Electrical Heat Tracing - Master PDF

Product Specifications
SYSTEM ACCESSORIES
HEAT TRACING CABLES
Application Freeze Protection and Process Temperature Maintenance

The 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.
Pipe Mount
Wall Mount
Terminator ZP... is designed to fabricate power

connections, in-line/T-splice connections or
for making end terminations. The Terminator
ZP-XP is suitable for use in hazardous areas
(Ex e T6/T4), harsh industrial environments and
has a IP66 rating. The upfront positioning of
the terminal block permits easy access during
assembly and for future routine maintenance.
The Terminator ZP kit includes; Pipe-mounted
expediter with suitable grommet, Junction box
with two M25 entries and one M25-B-Exe blind
plug, Four 6-mm2 line/load terminals, Two 6-mm2
earth terminals, Terminals rated to 22 amps (T6
85C) or 46 amps (T4 135C), Maximum voltage
rating of 750 Vac. Wallmount version is available.
Pipe Mount
Wall Mount
Terminator ZL... is designed to provide visual

indication of an energized heating circuit. The kit
may be utilized as a power connection or an end
termination kit. Electrical connections are made
in terminal blocks utilizing nickel-plated copper
terminals to ensure corrosion-free electrical
integrity.
Terminator Beacon... end-of-circuit light kits

are designed specifically for rapid, trouble-free
installation of Thermon self-regulating and powerlimiting, parallel resistance polymer insulated
heating cables. The Terminator Beacon utilizes
a high intensity green LED assembly for superior
day or night visibility.
The Terminator ZL kit includes; IP66 rated junction

box, yellow LED indicating lamp, four 6-mm2 line/
load terminals, two 6-mm2 earth terminal, pipemounted fitting, heater cable grommet.
Product Reference Legend:

ZE-B..... BSX, RSX, HTSX, KSX, VSX, FP, HPT

ZL-XP and ZL-WP.......RSX, VSX, BSX, HTSX,
KSX, FP, HPT

ZP-XP and ZP-WP....... RSX, VSX, BSX, HTSX,
KSX, FP, HPT
ZP-R-XP and ZP-R-WP.............................TESH
Terminator ZS/ZE...designed to fabricate

accessible outside-the-insulation splices or
end terminations 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.

ZS/ZE-XP........... BSX, RSX, HTSX, KSX, VSX,
FP, HPT

PETK-1.....................................BSX, RSX, VSX
PETK-2............................................ KSX, HTSX
PETK-3 .................................................FP, HPT
PETK-3-ECM .......................................FP, HPT
PETK-3-ZT ...........................................FP, HPT
PETK-4 .........................................HPT > 240C
SCTK...splice connection 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.
SCTK-1.....................................BSX, RSX, VSX
SCTK-2............................................ KSX, HTSX
SCTK-3..................................................FP, HPT
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 TEP0010U-0113 Thermon Manufacturing Co. Printed in U.S.A. Information subject to change.
SYSTEM ACCESSORIES
HEAT TRACING CABLES
Cable End Termination Kits, Attachment Tapes and Miscellaneous Items
CS-L-*-Ex. Circuit switch with lamp to be used as

an in-line isolation switch for single phase, phasephase and 3-phase heat tracing circuits. Available
in 16 A, 25 A and 40 A versions.
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 diameter
ABA-25...for pipes up to 25 mm diameter
ABA-40... for pipes up to 40 mm diameter
Terminator-LN-Tool...for tightening the locknuts of
the Terminator kits. Tool is recommended to ensure
enclosure is properly secured to the pipe-mounted
expediter.
IEK-SX...Insulation entry kit for use in (non)

hazardous locations that protects and seals the
heating cable while penetrating insulation cladding.
M25-SX.-Ex....Ex e approved nonmetallic gland for

use with M25 junction boxes.
M25-PWR-Exe, M25-B-Exe...Ex e approved

nonmetallic gland and plug for use with Terminator.
M25-SX.-IND....nonmetallic gland for use with

JB-K-0-M25 junction boxes
M25-PWR-Exe...power gland is suitable for securing

power cables with diameters between 8 and 17 mm.
FT-1L, FT-1H...fixing tape for attaching heating cable

to piping every 300 mm or as required by code or
specification.
BSX.....................................................M25-SXM-...
KSX, HTSX, FP, HPT.............................M25-SXS-...
RSX, VSX.............................................. M25-SXL-...
TESH.................................................. M20-PWR-...
M25-B-Exe...blind plug.
M25-PWR-IND, M25-B-IND, M25-LN-IND...nonmetallic 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.
BSX........................................................... IEK-SXM
KSX, HTSX, FP, HPT................................... IEK-SXS
RSX, VSX.................................................... IEK-SXL
TESH...........................................................IEK-TES
AL-20H, AL-30H...aluminium tapes for continuous (longitudinal) covering cable to piping and/
or equipment.
Item
Number
Max. Temp.
(Exposure)
FT-1L
FT-1H
AL-20H
AL-30H
93 C
260 C
150 C
150 C
Min. Temp.
Size
(Installation) (mm x m)
5 C
-40 C
-5 C
-5 C
12 x 33
12 x 33
50 x 55
76 x 55
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 necessary wire pins/lugs.
CL...vinyl-based peel-and-stick caution labels are

intended for direct exposure to industrial environments. 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.
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-2
XP-1-WP......................................... Terminator WP
ETS-05
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
II 2(1)G II 2D
Raychem ETS-05 Electronic Thermostat
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,
INDUSTRIAL HEAT TRACING SOLUTIONS
EN-RaychemETS05-DS-DOC2210-Rev1
1/4
ETS-05
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)
23
78
401
456
401
23
901
23
0
0
Power Terminals
1
Line
Out
Neutral
Out
Neutral
Supply
230V Supply
Earth
Earth
Earth
Terminals 2 and 3 are joined electrically

Terminals 5, 6 and 7 are joined electrically
Sensor/Failure Mode Select Terminals
Link 3-4 removed = Output OFF

Link 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
2/4
ETS-05
TYPICAL WIRING DIAGRAM FOR DIRECT SWITCHING
PE
MAX
32 AMP
30 mA
ETS-05
L1
out
in PE PE PE
3 4
Fail-Safe
option
* Circuit breaker configurations may vary

according to local standards/requirements
Link 3-4 removed = Output OFF

Link 3-4 fitted = Output ON
MOUNTING METHOD
Support bracket SB-100, SB-101, SB-110, Support bracket SB-100, or SB-101,
SB-111, SB-130 or surface mounting with SB-110, SB-111, SB-130 or surface
4 fixing holes on 106 x 82mm centres
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
3/4
HIQ
MINERAL INSULATED (MI) INCONEL SHEATHED HEATING CABLE
TYPICAL CABLE CONSTRUCTIONS
Inconel sheath
Magnesium oxide insulation
Nichrome conductor
APPLICATION
Area classification
APPROVALS
System (heating units)
Bulk cable
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.
Hazardous areas, Zone 1 or Zone 2 (Gas) or Zone 21 or zone 22 (Dust)

Ordinary areas
Baseefa02ATEX0046X
II 2GD Ex e II T6 to T1 Ex tD A21 IP6X
Actual T class temperature determined by design
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.
EN-RaychemHIQ-DS-DOC2210
Rev3
1/4
HIQ
TECHNICAL DATA
Cable sheath material
Conductor material
Max. exposure temperature
=Min. installation temperature

Min. bending radius
Max. supply voltage and power
Earth leakage
Min. cable spacing
Inconel 600
Nichrome
700C* (heating cables)
450C (brazed heating units)
700C* (laser welded heating units)
*Higher temperatures can be realized, contact Pentair Thermal Management
60C
6 x outer diameter at 60C
Max. power output*
Voltage (U0/U)
300/500 Vac
300 W/m
460/800 Vac (laser welded heating units) *typical value, depending on application
3 mA/100 m (nominal at 20C)
25 mm for hazardous areas
MI SERIES HEATING CABLES HIQ

Order Reference
HIQ1M10K
HIQ1M6300
HIQ1M4000
HIQ1M2500
HIQ1M1600
HIQ1M1000
HIQ1M630
HIQ1M400
HIQ1M250
HIQ1M160
Nominal resistance Outer diameter

(/km @ 20C)
(mm)
10000
3.2
6300
3.2
4000
3.2
2500
3.4
1600
3.6
1000
3.9
630
4.3
400
4.7
250
5.3
160
6.5
Temp. coefficient
(x 10-3/K)
0.09
0.09
0.09
0.09
0.09
0.09
0.09
0.09
0.09
0.09
Max. coil
length [m]
772
774
776
689
617
528
437
368
292
194
Nom.weight
(kg/km)
39
39
39
46
52
62
78
96
127
191
Resistance tolerance: 10%

RECOMMENDED COLD LEADS FOR HIQ MI SERIES HEATING CABLES
Nom. cross section
[mm2]
2.5
6
Order
reference
IC1H2.5
IC1H6
Max. current
(design B)
34
57
Outer diameter
(mm)
5.3
6.4
Standard
gland size
M20
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.
2/4
EN-RaychemHIQ-DS-DOC2210
Rev3
JBU-100
JUNCTION BOX FOR MODULAR SYSTEM
The JBU-100 kit is designed to connect power 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, maintenance-free operation.
The box is part of the modular component system,
it allows for maximum flexibility and can be either wall or
pipe mounted.
Connection kits (M25) and insulation entry 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 version (-L). These
include a unique light module with a superbright green LED
that simply plugs into the terminals, and a lens in the lid.
This provides indication that power is available in the box.
(JBU-100-L-E
shown with light)
DESCRIPTION
JBU-100-E
JBU-100-L-E
This box is for use in Europe and provides
four M25 threaded entries, stopping plugs
and one plastic power cable gland.
JBU-100-EP
JBU-100-L-EP
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.
1 junction box with terminals

1 l ight module (for -L only)
1 M
25 gland for 8-17 mm diameter
power cable
2 M
25 stopping plugs
1 junction box with terminals with earth

plate and external earth stud
1 light module (for -L only)
2 M25 stopping plugs
KIT CONTENTS
EN-RaychemJBU100-DS-DOC2210
Rev3
1/4
JBU-100
APPROVALS
Hazardous locations
PTB 09 ATEX 1061 U
II 2G Ex e (e mb) II
II 2D Ex tD (tD mbD) A21 IP66
IECEx PTB 09.0039U
Ex e (e mb) II
Ex 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 09.0039U
Ex e (e mb) II
Ex 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 approval
DNV Certificates No. E-11564 and No. E-11565
DNV approval
DNV Certificates No. E-11564 and No. E-11565
*For T-rating, see heating cable or design documentation

This 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
160
160
90
160
90
110
160
140
PRODUCT SPECIFICATIONS
Ingress protection
Entries
Terminals
Max. conductor size
Max. operation voltage
Max. current rating
2/4
110
140
IP66
IP66
4 x M25
4 x M25
50C to +56C* (JBU-100-E)
50C to +56C* (JBU-100-EP)
40C to +40C (JBU-100-L-E)
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.
Spring-type terminals
2 phase, 2 neutral, 2 ground
10 mm2 stranded, 10 mm2 solid
480 Vac
40 A
Spring-type terminals
2 phase, 2 neutral, 2 ground
10 mm2 stranded, 10 mm2 solid
480 Vac
40 A
Rev3
JBU-100
MATERIALS OF CONSTRUCTION
Enclosure, lid
Lid screws
Lid gasket
Earth continuity plate
Electrostatic charge-resistant
glass-filled engineered polymer, black
Stainless steel
Silicone rubber
N/A
Electrostatic charge-resistant
glass-filled engineered polymer, black
Stainless steel
Silicone rubber
Steel, zinc plated, and blue chromated
OPTIONAL LED INDICATOR LIGHT

Colour
Voltage rating
Power consumption
Green
100-254 Vac
<1W
Green
100-254 Vac
<1W
JUNCTION BOX
Part Description
PN (Weight)
JBU-100-E
051976-000 (1.7 kg)
JBU-100-EP
243948-000 (1.8 kg)
JUNCTION BOX WITH LIGHT

Part Description
PN (Weight)
JBU-100-L-E
069262-000 (2.1 kg)
JBU-100-L-EP
113974-000 (2.2 kg)
ACCESSORIES
Heating cable connection kits
C25-100, C25-21, CCON25-100
C25-100, C25-21, CCON25-100,

C25-100-METAL
IEK-25-04 or IEK-25-PIPE
GL-38-M25-METAL (optional)
SB-100, SB-101
Ordering details
Insulation entry kit

Power cable gland
Junction box support bracket
(optional)
IEK-25-04 or IEK-25-PIPE
GL-36-M25 (included)
SB-100, SB-101
Rev3
3/4
RAYSTAT-EX-03 AND RAYSTAT-EX-04

SURFACE AND AMBIENT SENSING, ELECTRONIC
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
THERMOSTAT
Area of use
RAYSTAT-EX-03
Surface sensing
RAYSTAT-EX-04
Ambient sensing
Hazardous area: Zone 1 or Zone 2 (Gas) or Zone 21 or Zone 22 (Dust) Ordinary
APPROVALS CERTIFICATION
Baseefa11ATEX0071X
IECEx BAS 11.0036X
II 2 GD
When the unit is powered with a supply voltage 99 and 230 Va.c.
Ex e mb ia IIC T6 Ta 50C to +60C Gb
Ex tb IIIC T85C Ta 55C to +60C Db IP66
When the unit is powered with a supply voltage > 230 253 Va.c.
Ex e mb ia IIC T5 Ta 50C to +60C Gb
Ex tb IIIC T100C Ta 55C to +60C Db IP66
PRODUCT SPECIFICATION
Temperature range
Ingress protection
Deluge testing
Switching accuracy
0C to 499C
IP66
Passed Shell UK requirements
1 K at 5C
1% of setpoint above 100C
0C to 49C
IP66
Passed Shell UK requirements
1 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)
EN-RaychemRAYSTATEX0304-DS-DOC2210
Rev3
1/3
RAYSTAT-EX-03 AND RAYSTAT-EX-04

PRODUCT SPECIFICATION (continued)
Switching capacity
16 A 110 Vac 10% 50/60 Hz
16 A 230/253 Vac 10% 50/60 Hz
resistive load
Supply voltage
16 A 110 Vac 10% 50/60 Hz

16 A 230/253 Vac 10% 50/60 Hz
resistive load
50C to +60C
110 Vac 10% 50/60 Hz
230/253 Vac 10% 50/60 Hz
Internal power consumption

Terminal size
50C to +60C
110 Vac 10% 50/60 Hz
230/253 Vac 10% 50/60 Hz
110 Vac ~ 4 VA, 230/253 Vac ~ 3 VA
max. 4 mm2
DIMENSIONS (IN MM)
RAYSTAT-EX-03
RAYSTAT-EX-04
max. 4 mm2
160
160
160
160
9090
90
90
140
140
140
140
52 52
3 3
110
160110
160
160
110
160 110
3 3
110
110
TYPICAL WIRING DIAGRAM FOR DIRECT SWITCHING

L1
N
PE
230 V / 50 Hz
max.
16 A/C
*
RAYST AT-EX-03/04
NO C
***
* 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
NC NO C
Sensor
Sensor
NC
12
**
Pt 100
Heating system
Cable entries
2 x M20 glands (cable 7.5 13 mm)

1 x M25 with M25(M)/M20(F) adaptor
L1
and (M20) plug
L2
2 x M20 glands (cable 7.5 13 mm)

1 x M25 with M25(M)/M20(F) adaptor
400 V / 50 Hz
and (M20) plug
Sensor
2 wire Pt 100, stainless steel sensor, 2N m long 2 wire Pt 100, stainless steel sensor,
max.with wind shield
complete
16 A/C
L3
MOUNTING METHOD
RAYST AT-EX-03/04
Sensor
Raychem support bracket SB-100 or SB-101, Raychem support bracket SB-100 or

1 2 3 4 5 6 7 8 9
12
SB125 or surface mounting with 4 fixing holes SB-101, SB125 or surface mounting
** with 4 fixing***
PE
on 110x140mm centres
holes on 110x140mm
centres
NO C
ORDERING DETAILS
Part Description
PN (Weight)
2/3
RAYSTAT-EX-03
333472-000 (3.0 kg)
EN-RaychemRAYSTATEX0304-DS-DOC2210
NC NO C
RAYSTAT-EX-04
462834-000 (3.1 kg)
Rev3
Pt 100
XMI-A (ALLOY 825)

HIGH TEMPERATURE CONSTANT WATTAGE
MINERAL INSULATED HEATING CABLES
PRODUCT OVERVIEW
Heating cable construction
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).
Heating conductor
(single)
Alloy 825
sheath
Insulation
(magnesium oxide)
Heating conductors
(dual)
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) 5456258.
TEMPERATURE RATING
Maximum continuous exposure
temperature 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
XMI-A
(Alloy 825 sheath)

Nonhazardous and Hazardous Locations
Class I, Div. 1 and 2, Groups A, B, C, D
Class II, Div. 1 and 2, Groups E, F, G
Class III
Class I, Div. 1 and 2, Groups A, B, C, D

Class II, Div. 1 and 2, Groups E, F, G
Class III
For use in Zone 1 and Zone 2 locations
Ex e IIC T* Gb
EN-RaychemXMIA-DS-H56870
09/14
1/8
XMI-A (ALLOY 825) HEATING CABLE

SPECIFICATIONS
Product
Family
Sheath
Material
Product
Code
Voltage
Rating
Number of
Conductors Max. Power Output** Bending Radius
XMI-A
XMI-A
XMI-A
Alloy 825
Alloy 825
Alloy 825
XMI-A61
XMI-A32
XMI-A62
600 V
300 V
600 V
1
2
2
61 W/ft; 200 W/m

60 W/ft; 197 W/m
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
Cold lead length
Heated length
Single conductor cable (XMI-A61 series only)
NPT gland
connector
Design B
Cold lead length
Heated length
Single conductor cable (XMI-A61 series only)
Cold lead length
NPT gland
connector
Design D
Cold lead length
Heated length
Dual conductor cable (XMI-A32 or XMI-A62 series only)
NPT gland
connector
Design E
Cold lead length
Heated length
Dual conductor cable (XMI-A32 or XMI-A62 series only)
2/8
09/14
Cold lead length
NPT gland
connector

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 /
D /
/ 3 /
32SA2200
/ 8 /
/ 40 / 538 / 208 / 7 / S25A / X / N12 /
10
11
12
RG1
PE
Position Characteristic Code Options
Description
Design
configuration
A, B, D or E
Designates the basic heating cable design configuration of the XMI-A engineered heating
unit.
Heating cable
reference
See Tables 3, 4 and 5
Indicates the XMI-A heating cable reference used in the design.
Heated length
Length of the heating Default value is in feet; if in meters add "M" after the length.
cable in feet or meters
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.
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).
MI cold lead
length
(length) or
(length)(length)
Default value is in feet; if in meters add "M" after the length.
Length of the MI cold

lead in feet or meters
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.
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.
Hot-cold joint
type
X type joint is used with all XMI-A engineered heating units.
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
12
Special feature S
Optional pulling eye to aid in pulling a cable inside a pipe or channel. Use with Design D
configuration only.
Indicates a special non-standard feature has been added to the heating cable.
09/14
3/8

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
(0.656 /m)
Heating cable length is 25 m (82 ft)
MI cold lead length is 2.1 m (7 ft) on both ends
MI cold lead code is LS23A (23 Amps)
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)
MI cold lead length is 5 ft (1.5 m) on one end and 7 ft (2.1 m) on the other end
D/32SA2200/40/538/208/7/S25A/X/N12/RG1/PE
Configuration is Design D
(6.56 /m)
Heating cable length is 40 ft (12.2 m)
MI cold lead length is 7 ft (2.1 m)
Supplied with 1 NPT reversed gland
Supplied with pulling eye
TABLE 1 HEATING CABLE REFERENCE DECODING
62SA 2 2 0 0
Position 1 2 3 4 5 6 7 8
Position Description
1
Maximum voltage rating
2
Number of conductors
3 = 300 V, 6 = 600 V
1 or 2
3
4
5
S = Alloy 825
A, B, C, F, P, Q, or T
1, 2, 3, 4, 5, or 6 places
6 to 8
4/8
Sheath material
Conductor material
Move decimal point to left
indicated number of places
Cable resistance to 3 whole
numbers (use with digit 5)
09/14
2200 = 2.00 /cable foot at 20C

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

in
mm
Gland size
(NPT)
Gland size
reference for Tail size
catalog no.
(AWG)
Design A, D, E
S25A
LS23A
S34A
S49A
S65A
600
300
600
600
600
25
23
34
49
65
0.355
0.319
0.402
0.496
0.543
1/2 in
1/2 in
3/4 in
3/4 in
3/4 in
N12
N12
N34
N34
N34
14
14
10
8
6
1/2 in
1/2 in
1/2 in
1/2 in
1/2 in
N12
N12
N12
N12
N12
12
10
8
6
4
9.0
8.1
10.2
12.6
13.8
Design B
S29A
600
29
0.215
5.5
S40A
600
40
0.273
6.9
S48A
600
48
0.253
6.4
S66A
600
66
0.319
8.1
S86A
600
86
0.355
9.0
Note: 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)

Nominal cable
resistance at 20C
Heating
cable reference /ft
/m
Approximate
cable diameter
Maximum unjointed
cable length
Nominal weight
lb/1000 ft kg/1000 m
in
mm
ft
61SA2200
2.00
6.56
0.146
3.7
1809
552
35
52
61SA2160
61SA2130
61SA2100
61SA3850
61SA3700
61SA3500
61ST3280
61SB3200
61SB3150
61SQ3118
1.60
1.30
1.00
0.850
0.700
0.500
0.280
0.200
0.150
0.118
5.25
4.27
3.28
2.79
2.30
1.64
0.919
0.656
0.492
0.387
0.163
0.160
0.160
0.170
0.160
0.170
0.170
0.180
0.170
0.175
4.1
4.1
4.1
4.3
4.1
4.3
4.3
4.6
4.3
4.4
1452
1508
1510
1338
1514
1344
1337
1198
1350
1260
443
460
460
408
462
410
408
365
412
384
44
42
43
48
43
49
48
55
51
50
66
63
64
72
64
73
72
82
76
75
61SQ4732
61SQ4581
61SP4467
61SP4366
61SP4290
61SP4231
61SP4183
61SP4145
61SP4113
61SC5651
61SC5409
61SC5258
61SC5162
61SC5102
61SC6640
0.0732
0.0581
0.0467
0.0366
0.0290
0.0231
0.0183
0.0145
0.0113
0.00651
0.00409
0.00258
0.00162
0.00102
0.00064
0.240
0.191
0.153
0.120
0.0951
0.0758
0.0600
0.0476
0.0371
0.0214
0.0134
0.00846
0.00531
0.00335
0.00210
0.170
0.172
0.170
0.173
0.177
0.174
0.170
0.170
0.186
0.187
0.191
0.215
0.268
0.253
0.319
4.3
4.4
4.3
4.4
4.5
4.4
4.3
4.3
4.7
4.7
4.9
5.5
6.8
6.4
8.1
1338
1308
1337
1292
1236
1282
1347
1351
1130
1110
1069
848
546
622
391
410
399
408
394
377
391
411
412
345
338
326
259
166
190
119
48
50
48
50
53
52
50
51
61
60
64
83
129
124
197
72
75
72
75
79
78
75
76
91
89
95
124
192
185
294
09/14
5/8

TABLE 4 XMI-A32 SERIES MI HEATING CABLE SPECIFICATIONS (300 V, DUAL CONDUCTOR)
Nominal cable
resistance at 20C
Approximate
cable diameter
Maximum unjointed
cable length
Nominal weight
Heating
cable reference /ft
/m
in
mm
ft
lb/1000 ft kg/1000 m
32SF1110
36.1
0.130
3.3
2283
696
28
42
29.5
24.6
19.7
13.1
9.02
6.56
5.58
3.74
2.30
1.55
1.23
0.961
0.656
0.492
0.328
0.241
0.191
0.150
0.106
0.140
0.157
0.135
0.146
0.153
0.169
0.167
0.174
0.170
0.177
0.183
0.179
0.161
0.168
0.185
0.174
0.178
0.188
0.184
3.6
4.0
3.4
3.7
3.9
4.3
4.2
4.4
4.3
4.5
4.6
4.5
4.1
4.3
4.7
4.4
4.5
4.8
4.7
1969
1565
2121
1816
1657
1359
1395
1279
1347
1232
1153
1206
1498
1378
1140
1284
1230
1105
1145
600
477
647
554
505
414
425
390
411
376
352
368
457
420
348
391
375
337
349
32
41
30
36
40
49
48
51
50
52
55
53
44
49
60
52
55
62
57
48
61
45
54
60
73
72
76
74
78
82
79
66
73
89
78
82
92
85
32SF2900
32SF2750
32SA2600
32SA2400
32SA2275
32SA2200
32SA2170
32SB2114
32SB3700
32SQ3472
32SQ3374
32SQ3293
32SQ3200
32SQ3150
32SQ3100
32SP4734
32SP4583
32SP4458
32SC4324
11.0
9.0
7.5
6.00
4.00
2.75
2.00
1.70
1.14
0.700
0.472
0.374
0.293
0.200
0.150
0.100
0.0734
0.0583
0.0458
0.0324
TABLE 5 XMI-A62 SERIES 62 MI HEATING CABLE SPECIFICATIONS (600 V, DUAL CONDUCTOR)

Nominal cable
resistance at 20C
Approximate
cable diameter
Maximum unjointed
cable length
Nominal weight
Heating
cable reference /ft
/m
in
mm
ft
lb/1000 ft kg/1000 m
62SF1110
62SF2900
62SF2600
62SA2414
62SF2200
62ST2115
62SB3700
62ST3505
62SQ3286
62SQ3200
62SQ3150
62SQ3100
62SP4775
62SP4561
62SP4402
62SP4281
62SC4200
62SC4130
62SC5818
62SC5516
62SC5324
62SC5204
62SC5128
36.1
29.5
19.7
13.6
6.56
3.77
2.30
1.66
0.938
0.656
0.492
0.328
0.254
0.184
0.132
0.0922
0.0656
0.0427
0.0268
0.0169
0.0106
0.00669
0.00420
0.194
0.194
0.194
0.209
0.245
0.215
0.245
0.215
0.222
0.227
0.227
0.257
0.250
0.263
0.277
0.292
0.285
0.304
0.331
0.364
0.402
0.496
0.543
4.9
4.9
4.9
5.3
6.2
5.5
6.2
5.5
5.6
5.8
5.8
6.5
6.4
6.7
7.0
7.4
7.2
7.7
8.4
9.2
10.2
12.6
13.8
1023
1024
1025
883
644
834
644
837
783
750
751
586
618
560
505
456
476
419
354
294
242
159
469
312
312
313
269
196
254
196
255
239
229
229
179
188
171
154
139
145
128
108
90
74
48
143
61
61
62
76
100
76
100
77
81
86
86
111
104
116
130
147
135
156
187
230
290
438
516
6/8
11.0
9.00
6.00
4.14
2.00
1.15
0.700
0.505
0.286
0.200
0.150
0.100
0.0775
0.0561
0.0402
0.0281
0.0200
0.0130
0.00818
0.00516
0.00324
0.00204
0.00128
09/14
91
91
92
113
149
113
149
115
121
128
128
165
155
173
194
219
201
233
279
343
432
653
769

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.
Power On
Power Off
3.0
C
2.5
2.0
1.5
P
Q
T
A,B,F
1.0
0.5
Resistance Multiplier for

Conductor Materials
Resistance Multiplier for

Conductor Materials
3.0
0
32 122 212 302 392 482 572 662 752
50 100 150 200 250 300 350 400
0
Pipe Temperature to be Maintained (F/C)
2.5
2.0
1.5
P
Q
T
A,B,F
1.0
0.5
0
58
50
32
0
122 212 302 392 482 572 662 752

50 100 150 200 250 300 350 400
Pipe Temperature (F/C)
ALLOY 825 QUICK REFERENCE GUIDE
Hydrochloric acid
Hydrofluoric acid
Phosphoric acid
Nitric acid
Organic acid
Alkalis
Salts
Seawater
Chloride cracking
Oxidation
1500F (815C)
Other
Chromium
Iron
42.0 30.0 21.5 Mo 3.0 77 164 G-E

Cu 2.2 (11.1) (23.6)
A = Acceptable
X = Check for specific data
Sulfuric acid
Excellent resistance to a wide variety of corrosives.

Resists pitting and intergranular type corrosion,
reducing acids and oxidizing chemicals
Corrosion resistance
G-E = Good to excellent
NR = Not recommended
Carburization
INCOLOY
Alloy 825
nickel-ironchromium
Description
Nickel (+Cobalt)
Alloy
70F (20C)
High
Thermal
temperature
conductivity resistance
Btu-in/ft2-hr- +1000F
F (W/m-C)
(+540C)
Nominal chemical
composition, %
(major elements)
G-E
G-E
G-E
G-E
G-E
G-E
G-E
G-E
G-E
G-E
G-E
*From Huntington Alloys Publication 78-348-2
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, groundfault 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.
09/14
7/8
Terminator
Heating Cable Termination Kits

Application
Terminator 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
4
after installation).
Terminator
ZE-B Beacon
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.
Ratings
Enclosure rating..................................................... IP66
Maximum pipe exposure temperature 1................ 250C
Minimum installation temperature 1.......................-60C
Operating ambient temperature.............-60C to +55C
Maximum voltage rating 2.................................. 750 Vac
Notes
1. 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 Reference Legend

ZP-XP
Area Designation
Mounting Options
Z = Category 2 and 3
(Zone 1 and 2) Areas
XP = Pipe-Mount Expediter
Kit Type
WP = Wall Mount Bracket with

Expediter
P = Power Connection
Terminator ZP
(shown)
Construction
1 Junction box, glass-reinforced polymer with DIN rail
mounted terminal blocks
2 Pipe-mount expediter, glass-reinforced polymer
3 Stainless steel mounting bracket
4 LED end of circuit light (available on Beacon only).
Certifications/Approvals
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
Terminator has additional hazardous area approvals including:

ABS CSA CQST DNA KOSHA Lloyds TR TC
L = Lighted Power
Connection/End Termination
S = In-line or T-Splice
E = End Termination
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 Kit
Kits for TEK, HTEK Cables

European Headquarters: Boezemweg 25 PO Box 205 2640 AE Pijnacker The Netherlands Phone: +31 (0) 15-36 15 37

Terminator
Heating Cable Termination Kits

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 ZP or ZL
with Pipe Mount Expediter
Terminator ZS/ZE is designed to fabricate accessible

outside-the-insulation splices
or end terminations 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.)
Terminator ZP or ZL
with Wall Mount Bracket
Terminator ZS/ZE
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.
SCTKsplice connection
termination kits are required
when preparing outside-theinsulation 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 mm2
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 Amps
T4 @ 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 Range
n/a
n/a
n/a
100 to 277 Vac
12 to 270 Vac
N/A
Notes
1. 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.
VPL
Self-regulating
heating cable
High-temperature
power-limiting heating cable
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.
HEATING CABLES
VPL is a family of power limiting

heating cables designed for pipe and
equipment heat-tracing in industrial
applications.
Heating cable construction
High temperature
fluoropolymer outer jacket
Nickel plated copper braid
High temperature
fluoropolymer inner jacket
COMPONENTS
Power-limiting heating element

Conductor connection
White jacket
High temperature
fluopolymer conductor insulation
Application
Area classification
Traced surface type
Chemical resistance
CONRTROL AND MONITORNING
3.3 mm2 nickel plated copper conductors
Hazardous, Zone 1, Zone 2 (Gas), Zone 21, Zone 22 (Dust) Ordinary

Carbon steel
Stainless steel
Painted or unpainted metal
Organics and corrosives
For aggressive organics and corrosives consult your local Tyco Thermal Controls representative
Supply voltage
VPL2: 208-277 Vac
VPL4: 400-480 Vac
Approvals
ACCESSORIES
The 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.
www.tycothermal.com
EN-VPL-DS-DOC2210
1-3
VPL
Specifications
Cable
5VPL2-CT
10VPL2-CT
15VPL2-CT
20VPL2-CT
5VPL4-CT
10VPL4-CT
15VPL4-CT
20VPL4-CT
Maximum maintain or
continuous exposure
temperature (power on)
208 V
235C
220C
200C
150C
230 V
230C
210C
180C
150C
254 V
225C
200C
145C
277 V
225C
195C
105C
400 V
230C
215C
195C
150C
480 V
230C
205C
160C
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
Minimum bend radius
Thermal output rating
Nominal power output A
rating on insulated
B
steel pipes at 240
C
V and 480 V (power
D
output of VPL4 at
400 V will be lower)
60C
at 60C: 20 mm | at +20C: 20 mm
20VPL-CT
80
15VPL-CT W/m
10VPL-CT
70
5VPL-CT
60
50
B
To choose the correct
heating cable for your
application use the
TraceCalc design
software.
40
30
20
10
0
0
20
40
60
80
100
120
140
160
180 200 220 240

Pipe temperature (C)
Adjustment Factors
254 V
277 V
400 V
Power output
Circuit length
Power output
Circuit length
Power output
Circuit length
Nominal power output (W/m at 10C)

VPL2 at 230 V
VPL2 at 240 V/VPL4 at 480 V
VPL4 at 400 V
5VPL2-CT
1.20
1.05
1.30
1.13
5VPL4-CT
0.72
0.86
10VPL2-CT
1.19
1.04
1.28
1.11
10VPL4-CT
0.73
0.87
15VPL2-CT
1.19
1.04
1.26
1.09
15VPL4-CT
0.74
0.89
20VPL2-CT
Not allowed
Not allowed
Not allowed
Not allowed
20VPL4-CT
0.75
0.90
5VPLx-CT
15
16
12
10VPLx-CT
30
33
24
15VPLx-CT
45
49
36
20VPLx-CT
61
65
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
1.2 (VPL2)
2.4 (VPL4)
200
0.9 (VPL2)
1.7 (VPL4)
200
0.6 (VPL2)
1.3 (VPL4)
200
0.5 (VPL2)
1.1 (VPL4)
200
Nominal cold lead/ heating

zone length (m)
Weight (g/m)
2-3
EN-VPL-DS-DOC2210
www.tycothermal.com
VPL
Maximum circuit length based on type C circuit breakers according to EN 60898

VPL2 at 230 V
5VPL2-CT
Electrical protection
sizing
16 A
Start-up
temperature
20C
+10C
20C
+10C
20C
+10C
20C
+10C
25 A
32 A
40 A
VPL4 at 480 V and 400 V
Electrical protection
sizing
16 A
25 A
32 A
40 A
10VPL2-CT
15VPL2-CT
20VPL2-CT
Maximum heating cable length per circuit (m) at 230 Vac

195
215
220*
220*
220*
220*
220*
220*
5VPL4-CT
Start-up
temperature
20C
+10C
20C
+10C
20C
+10C
20C
+10C
390 (335)
425 (365)
450* (450)
450* (450)
450* (450)
450* (450)
450* (450)
450* (450)
100
110
155*
155*
155*
155*
155*
155*
10VPL4-CT
70
75
105
115
130*
130*
130*
130*
15VPL4-CT
50
55
80
85
100
110*
110*
110*
20VPL4-CT
Maximum heating cable length per circuit (m)

at 480 Vac and (at 400 Vac)
195 (170)
130 (115)
210 (185)
140 (125)
310 (265)
205 (185)
320* (290)
220 (195)
320* (320)
260* (235)
320* (320)
260* (250)
320* (320)
260* (260)
320* (320)
260* (260)
100 (90)
105 (95)
155 (140)
165 (150)
200 (180)
210 (190)
225* (225)
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
Part No.
Part description
Part No.
5VPL2-CT
451828-000
5VPL4-CT
P000000678
10VPL2-CT
892652-000
10VPL4-CT
P000000679
15VPL2-CT
068380-000
15VPL4-CT
P000000680
20VPL2-CT
589252-000
20VPL4-CT
P000000681
Components
Tyco 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.
www.tycothermal.com
EN-VPL-DS-DOC2210
3-3
RMM2-E
Trace-Heating Remote Monitoring Module
Externes Beheizungs-berwachungsmodul
Module de surveillance distance pour traage
lectrique
Industrial Heat Tracing Solutions
ML-RaychemRMM2E-IM-INSTALL061 R7
Installation 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.
Approvals
Hazardous 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)
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.
Specifications
Supply voltage (nominal):
115/230 Vac, 10%, jumper selectable, 50/60 Hz
Power consumption:
2,5 VA
Ambient operating range:
40C to +60C

20C to +60C (Exn enclosure and glands)
Relative humidity:
5 to 95%, noncondensing
Temperature 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 m
Replaceable fuse:
F 200 mA/250 V, Wickmann part number 19370-034-K (FAST BLOW)
Installation materials (not supplied)

Fasteners
4 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 gland
MONI-PT100-EXE
Temperature sensor for hazardous areas
Remote Monitoring Module (RMM2-E)

2
125 mm
125 mm
60 mm
60 mm
9
1
7
75 mm
5
0
75 mm
42 mm
15
mm
42 mm
15
mm
1 Fuse (200 mA, 250V)

2 Terminals for power input with provision
for daisy chaining
3 Voltage selector jumpers

4 Terminals for RS-485 bus
5 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 wires

9 Shorting block to select RS-485
termination mode
Overview of Installation Procedure for the RMM2-EX-E

A. 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 Cables
1. 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 cables
Install power cable(s), RS-485 cable(s) and RTD
cables into enclosure using glands supplied.
Keep stopping plugs in unused entries.
91
260
240
6.5
0
160
110
B. Connect Power and Earth Wiring and

Select Voltage Operating Range
3. Select the voltage operating range
Connect 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.
3
0
Jumpered
for 115V
Jumpered
for 230V
2
0
C. Connect RTD Cables to the RMM2-E

The 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).
RMM2-E
terminal no.
1
2
3
4
5
6
7
8
Piping drawing
identification
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.
Description or location
D. 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:
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.
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
11. Connect the RS-485 bus

Note: 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.
The 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
Power & End Termination Kit
INSTALLATION PROCEDURES

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
PETK
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.
Receiving, Storing and Handling . . .
1. Inspect materials for damage incurred during shipping.
2. Report damages to the carrier for settlement.
3. Identify parts against the packing list to ensure the
proper type and quantity has been received.
4. Store in a dry location.
PETK Power and End Termination Kits (per cable)
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
Component approvals and performance ratings are

based on the use of Thermon specified parts only.
Minimum bending radius of heating cable is 32 mm

(except HPT is 57 mm and FP is 19 mm).
3
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.
Keep ends of heating cable and kit components dry

before and during installation.
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.
De-energize all power sources before opening

enclosure.
Kit Contents . . .
1
Warnings . . .
Individuals installing these products are responsible

for 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.
Tools Required . . .
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.
Item
Qty.
Description
RTV Tube
PETK Certifications/Approvals 1 . . .
Power Connection Boot
End Cap
Tape Strip (PETK-3 Only)
End Termination Caution Label
Grommet (For PETK-3 Terminator kits only)
Ground Sleeve
Note:
Wire pins may be required as per client/project specification (order seperately).
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
Note:
1. These sets have been evaluated as components of Thermons Approved connection kits, such that the area use ratings depend on the rating of the connection kits.
PETK
IMPORTANT!
Heating cable must be
properly installed within
expediter assembly and
mounted to pipe prior to
terminating with PETK kit.
GRW
GRW-G
GRW-GT2
GRW-G/Tstat
See Terminator Installation

Instructions for expediter
mounting details.
Terminator: Route cable through base entry
and mount expediter to pipe using pipe band.
Do not band over cable.
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
Step 1: Remove Heating Cable Overjacket and Separate Metallic Braid to Form Pigtail
152 mm
(6)
1a. Cut and remove heating cable overjacket.

Do not cut metallic braid.
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.
Step 2: Matrix Removal for BSX, RSX, HTSX, KSX, and VSX Cables
4 mm
(.15)
2a. Cut and remove primary insulation jacket

(BSX and RSX cables only).
2b. Cut a 4mm strip of conductive matrix

between the conductors.
Do not cut bus wire strands.
4 mm
(.15)
2c. Cut and remove the 4mm matrix strip.
PETK
Step 2: Heating Element Removal for HPT and FP Cables
120 mm
(4.75)
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.
117 mm
(4.62)
2b. Cut and remove fiberglass overlay and

heating element. Push any remaining
heating element wire under the primary
insulation jacket.
2c. Cut and remove pairing jacket.

Do not cut bus wire insulation.
Step 3: Install Power Boot on Heating Cables
13 mm
(.5)
3a. Apply RTV sealant to cable to cover distance 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.
3c. Crimp conductor wire pins on each con-
ductor and on twisted braid if required

as per client/project specification (order
separately).
PETK
Step 4: End Termination for BSX, RSX, HTSX, KSX, and VSX Cables
13 mm
(.5)
4a. 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
75 mm
(3)
25 mm
(1)
19 mm
(.75)
Bus
Connection
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.
6 mm
(.25)
4d. Cut and remove fiberglass overlay and 4e. Cut and remove pairing jacket. Stagger 4f. Tape
heating element. Push any remaining
heating element wire under the primary
insulation jacket.
cut one of the bus wires.
Do not cut bus wire strands.
bus wires individually and then

together. Continue taping to cover overjacket. 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.
Cable 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

0
mm
inches
0
10
10
20
20
mm
inches
30
30
40
40
50
50
60
60
70
70
3
80
90
80
90
100
100
110
110
120
120
5
130
140
130
140
150
160
150
160
NOTE:
Bus connection must be no more
than 50 mm (2) from pipe as addressed in connection kit instructions.
For Power Connection Boot Termination
For End Cap Termination
NOTE:
Images may not be printed to scale.
THERMON . . . The Heat Tracing Specialists
www.thermon.com
European Headquarters
Boezemweg 25 PO Box 205
2640 AE Pijnacker The Netherlands
Phone: +31 (0) 15-36 15 370
Corporate Headquarters
100 Thermon Dr. PO Box 609
San Marcos, TX 78667-0609 USA
Phone: +1 512-396-5801
Specifications and information subject to change without notice. PN50136U-0514
For the Thermon office nearest you

visit us at . . .
www.thermon.com
BSX SELF-REGULATING HEATING CABLE

1
APPLICATION
BSX self-regulating heating cables are designed to provide
freeze protection or process temperature maintenance
to metallic and nonmetallic piping, tanks and equipment.
The heat output of BSX cable varies in response to the
surrounding conditions along the entire length of a circuit.
Whenever the heat loss of the insulated pipe, tank or
equipment increases (as ambient temperature drops), the
heat output of the cable increases. Conversely, when the
heat loss decreases (as the ambient temperature rises or
product flows), the cable reacts by reducing its heat output.
BSX cables are approved for use in ordinary (nonclassified)
areas and hazardous (classified) areas.
RATINGS
Available watt densities................. 3, 5, 8, 10 w/ft @ 50F
(10, 16, 26, 33 w/m @ 10C)
Supply voltages...........................110-120 or 208-277 Vac
Max. 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, 8 w/ft (10, 16, 26 W/m)................T6 185F (85C)
10 w/ft (33 W/m)................................T5 212F (100C)
Notes
1. T-rating per the National Electrical Code and Canadian Electrical Code.
2
3
5
6
CONSTRUCTION
1 Nickel-plated copper bus wires (16 AWG)
2 Radiation cross-linked semiconductive heating matrix
3 Radiation cross-linked dielectric insulation
4 Tinned copper braid
5 Polyolefin overjacket provides additional protection for
cable and braid where exposure to aqueous inorganic
chemicals is expected.
OPTIONS
6 FOJ Fluoropolymer overjacket over tinned copper braid
provides additional protection to cable and braid where
exposure to organic chemicals or corrosives is expected.
BASIC ACCESSORIES
Thermon offers system accessories designed specifically
for rapid, trouble-free installation of Thermon heating
cables.
All cables require a connection kit to comply with approval
requirements. Information on accessories to complete
a heater circuit installation can be found in the Heating
Cable Systems Accessories product specification sheet
(Form TEP0010).
Form TEP0067-0714 Thermon Manufacturing Co. Printed in U.S.A. Information subject to change.
BSX SELF-REGULATING HEATING CABLE

POWER OUTPUT CURVES 1
The 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
on other service voltages, contact Thermon.
Catalog Number
120 Vac Nominal
Catalog Number
240 Vac Nominal
Power Output
at 50F (10C)
w/ft (m)
BSX 3-1
BSX 3-2
3 (10)
BSX 5-1
BSX 5-2
5 (16)
BSX 8-1
BSX 8-2
8 (26)
BSX 10-1
BSX 10-2
10 (33)
120 Vac Service Voltage

Catalog
Number
12
(39)
Watts per Foot (w/m)
10
(33)
BSX 3-1
BSX 10
8
(26)
CIRCUIT BREAKER SIZING 2

Maximum circuit lengths for various circuit breaker
amperages are shown below. Breaker sizing should be
based on the National Electrical Code, Canadian Electrical
Code or any other applicable code. The National Electrical
Code and Canadian Electrical Code require ground-fault
protection of equipment for each branch circuit supplying
electric heating equipment. Check local codes for groundfault protection requirements.
BSX 8
BSX 5-1
6
(20)
4
(13)
BSX 5
2
(6)
BSX 3
BSX 8-1
0
30
(-1)
50
(10)
70
(21)
90
(32)
110
(43)
130
(54)
150
(66)
BSX 10-1
Pipe Temperature F (C)
CERTIFICATIONS/APPROVALS

FM Approvals
Ordinary Locations
Hazardous (Classified) Locations
Class I, Division 2, Groups B, C and D
Class II, Division 2, Groups F and G
Class III, Divisions 1 and 2
Class I, Zones 1 and 2, AEx e II
Underwriters Laboratories Inc.

Ordinary Locations
Class I, Division 2, Groups A, B, C and D
Class II, Division 2, Groups F and G
Class III, Divisions 1 and 2

Canadian Standards Association

Ordinary Locations


Class I, Divisions 1 & 2, Groups A, B, C and D

Class II, Divisions 1 & 2, Groups E, F and G
Ex e II
Notes
1. For more precise power output values as a function of pipe temperature, refer to
CompuTrace.
2. Based on the trip current characteristic of Type QOB or Type QO equipment
protection devices. For devices with other trip current characteristics, contact
Thermon.
3. The maximum circuit length is for one continuous length of cable, not the sum of
segments of cable. Refer to CompuTrace design software or contact Thermon
for current loading of segments.
Start-Up
Temperature
F (C)
20A
30A
40A
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)
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)
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)
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

Catalog
Number
BSX 3-2
BSX 5-2
BSX 8-2
BSX 10-2
Max. Circuit Length 3 vs. Breaker Size

ft (m)
Start-Up
Temperature
F (C)
Max. Circuit Length 3 vs. Breaker Size

ft (m)
20A
30A
40A
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)
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)
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)
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)
Power Connection Kit

Terminator ZP-L-XP
for use with RSX, TSX, VSX self-regulating heating cables
Terminator ZP-S-XP
for use with BSX, HTSX, KSX self-regulating, HPT power-limiting,

and FP constant watt heating cables
For Power Connection (1-3 Heating Cables), In-Line Splice Connection,

T-Splice Connection, or End Termination (1-2 Heating Cables) Applications
Kit Contents
Item Qty
Description
Expediter Assembly
Support Cap w/ O-ring

Threaded Grommet Compressor
Grommet
Support Base w/ O-ring
Junction Box Lid
Junction Box Base w/ O-ring
Terminal Blocks w/ DIN Rail
Junction Box Lid Cord
Nut
Banding Guide
Power Gland
Blind Plug
10
Conductor Wire Pins (per cable)
11
Braid Wire Pin
12
Power Connection Boot
13
Ground Sleeve
14
RTV Tube
15
Banding
(Refer to terminal specifications for maximum allowable wire size)
(per cable)
(per cable)
(per cable)
(per cable)
Tools Required
Terminator-LN-Tool
3 mm
8 mm
(order separately)
28 mm
29 mm
33 mm
Certifications/Approvals
IP66 NEMA/Type 4X -60C Ta +55C
Listed Heat Tracing Cable System 137M
Ordinary & Hazardous Locations
Class I, Division 2, Groups A, B, C & D
Class II, Division 2, Groups F & G, Class III
Class I, Zone 1, AEx e II T4-T6
Ex e II T4-T6
0539
PETK power termination components (per cable) - order separately

PETK-1: for RSX, TSX, VSX
PETK-2: for BSX, KSX, HTSX
PETK-3: for HPT
10
12
13
14
11
B-type banding - order separately
B-4: for pipes up to 4
15
II 2 G & D Ex e II T4-T6 DEMKO 06ATEX0622119
Warnings
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).
1.
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.
5.
Mount expediter to pipe using pipe band. Do not band over

cable.
2.
Insert cable into expediter. If mounted on bottom or side of

pipe, punch out weep hole.
6.
Cut off end of cable.
3.
Slide expediter toward pipe and route cable through support

base entry.
7.
Terminate cable with appropriate PETK termination kit.

Refer to PETK installation instructions.
4.
Insert banding guide into expediter and snap into place.
8.
Push excess cable back through expediter. Tighten cap

securely. Tape cable expansion loop to pipe.
9.
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.
13.
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.
10.
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.
14.
Install junction box lid and twist hand tight. Insert screwdriver into ratchet slots located on side of junction box base.
11.
Install power cable (if necessary). The insulation on the

conductors is to be stripped back in accordance with the
terminal block manufacturers recommendations.
15.
Use screwdriver to ratchet on junction box lid. Lid will rotate

30 degrees.
12.
Install quick mount terminal blocks and tighten screws (if

necessary).
16.
Lid latch mechanism fully engaged. To remove lid, repeat

steps 14 and 15 but in the opposite direction.
Two Cable Layout Tips
A1.
A2.
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.
Insert two cables into expediter.
Three Cable Layout Tips
B1.
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.
B2.
Insert three cables into expediter.
B3.
Mount expediter with three cables.

Do not band over cable.
Wiring Details
C1.
Power Connection (1 to 3 Heating Cables)
C2.
In-Line Splice and T-Splice
C3.
End Termination (1 to 2 Heating Cables)

Remove jumpers for 2 cable terminations.
Translation
Franaise
Instructions dinstallation des kits de connexion

ZP-S-XP pour utilisation avec les cbles chauffants Thermon de type BSX, HTSX, KSX, HPT et FP
ZP-L-XP; pour utilisation avec les cbles chauffants Thermon de type RSX, TSX et VSX
Raccordement de 1 3 cbles, pissure en ligne dun cble ou la terminaison de 1 2 cbles
Les kits de terminaison des cbles et les colliers de serrage ne sont pas inclus dans ces kits
Attention: Le circuit doit tre hors tension avant louverture du botier. Ce produit doit tre install correctement. viter toute migration dhumidit, avant, pendant et aprs linstallation pour liminer tout risque
lectrique (arc, court-circuit, choc)
Avant linstallation, lire ces instructions entirement

Les systmes de traage THERMON doivent tre surveills par des dispositifs de protection
lectriques diffrentiels.

Les tresses de protection lectrique doivent tre connectes la terre
Utiliser des outils en bon tat et calibrs si ncessaire.

Linstallation doit tre conforme aux normes lectriques en vigueur.

Vrifier galement les instructions dinstallation du cble chauffant et des kits de raccordement.

Rayon de courbure mini des cbles autorgulants 32 mm (19 mm pour FP et 57 mm pour HPT)
Schmas:
Toutes les dimensions sont en millimtres
1. Pour les cbles HPT et FP, localiser les jonctions entre llment chauffant et les conducteurs.
Couper le cble en biseau pour faciliter le perage de la cavit du joint. Prvoir une surlongueur
pour des modifications ultrieures. Voir page 4 les recommandations pour linstallation de plusieurs
cbles.
2. Glisser le cble dans le pied support. Vrifier que le trou dvacuation est bien orient et bien perc
si le pied est mont sous la tuyauterie, ou horizontalement.
3. Glisser le pied en place sur la tuyauterie.
4. Fixer le guide de serrage en place
5. Fixer le pied avec le collier de serrage adquat, ne pas pincer le cble sous le collier
6. Couper lextrmit du cble
7. Raliser les kits de terminaisons PETK appropris (se rfrer aux instructions dinstallations des kits
PETK)
8. Ajuster la longueur du cble, repousser lexcs de cble travers le pied support. Serrer le capot
suprieur. Fixer la surlongueur de cble sur la tuyauterie.
9. Installer le botier sur le pied support. Utiliser les guides pour bien orienter le botier. Selon
lorientation de montage, assurez vous que les perages pour presse toupe sont orients vers le
bas.
10. Installer les presse-toupe et bouchon M25. Pour les applications de terminaison ou de raboutage,
installer des bouchons supplmentaires la place des presse-toupe. (rfrence M25-B-EXE,
commander sparment)
11. Raccorder le cas chant, le cble dalimentation lectrique.
12. Positionner lensemble bornier et rail et bloquer les vis si ncessaire. (couple de serrage de 1.4Nm)
13. Raliser le cblage. Fixer lensemble
14. Positionner le couvercle de la bote manuellement. Glisser un tournevis dans les fentes sur la
priphrie de u botier
15. Utiliser le tourne vis pour bloquer le couvercle (rotation denviron 30 degrs)
16. La scurit de blocage est compltement engage. Pour ouvrir le botier rpter 14 & 15 mais dans
lautre sens de rotation
A1. Pour les cbles HPT et FP, localiser les jonctions entre llment chauffant et les conducteurs.
Couper le cble en biseau pour faciliter le perage de la cavit du joint. Prvoir une surlongueur pour
des modifications ultrieures.
A2. Glisser deux cbles dans le pied support.
B1. Pour les cbles HPT et FP, localiser les jonctions entre llment chauffant et les conducteurs.
Couper le cble en biseau pour faciliter le perage de la cavit du joint. Prvoir une surlongueur pour
des modifications ultrieures.
B2. Glisser trois cbles dans le pied support
B3. Fixer le pied avec les trois cbles. Ne pas pincer les cbles sous le collier de serrage
C1. Alimentation lectrique 1 3 cbles
C2. pissure en ligne ou T
C3. Terminaison (1 2 cbles). Enlever les barrettes pour installer deux terminaisons.
Nederlands
Toepassingen.
Aansluitkast met opvoersok voor voedingsaansluiting, doorverbinding of eindafsluiting buiten de isolatie
van Thermon SX zelfbegrenzende, vermogen begrenzende of constant vermogen verwarmingskabels.
Voor gebruik in explosiegevaarlijke en industrile omgevingen. Het maximale aantal verbindingen is vier,
te weten 1 voeding in en 3 tracers uit of 2 voedingen (1 in en 1 uit) met 2 tracers uit.
Gebruik type ZP-L-XP voor tracing kabel type RSX, TSX en VSX.
Gebruik type ZP-S-XP voor tracing kabel type BSX, KSX, HTSX, HPT en FP.
Te gebruiken met Thermon PETK/XP PLUS-. afwerkingsets en bevestigingsbanden type B.. (zijn niet
in deze set aanwezig).
LET OP: Schakel altijd eerst de spanning af, voordat de aansluitkast geopend wordt. De installatie moet
correct worden uitgevoerd. Inwateren moet voorkomen worden, zowel voor, tijdens en na installatie
om een elektrische schok, kortsluiting en vonkvorming te voorkomen.
Lees deze instruktie in zijn geheel voor installatie van het product.

Thermon verwarmingssystemen moeten altijd genstalleerd worden met de correcte elektrische
beveiligingen. Thermon adviseert altijd een installatie automaat/zekering met aardlekbeveiliging toe
te passen.
Verbind de metalen omvlechting van de verwarmingskabel met aarde.

Gebruik alleen pers krimptangen met moment ontgrendeling.

De installatie moet in zijn geheel voldoen aan de locale voorschriften voor elektrische installaties en
aan de IEC 60079-14 bij gebruik in explosiegevaarlijke omgevingen.
Component certificaten zijn gebaseerd op alleen gebruik van Thermon onderdelen.

Zie ook de installatie instrukties van de desbetreffende verwarmingskabel voor de voedings- en

eindaansluiting.

Zorg dat zowel voor als tijdens de montage de open verwarmingskabel uiteinden en de set onderdelen droog zijn.

De minimale buigradius van verwarmingskabel is 32 mm (behalve HPT deze is 57 mm en FP is 19
mm).
Afbeeldingen:
1. Bepaal het knooppunt in de verwarmingskabel (alleen voor HPT en FP) zoals aangegeven. Snij het
einde van de kabel schuin af, om het doorsteken door het doorvoerrubber mogelijk te maken. Zorg
dat er een extra lus in de kabel aanwezig is. Zie blad 4 voor tips met meerdere kabels.
2. Steek de kabel door het rubber en de opvoersok heen. De voorkeur montage van de opvoersok is
boven op de leiding. Indien montage aan de zijkant of aan de onderzijde van de leiding nodig is,
moet het drainagegaatje aan de onderzijde zitten en open gemaakt worden.
3. Schuif de opvoersok naar de leiding en voer de verwarmingskabel door de daartoe dienende opening van de opvoersok.
4. Klik het bevestiging steuntje in de opvoersok.
5. Monteer de opvoersok op de leiding m.b.v. montageband type ABA of B. Zorg dat de montageband niet over de tracing kabel loopt.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
A1.
A2.
B1.
B2.
B3.
C1.
C2.
C3.
5
Knip de tracing kabel 180 mm boven de opvoersok recht af.
Gebruik de installatie instrukties van de desbetreffende PETK-set voor het maken van een voedingaansluiting of eindafsluiting van de verwarmingskabel.
Duw eventuele overlengte van de verwarmingskabel terug. Draai de moer vast aan. Monteer de lus
in de verwarmingskabel vast op de pijp m.b.v. tape
type FT- .
Monteer het bodemdeel van de aansluitkast op de opvoersok, zorg dat de O-ring op de opvoersok
aanwezig is. De vergrendelnokken en uitsparingen in de opvoersok en het bodemdeel moeten
overeenkomen. Draai de moer op de nippel, en draai deze vast m.b.v. LN montage sleutel. Zorg dat
de wartels niet inwaterend zijn.
Monteer de bijgesloten M25 voedingskabelwartel en de M25 blindplug goed vast in het bodemdeel
m.b.v. een steeksleutel en een inbussleutel. Indien twee kabelwartels of blindpluggen nodig zijn,
moeten deze apart erbij besteld worden.
Monteer en snij voedingskabel aan. Voedingskabel aansluitingen kunnen verschillend zijn per type
voedingskabel. Neem voor meer installatie instrukties kontakt op met de leverancier van de voedingskabel.
Monteer de klemmenrail met de aansluitklemmen in het bodemdeel, schroef de twee schroeven vast.
Sluit alle draden op de desbetreffende aansluitklemmen aan, voor meer details zie blad 5. Draai de
schroeven in de aansluitklemmen met een koppel van 1,4 Nm aan.
Breng het deksel op het bodemdeel van de aansluitkast aan, en draai het deksel handmatig vast.
Steek een schroevendraaier aan de zijkant onder een deksellip in de opening van het bodemdeel.
Draai het deksel tot aan de aanslag dicht, m.b.v. de schroevendraaier. Monteer het meegeleverde
koordje, bevestig n zijde aan de deksel en de andere zijde aan de bodem van de aansluitkast.
Om het deksel te verwijderen, moeten de stappen 14 en 15 in omgekeerde volgorde uitgevoerd
worden.
Bepaal het knooppunt in de verwarmingskabel (alleen voor HPT en FP) zoals aangegeven. Snij het
dat er een extra lus in de kabel aanwezig is.
Montage van twee kabels in de opvoersok.
Bepaal het knooppunt in de verwarmingskabel (alleen voor HPT en FP) zoals aangegeven. Snij het
dat er een extra lus in de kabel aanwezig is.
Montage van drie kabels in de opvoersok.
Montage van opvoersok met drie kabels op pijp. Zorg dat de montageband niet over de tracing
kabels loopt.
Voedingaansluiting (1 tot 3 verwarmingskabel).
Twee - of drievoudige verwarmingskabel doorverbinding.
Eindafsluiting van verwarmingskabel. Bij aansluiting van twee kabels moeten de doorverbindingen
op de aansluitklemmen verwijderd worden.
Deutsch
Anschlussset Terminator - Montageanleitung

Terminator ZP-L-XP zur Verwendung mit selbstregulierenden Heizkabeln RSX, TSX und VSX
Terminator ZP-S-XP zur Verwendung mit selbstregulierenden Heizkabeln BSX, HTSX und KSX, sowie
leistungsbegrenzenden Parallelheizleitungen HPT und Parallelheizleitungen FP
Zum Betriebspannungsanschluss ( 1-3 Heizkabel ), Heizkabelverbindung, T-Abzweig oder Endabschluss
( 1-2 Heizkabel ).
Das Anschlusssystem PETK und Montageband sind nicht im Anschlussset enthalten.
Sicherheitshinweise:

Zur Vermeidung von Stromschlgen, Lichtbgen und Feuer, die durch mechanische Beschdigung
des Heizkabels oder unsachgeme Verwendung bzw. Installation und Wartung hervorgerufen
werden knnen, ist ein Fehlerstrom-Schutzschalter ( FI ) je Heizkreis vorzusehen.

Die Installation muss zu der Montageanleitung der THERMON sowie den internationalen Richtlinien
aus IEC 60079-14 fr explosionsgefhrdete Bereiche
( wo zutreffend ) oder anderer nationaler/ regionaler Anforderungen konform ausgefhrt werden.

Zulassungen fr Einzelkomponenten und Leistungskenndaten gelten nur fr originale THERMON
Produkte.

Vor Arbeiten am Beheizungssystem Energieversorgung allpolig abschalten.

Heizkabelenden und Anschlusskomponenten sind whrend der gesamten Verarbeitungszeit trocken
zu halten.

Der Mindestbiegeradius bei selbstregulierenden Heizkabeln betrgt 32mm.
Bei HPT-Heizkabeln sind 57mm, FP-Heizkabeln 19mm zu bercksichtigen.
Illustrationen:
1. Bereiten Sie die Montage des Heizkabels wie in der Darstellung gezeigt vor. Bei Heizkabeln
der Referenz HPT bzw. FP sind die markierten Kontaktstellen zu beachten. Schneiden Sie das
Heizkabelende zwecks leichterer Einfhrung in das Grommet schrg ein. Lassen Sie eine kleine
Schlaufe Heizband zum Ausgleich von Bewegungen whrend des Betriebs auf dem Rohr. Seite 4
gibt Hinweise zur Installation.
2. Fhren Sie das Heizkabel von unten in den Standfu ein. Wird der Terminator nicht auf der
Oberseite des Rohres montiert sondern seitlich oder unterhalb, so ist die seitliche Einfhrung herauszudrcken.
3. Setzen Sie den Standfu auf das Rohr und ziehen Sie das Heizkabel passend ein.
4. Heben Sie den Standfu wieder ab und rasten Sie die Bandfhrung in den Standfu ein.
5. Endmontage des Standfues auf dem Rohr. Ziehen Sie dazu das Montageband durch die Aufnahmeffnungen des Standfues ohne dabei das Heizkabel zu kreuzen!
6. Schneiden Sie das Heizkabelende waagerecht ab.
7. Montieren Sie den zum Heizkabel passenden Heizkabelanschluss PETK. Zur Montage beachten Sie
die Montageanleitungen im Beipack.
8. Schieben Sie das konfektionierte Heizkabel in den Standfu zurck. Verschrauben Sie die Kappe
vorsichtig. Befestigen Sie die Heizbandschlaufe mit Band auf dem Rohr.
9. Plazieren Sie das Anschlussgehuse auf der Montagesule.
Fhren Sie die Mutter ber die Kabelenden und schrauben Sie diese auf dem Standfu auf.
Verwenden Sie dazu das Terminator-Montagewerkzeug.
Bei waagerechter Montage mssen die Verschraubungsffnungen zum Boden gerichtet werden.
10. Setzen Sie die Verschraubung Typ M25 fr die Energieversorgung und den Blindstopfen ein. Bei
Heizkabelverbindungen oder T-Abzweigen bzw. Endabschlssen zustzlichen M25-Blindstopfen
einschrauben ( bestellen Sie M25-B-EXE separat ) anstelle der M25-Verschraubung fr die Energieversorgung.
11. Ziehen Sie das Kabel zur Energieversorgung in das Anschlussgehuse ein ( falls notwendig ).
12. Positionieren Sie den auf der Montageschiene befestigten Klemmenblock und schrauben Sie diesen
fest ( falls erforderlich ).
13. Fhren Sie die Anschlussleiter auf die entsprechenden Klemmen. Anzugsmoment fr die Klemmen:
1,4Nm. Beachten Sie die Verdrahtungshinweise auf Seite 5.
14. Stecken Sie die Gehuseabdeckung auf das Anschlussgehuse und schrauben Sie diese mit der
Hand auf. Stecken Sie einen Schraubendreher in die Ratschenffnungen, die sich an der Seite des
Anschlussgehuses befinden.
15. Verwenden Sie den Schraubendreher zum Einrasten des Gehusedeckels.
Dabei dreht sich der Deckel um etwa 30 ( siehe Darstellung ).
16. Darstellung zeigt die Rastung in Endlage. Um den Gehusedeckel wieder zu entfernen, vollziehen
Sie die Schritte 14 und 15 in umgekehrter Richtung.
A1. Positionieren Sie die Heizkabel der Referenzen HPT und FP wie in der Darstell-lung gezeigt.
Beachten Sie dabei die Parallelleiterverbindungen der Heizkabel. Schneiden Sie das Heizkabelende
schrg ein und die Einfhrung in den Grommet zu erleichtern. Lassen Sie eine kleine Schlaufe
Heizband zum Ausgleich von Be-wegungen whrend des Betriebs auf dem Rohr.
Translation
A2. Fhren Sie beide Heizkabel in den Standfu ein.
B1. Positionieren Sie die Heizkabel der Referenzen HPT und FP wie in der Darstell-lung gezeigt.
Beachten Sie dabei die Parallelleiterverbindungen der Heizkabel. Schneiden Sie das Heizkabelende
schrg ein und die Einfhrung in den Grommet zu erleichtern. Lassen Sie eine kleine Schlaufe
Heizband zum Ausgleich von Be- Wgungen whrend des Betriebs auf dem Rohr.
B2. Fhren Sie die drei Heizkabel in den Standfu ein.
B3. Befestigen Sie die Montagesule mittels Montageband. Dabei darf das Montage-band das Heizkabel
nicht kreuzen.
C1. Anschlussplan (1-3 Heizkabel)
C2. Anschlussplan Heizkabelverbindung oder T-Abzweig
C3. Anschlussplan Endabschluss (1-2 Heizkabel). Beide Klemmenbrcken entfernen.

Terminator ZP-L-XP
RSX, TSX, VSX.
Terminator ZP-S-XP
BSX, HTSX, KSX, HPT
FP.
(1-3 ), , -
.
PETK .
Espaol
Kits conexin de alimentacin. Instrucciones de instalacin.
Terminator ZP-L-XP para la utilizacin con cables calefactores autorregulantes RSX, TSX, VSX.
Terminator ZP-S-XP para la utilizacin con cables calefactores autorregulantes BSX, HTSX, KSX, de
potencia limitante HPT, y cables calefactores de potencia constante FP
Adecuado para la conexin de alimentacin (1-3 cables calefactores), empalme en lnea, empalme en T, o
terminacin en extremo final (1-2 cables calefactores)
Los siguientes componentes no forman parte del producto y han de pedirse por separado:
- Para la conexin de alimentacin de cada cable; PETK-1 (en cables RSX, TSX, VSX), PETK-2 (en
cables BSX, KSX, HTSX) y PETK-3 (en cable HPT)
- Abrazadera; B-4 (para tuberas de hasta 4), B-10 (para tuberas de hasta 10), B-21 (para tuberas de
hasta 21)
Advertencias

Debido a los riesgos de descarga elctrica, formacin de arco o fuego ocasionados por el producto
en mal estado, o por una instalacin o mantenimiento inadecuados, es necesario instalar un dispositivo de proteccin diferencial.

La instalacin debe cumplir los requisitos de Thermon e instalarse de acuerdo con la normativa
vigente como la norma EN IEC 60079-14 para zonas clasificadas con riesgo de explosin (en su
caso), o cualquier otro reglamento y norma que le sea de aplicacin.

La certificacin y funcionamiento adecuado estn basados nicamente en el uso de los componentes
especificados por Thermon.

Desconectar todas las fuentes de alimentacin antes de abrir la caja.

Mantener secos los extremos del cable calefactor y los componentes del kit, antes y durante la
instalacin.

El radio mnimo de curvatura del cable calefactor son 32 mm (excepto cable HPT con un radio de 57
mm y el cable FP con un radio de 19 mm).
Instrucciones de instalacin
1. Situar la zona de conexin segn se muestra (slo para los cables HPT y FP).Cortar el extremo final
del cable en ngulo para facilitar la entrada del prensacables. Dejar cable adicional para el bucle de
dilatacin. Consultar en la pgina 4 las indicaciones para la instalacin de varios cables.
2. Introducir el cable en el soporte de fijacin. Si se monta en la parte inferior o lateral de la tubera,
perforar el agujero para el desage.
3. Acercar el soporte de fijacin hacia la tubera y pasar el cable a travs de la entrada de la base del
soporte.
4. Insertar la gua para la abrazadera en el soporte de fijacin y presionarla para colocarla en su lugar.
5. Montar el soporte de fijacin en la tubera utilizando la abrazadera. La abrazadera no debe pasar por
encima del cable.
6. Cortar el extremo final del cable.
7. Colocar en el extremo del cable el kit de terminacin PETK adecuado. Ver las instrucciones de
instalacin PETK.
8. Empujar el cable excedente a travs del soporte de fijacin. Apretar el sombrerete firmemente. Fijar
con cinta el bucle de dilatacin del cable sobre la tubera.
9. Montar la base de la caja de conexin en el soporte de fijacin. Asegurarse de alinear las ranuras
para orientar adecuadamente la base de la caja de conexin. Apretar la tuerca con la herramienta
Terminator-LN-Tool. Si el montaje es horizontal, los orificios roscados para los prensaestopas deben
quedar orientados hacia abajo.
10. Instalar el prensaestopas M25 y el tapn M25. Para el empalme en lnea, empalme en T o la terminacin en extremo final, instalar un tapn adicional M25 (pedir M25-B-EXE por separado) en lugar
del prensaestopas M25.
11. Instalar el cable de alimentacin (si es necesario).
12. Instalar la regleta de terminales y apretar los tornillos (si es necesario).
13. Completar el sistema de cableado. Los tornillos de la regleta de bornes debern apretarse con un par
de apriete de 1,4 Nm (12,4 lb-in). Consultar la pgina 5 para ver los detalles de cableado.
14. Instalar la tapa de la caja de conexin y girar a mano con firmeza. Introducir el destornillador en las
ranuras de trinquete situadas en el lateral de la base de la caja de conexin.
15. Utilizar el destornillador para actuar sobre el trinquete en la tapa de la caja de conexin. La tapa
girar 30.
16. La tapa debe girarse hasta que el mecanismo de cierre de las dos partes quede acoplado. Para
retirar la tapa, repetir los pasos 14 y 15 en la direccin opuesta.
Indicaciones para la instalacin de dos cables
A1. Situar la zona de conexin segn se muestra (slo para los cables HPT y FP). Cortar el extremo final
del cable en ngulo para facilitar la entrada del prensaestopas. Dejar cable adicional para el bucle de
dilatacin.
A2. Introducir los dos cables en el soporte de fijacin.
Indicaciones para la instalacin de tres cables
B1. Situar la zona de conexin segn se muestra (slo para los cables HPT y FP). Cortar el extremo final
del cable en ngulo para facilitar la entrada del prensaestopas. Dejar cable adicional para el bucle de
dilatacin.
B2. Introducir los tres cables en el soporte de fijacin.
B3. Montar el soporte de fijacin con los tres cables. La abrazadera no debe pasar por encima del cable.
Detalles de cableado
C1. Conexin de alimentacin (1 a 3 cables calefactores).
C2. Empalme en lnea y empalme en T
C3. Terminacin extremo final (1 a 2 cables calefactores)
Quitar los puentes cuando deban realizarse las terminaciones de dos cables
:
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Thermon EN
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32 ( HPT - 57 FP - 19 ).
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Terminator ZT
Pipewall Sensing Thermostats

Application . . .
Electric Heat Tracing Control

The ZT is designed for use as an adjustable control thermostat
for freeze protection and temperature maintenance applications
requiring tankwall or pipewall sensing. The ZT is available in four
temperature control and bulb exposure temperature ranges and
has a flexible capillary armouring complete with capillary gland and
insulation entry device. The ZT includes an expediter to facilitate
attaching the thermostat directly on the pipe and permits two
heating cables to enter and be connected within the enclosure.
Terminator ZT kit is approved for use in ordinary (nonclassified)

and hazardous (classified) areas.
Ratings/Specifications . . .
Enclosure rating......................................................................... IP66

Maximum pipe exposure temperature.....................................250C
Minimum installation temperature............................................-60C
Operating ambient temperature
-60C Ta +55C..........................16 Amps Max, T6 85C
-60C Ta +50C........................25 Amps Max, T5 100C
Voltage rating.................................. 230 Vac nominal up to 253 Vac1
Switch rating ........................................... 25 A (Ohmic, NC contact)
Switch type........................................................................ Controller
Electrical connection2................................................ Terminal block3
Adjustable control range4
ZT-C-100..........................................................0C to 100C
ZT-C-200..........................................................0C to 200C
ZT-C-300..........................................................0C to 300C

ZT-C-500 .......................................................20C to 500C
Maximum control differential/accuracy
ZT-C-100 ................................................... 7% / -1 K to +7 K
ZT-C-200 ..............................................2.5% / -2 K to +10 K
ZT-C-300 ..............................................2.5% / -2 K to +16 K
ZT-C-500...............................................2.5% / -2 K to +28 K
Maximum bulb exposure temperature
ZT-C-100.....................................................................230C
ZT-C-200.....................................................................230C
ZT-C-300.....................................................................345C
ZT-C-500.....................................................................530C
Bulb dimensions/material/capillary length
ZT-C-100.............................. 6 x 76 mm/stainless steel/1 m
ZT-C-500............................ 6 x 280 mm/stainless steel/1 m
Max. electrical switching frequency.........................180 cycles/hour
Electrical durability operating cycles................. min. 100.000 cycles
Mechanical durability operating cycles............. min. 300.000 cycles
Construction . . .
1 Junction Box, Glass-Reinforced Polymer

with DIN Rail Mounted Terminal Blocks
2 Pipe-Mount Expediter, Glass-Reinforced

Polymer
3 Capillary Temperature Sensor
Certifications/Approvals . . .
II 2 G Ex db eb IIC T5-T6 FM10ATEX0058X
II 2 D Ex tb IIIC T100C-T85C
International Electrotechnical Commission
IEC Certification Scheme for Explosive Atmospheres
FMG 10.0022X
Typical Wiring Diagram . . .

PE
Notes . . .
1. 400 Vac/16A version available on request.
2. Thermostats are shipped with an M25 dust cap that can be replaced with an Ex e
approved gland to permit power or heating cable connection.
Product Reference Legend . . .
3. Terminal block consists of six line/load terminals and two PE terminals.
ZT-C-100-P
4. The 300C and 500C thermostats are only available in wall mount bracket.
Area Designation
Z = Zone Areas
Kit Type
T = Thermostat
Switch Type
C = Controller
Control Range
100 = 0C to 100C
200 = 0C to 200C
300 = 0C to 300C
500 = 20C to 500C
European Headquarters
Boezemweg 25
PO Box 205
2640 AE Pijnacker
The Netherlands
Phone: +31 (0) 15-36 15 370
Corporate Headquarters
100 Thermon Dr.
PO Box 609
San Marcos, TX 78667-0609
USA
Phone: +1 512-396-5801
Cable Profile
P = RSX, TSX, VSX, BSX,
HTSX, KSX, FP, HPT
MI = MIS, MIQ
M = TEK, HTEK
For the Thermon office nearest you

visit us at . . .
www.thermon.com

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Product Specifications

Application Freeze Protection and Process Temperature Maintenance

Terminator ZP... is designed to fabricate power

Terminator ZL... is designed to provide visual

Terminator Beacon... end-of-circuit light kits

The Terminator ZL kit includes; IP66 rated junction

Product Reference Legend:

Product Reference Legend:

Product Reference Legend:

Terminator ZS/ZE...designed to fabricate

PETK...circuit fabrication kits are required for

Product Reference Legend:

Product Reference Legend:

SCTK...splice connection termination kits are

THERMON The Heat Tracing Specialists

Cable End Termination Kits, Attachment Tapes and Miscellaneous Items

CS-L-*-Ex. Circuit switch with lamp to be used as

B-4, B-10, B-21...stainless steel attachment bands

IEK-SX...Insulation entry kit for use in (non)

M25-SX.-Ex....Ex e approved nonmetallic gland for

M25-PWR-Exe, M25-B-Exe...Ex e approved

M25-SX.-IND....nonmetallic gland for use with

M25-PWR-Exe...power gland is suitable for securing

FT-1L, FT-1H...fixing tape for attaching heating cable

M25-LN-IND...locknut for securing M25 glands in

SK-SX-OJ...Ex e approved under-the-insulation

CL...vinyl-based peel-and-stick caution labels are

XP-1-...predrilled stainless steel (type 304) mounting

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

Temperature measurement range

Maximum sensor lead resistance

Switching differential (Hysteresis)

Single Pole change over type (SPST)

Single Pole change over type (SPST)

Ambient temperature range

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

230 V +10% / 15% 50/60 Hz

Internal power consumption

M16 gland with 3 wire PT100

M16 gland with 3 wire PT100,

INDUSTRIAL HEAT TRACING SOLUTIONS

Green: ETS-05 powered on,

Yellow: ETS-05 powered on,

Yellow: ETS-05 powered on,

Red flashing: Sensor failure - controller

Red flashing: Sensor failure - controller

DIMENSIONS (IN MM)

Terminals 2 and 3 are joined electrically

Link 3-4 removed = Output OFF

INDUSTRIAL HEAT TRACING SOLUTIONS

* Circuit breaker configurations may vary

Link 3-4 removed = Output OFF

INDUSTRIAL HEAT TRACING SOLUTIONS

Raychem HIQ mineral insulated (MI) Inconel 600 series

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

INDUSTRIAL HEAT TRACING SOLUTIONS

=Min. installation temperature

MI SERIES HEATING CABLES HIQ

Nominal resistance Outer diameter

Resistance tolerance: 10%

INDUSTRIAL HEAT TRACING SOLUTIONS

1 junction box with terminals

1 junction box with terminals with earth