80) 262 (80) 486 (148) 492 (150) 492 (150) 525 (160) 525 (160) 525 (160)

0 (-18) 197 (60) 262 (80) 262 (80) 394 (120) 492 (150) 492 (150) 394 (120) 525 (160) 525 (160)

-20 (-29) 161 (49) 262 (80) 262 (80) 328 (100) 443 (135) 476 (145) 328 (100) 525 (160) 525 (160)

-40 (-40) 157 (48) 256 (78) 262 (80) 312 (95) 394 (120) 476 (145) 315 (96) 512 (156) 525 (160)

8 PSB

07-5801-.26.

+50 (+10) 190 (58) 207 (63) 207 (63) 344 (105) 377 (115) 377 (115) 381 (116) 413 (126) 413 (126)

0 (-18) 125 (38) 184 (56) 207 (63) 246 (75) 312 (95) 344 (105) 246 (75) 374 (114) 413 (126)

-20 (-29) 105 (32) 177 (54) 207 (63) 203 (62) 289 (88) 322 (98) 210 (64) 348 (106) 404 (123)

-40 (-40) 98 (30) 164 (50) 207 (63) 190 (58) 272 (83) 302 (92) 197 (60) 328 (100) 387 (118)

10 PSB

07-5801-.33.

+50 (+10) 148 (45) 167 (51) 180 (55) 262 (80) 312 (95) 312 (95) 295 (90) 335 (102) 361 (110)

0 (-18) 98 (30) 138 (42) 148 (45) 190 (58) 256 (78) 295 (90) 197 (60) 276 (84) 295 (90)

-20 (-29) 85 (26) 125 (38) 131 (40) 164 (50) 230 (70) 269 (82) 171 (52) 236 (72) 262 (80)

-40 (-40) 72 (22) 115 (35) 118 (36) 131 (40) 180 (55) 230 (70) 131 (40) 197 (60) 230 (70)

Heating circuit length (HSB trace heaters)

The following table shows the maximum circuit lengths in ft (m) for the different HSB trace heater types with standard circuit breaker amperages. Breaker sizing should be based on the National Electrical Code, Canadian Electrical Code or any other local or applicable code.

Power output

Trace heater type

Start-up temperature

°F (°C)

Maximum heating circuit length in ft. (m)

Operating Voltage: 120 VAC Operating Voltage: 208 VAC Operating Voltage: 240 VAC

20 A 30 A 40 A 20 A 30 A 40 A 20 A 30 A 40 A

5 HSB

07-5803-.15.

+50 (+10) 312 (95) 312 (95) 312 (95) 541 (165) 541 (165) 541 (165) 620 (189) 620 (189) 620 (189)

0 (-18) 262 (80) 312 (95) 312 (95) 492 (150) 541 (165) 541 (165) 502 (153) 620 (189) 620 (189)

-20 (-29) 246 (75) 312 (95) 312 (95) 443 (135) 541 (165) 541 (165) 489 (149) 620 (189) 620 (189)

-40 (-40) 246 (75) 312 (95) 312 (95) 427 (130) 541 (165) 541 (165) 472 (144) 620 (189) 620 (189)

10 HSB

07-5803-.30.

+50 (+10) 184 (56) 190 (58) 190 (58) 315 (96) 374 (114) 374 (114) 361 (110) 374 (114) 374 (114)

0 (-18) 154 (47) 190 (58) 190 (58) 279 (85) 374 (114) 374 (114) 312 (95) 374 (114) 374 (114)

-20 (-29) 148 (45) 190 (58) 190 (58) 262 (80) 374 (114) 374 (114) 302 (92) 374 (114) 374 (114)

-40 (-40) 141 (43) 190 (58) 190 (58) 256 (78) 367 (112) 374 (114) 279 (85) 367 (112) 374 (114)

15 HSB

07-5803-.45.

+50 (+10) 131 (40) 135 (41) 135 (41) 230 (70) 269 (82) 269 (82) 262 (80) 269 (82) 269 (82)

0 (-18) 112 (34) 135 (41) 135 (41) 203 (62) 269 (82) 269 (82) 223 (68) 269 (82) 269 (82)

-20 (-29) 108 (33) 135 (41) 135 (41) 190 (58) 269 (82) 269 (82) 217 (66) 269 (82) 269 (82)

-40 (-40) 98 (30) 135 (41) 135 (41) 187 (57) 262 (80) 269 (82) 210 (64) 262 (80) 269 (82)

20 HSB

07-5803-.60.

+50 (+10) 98 (30) 105 (32) 105 (32) 177 (54) 210 (64) 210 (64) 197 (60) 210 (64) 210 (64)

0 (-18) 89 (27) 105 (32) 105 (32) 154 (47) 210 (64) 210 (64) 174 (53) 210 (64) 210 (64)

-20 (-29) 82 (25) 105 (32) 105 (32) 148 (45) 210 (64) 210 (64) 164 (50) 210 (64) 210 (64)

-40 (-40) 75 (23) 105 (32) 105 (32) 141 (43) 203 (62) 210 (64) 157 (48) 203 (62) 210 (64)



Page 6 / 21

Required tools

The following tools are required for installation of the trace heating system:

Wire cutters Flat screwdriver Cross-head screwdriver Electricians screwdriver Tape measure

Utility knife Needle-nose pliers (2x) Tongue and groove pliers Crimping pliers

Cautions and warnings

WARNING Risk of fire or electrical shock. De-energize all power circuits before installation or servicing. Always use ground fault equipment within the heat tracing system.

Double-check that all power circuits are de-energized before you begin your work.

Make sure that you do not exceed the maximum heating circuit length for the trace heater type you use.

Unrolling the trace heater

WARNING Risk of short cuts and/or material damage. Keep the trace heater ends dry before and during installation. Observe the trace heater’s installation instructions.

Unroll the required trace heater in a straight line and cut to the correct length. Cut off the trace heater ensuring a straight cut.

Do not bend or pinch the trace heater, or pull it over sharp edges.

Installation on pipes

This step is necessary for plastic pipes only since plastic pipes conduct heat less efficiently than metal pipes do. For metal pipes continue with step 5.

Place aluminium tape where the trace heater will be attached for better heat distribution.

CAUTION Risk of injury and/or material damage. Never tread on or drive over the trace heater. Do not use it as a loop for stepping on.

Preferably install the trace heater in a straight line around the pipe. This saves time, helps to avoid installation mistakes and prevents damage to the trace heater during the thermal insulation work. Fur-thermore the trace heater can be easily localised later on.

The trace heater should be installed spirally only if this is expressly specified in the project planning.

NOTICE When installing allow for an additional length of trace heater for assembling splice connections, tee branches, end seals etc. (ap-prox. 1.6 ft (0.5 m) for each).

2

3

4

5

2 x

1

2 x


Page 7 / 21

Preferably install the trace heater in the lower half of the pipe, but not on the lowest point. This prevents mechanical damage and allows for better heat distribution.

If you use multiple trace heaters, position them with an offset of 90”.

Fastening

At first, select the correct fastening material:

Always use polyester adhesive tape or glass cloth tape that suits the expected temperatures.

Preferably use BARTEC adhesive tapes. Never use PVC insulating tape or self-adhesive tapes containing

PVC or VC. Do not use metal fixtures.

Fasten the trace heater with the adhesive tape or zip ties at inter-

vals of at least 12" (300 mm) on plastic pipes or 36" (900 mm) on steel pipes.

NOTICE In order to ensure good heat transmission the trace heater must have a flat, flush fit over the whole length. If necessary, reduce the distances between the fixing points.

Preparation of the trace heaters

Pass 2 trace heaters through the base unit of the mounting stand. Do not fix the mounting stand on the pipe yet.

Slide the 2 Trace heater grommets onto the trace heaters and into

the seal seat. Make sure that the trace heaters stand out approximately

10” (25 cm). This makes cable preparation easier.

6

8

7

10

9



Page 8 / 21

Slide the top unit of the mounting stand over the trace heaters. Slightly tighten the 4 fixing screws using a crosshead screwdriver.

Do not tighten them fully yet to allow the trace heaters to be moved.

This step is only necessary for the 3rd trace heater (if any).

Install an insulation entry bush (Catalog No.: IEB-P/-H) onto the remaining trace heater. To do so, refer to the installation manual that comes with the kit.

Then install an off pipe cable gland kit (Catalog No.: CAK-PH-A). To do so, refer to the installation manual that comes with the kit.

Remove 5 ¾" (145 mm) of the outer jacket on the end of the trace heater.

Repeat steps 13-27 for all trace heaters.

Push the grounding braid back. Use the screwdriver to form an eyelet. Be careful not to damage the internal insulation jacket.

Bend the trace heater and pull the heating element out of the grounding braid.

14

15

11

13

12


Page 9 / 21

Twist the grounding braid in order to form a wire.

Push the green/yellow tube onto the twisted grounding braid.

Remove 4 1/2" (115 mm) of the internal insulation jacket.

Make a small cut over and under each bus wire. Take care not to damage the bus wires.

Carefully make an incision into the edges of the heating element. Take care not to damage the bus wires.

16

17

18

19

19



Page 10 / 21

Pull off the bus wires while holding the heating element.

Remove any remaining heating element that sticks to the bus wires.

CAUTION Risk of malfunction of the heating system. Before you continue, make sure that the bus wires are in a faultless condition.

Twist the bus wires.

Remove the remaining heating element. Take care not to damage the bus wires.

20

21

22


Page 11 / 21

Carefully cut in a triangle (1/4” / 5 mm) between the bus wires. Take care not to damage the bus wires.

WARNING The silicone adhesive may cause irritation to skin and eyes. Avoid eye contact. Avoid repeated or prolonged skin contact. Follow the safety instructions given on the packaging.

Put silicone adhesive onto the exposed heating element and insula-tion jacket.

Thread the bus wires into the silicone pants. You might add further silicone adhesive to ensure optimal sealing. Slide the silicone pants all the way onto the heating element.

Crimp a ferrule onto the twisted grounding braid.

Crimp a ferrule onto each of the bus wires.

24

27 25

26

23



Page 12 / 21

Installation of the mounting stand

Pull back the trace heaters. For easy cable connection it is enough when the silicone pants stands out of the mounting stand.

Now, tighten the 4 fixing screws of the top unit of the mounting stand using a cross-head screwdriver.

28 29


Page 13 / 21

Install the pipe straps and tighten them firmly using a screwdriver.

30



Page 14 / 21

Preparation of the power connection box

Unscrew the lock nut of the top unit of the mounting stand. Feed the prepared trace heaters into the junction box. Slide the junction box onto the top unit of the mounting stand. Install the lock nut and tighten it using tongue and groove pliers.

31


Page 15 / 21

If you want to connect 2 trace heaters continue with step 38 on page 18. If you want to connect 3 trace heaters continue here:

Unscrew the M20 bolt from the cable entry using an adjustable wrench.

Feed the 3rd trace heater into the power connection box.

33

32



Page 16 / 21

Feed the gland body into the power connection box. Slide the bonding jumper and the lock nut onto the gland body.

Tighten the gland body while locking the lock nut using 2 adjustable wrenches. Make sure that the final tightening torque is 7.5 lbf ∙ ft (10 Nm).

34

35

7.5 lbf ∙ ft


Page 17 / 21

Slide the grommet into the gland body and the fixing nut onto the gland body.

Tighten the fixing nut. Make sure that the final tightening torque is 1.5 lbf ∙ ft (2 Nm).

37

1.5 lbf ∙ ft

36



Page 18 / 21

GND L1 L2 / N

Install the conduit pipe and conduit hub according to the manufacturer’s installation instructions. Feed the cold lead cable into the junction box.

Wiring

For wire connection at the terminals, insert a small screwdriver into the screwdriver slot, then insert the wire.

Connect all wires as shown on the right.

39

38


Page 19 / 21

Mount the cover of the junction box and tighten the 4 fixing screws using a screwdriver.

Apply the pipe’s insulation according to the manufacturer’s installation instructions. Apply an electrical warning label every 10 ft. on a clearly visible place.

41

40



Page 20 / 21

Installation of the end seal

Cut the trace heater off straight. Remove 3/4″ (20 mm) of the outer jacket.

Remove the exposed grounding braid. Make sure that the insulation jacket is not damaged.

Cut in a triangle (1/4″ / 5 mm) between the bus wires.

WARNING The silicone adhesive may cause irritation to skin and eyes. Avoid eye contact. Avoid repeated or prolonged skin contact. Follow the safety instructions given on the packaging.

Put silicone adhesive onto the exposed insulating jacket and into the end cap.

Push the end cap over the end of the trace heater.

NOTICE Allow the adhesive to cure for 20 minutes, then visually inspect. Full strength is reached after 24 hours.

39

43

42

41

40


Page 21 / 21

Troubleshooting

Problem Possible cause Remedy

Trace heater remains cold No power supply

Trace heater or cold lead cable not properly connected

Control unit adjusted incorrectly

Check the supply line

Connect the trace heater and cold lead cable according to the installation instructions

Adjust the control unit according to the installa-tion instructions

Automatic circuit breaker disengages Automatic circuit breaker defective

Automatic circuit breaker has wrong tripping characteristics, e. g. “B” instead of “C”

Nominal circuit breaker size is insufficient

Maximum heating circuit length has been exceeded

End seal has not been installed

Short circuit

Humidity inside the connection system or end seal

Replace the automatic circuit breaker

Install an automatic circuit breaker with Type-C tripping characteristics

Install an automatic circuit breaker with higher capacity (max. C 30 A)

Split the heating circuit into separate circuits

Install the end seal according to the installation instructions

Identify the cause and remedy the fault (e. g. ensure that tape tails are not twisted)

Replace the connection system / end seal

Ground fault protection is disengaged Trace heater damaged

Moisture in the junction box

Maximum monitoring length of the ground fault protection has been exceeded

Ground fault protection defective

Replace the trace heater at the point where it is damaged

Dry the junction box Be sure that the conduit drain is installed and breathing properly.

Install additional ground fault protection devic-es

Replace the ground fault protection device(s)

BARTEC GmbH

Max-Eyth-Straße 16

97980 Bad Mergentheim

Germany

Phone: +49 7931 597-0

Fax: +49 7931 597-499

[email protected]

www.bartec.de

BARTEC US

650 Century Plaza Drive, Suite D120

Houston, Texas

USA

Phone: +1 281 214-8542

Fax: +1 281 214-8547

[email protected]

www.bartec.de

21-5

4E1-

6D00

17

PBM-200-A Multiple entry power junction box -...

Documents

Transcript of PBM-200-A Multiple entry power junction box -...