PCA-COM Power Connection and End Termination Kit
Product Information: PCA-COM Power Connection and End
Termination Kit
The PCA-COM Power Connection and End Termination Kit is an
installation kit for power connection, in-line splice connection,
T-splice connection, or end termination applications for FLX and
HSX Heat Tracing. The kit includes an expediter assembly, locknut,
gasket, NPT threaded cap, grommet, expediter base, RTV tube, end
cap ET-6, TBX-3L power connection boot, junction box with cover,
end termination caution label, wire nut, and aluminium foil (for
HSX cable only). The kit is designed to be used with up to three
trace heaters and comes with all necessary components for
installation.
Product Usage Instructions: PCA-COM Power Connection and End
Termination Kit
The following are the suggested guidelines for the installation
of Thermon’s PCACOM connection systems:
Receiving, Storing and Handling
- Inspect materials for damage incurred during shipping.
- Report damages to the carrier for settlement.
- Identify parts against the packing list to ensure the proper
type and quantity have been received. - Store in a dry location.
Note: Electrical lockout may be required before working on this
line or removal of thermal insulation.
Installation Precautions
Before starting the installation process, make sure to take the
following precautions:
- Refer to the dimensions provided in the manual for proper
installation. - Make sure to have all the necessary tools required for
installation.
Power Connection for FLX and HSX
Follow the below steps for power connection:
- For one, two or three trace heaters, insert the trace heater
into the expediter, grommet, and NPT threaded cap. - For two trace heaters, insert both the trace heaters into the
expediter, grommet, and NPT threaded cap. - For three trace heaters, insert all three trace heaters into
the expediter, grommet, and NPT threaded cap. - Slide expediter toward the pipe and secure the cap to the base
with captive screws. - Mount expediter to pipe using two (2) tapes provided
separately. - Cut and remove overjacket. Do not cut metallic braid. For HSX
cable only, gently score the aluminium foil layer and peel
away. - Separate braid strands at the edge of the overjacket and pull
trace heater through the opening. - Twist braid into a pigtail and trim ends of braid.
- Apply a liberal amount of RTV sealant to trace heater.
- Slide boot onto the end of the trace heater.
End Termination for FLX and HSX
Follow the below steps for end termination:
- Cut and remove overjacket.
- Trim ends of braid. For HSX tracer only, gently score the
aluminium foil layer and peel away. - Apply a liberal amount of RTV sealant to trace heater and
inside end cap. - Slide end cap onto the end of the trace heater.
Mount Junction Box and Make Connections
Follow the below steps for mounting junction box and making
connections:
- Mount junction box on expediter using gasket and locknut
provided. - Install power connection fittings (supplied by others) and pull
in power and ground wires. - Complete system wiring (components supplied by others). Refer
to the typical wiring details provided in the manual for proper
wiring.
In-Line Splice and T-Splice
The manual does not provide instructions for in-line splice and
T-splice. Please refer to good engineering or field construction
practices for proper installation.
PCA-COM
Power Connection and End Termination Kit
INSTALLATION PROCEDURES
Power Connection, In-Line Splice Connection, T-Splice Connection, or End Termination Applications with for FLX and HSX Heat Tracing
PCA-COM
The following installation procedures are suggested guidelines for the installation of Thermon’s PCACOM connection systems. They are not intended to preclude the use of other methods and good engineering or field construction practices.
Receiving, Storing and Handling 1. Inspect materials for damage incurred during
shipping. 2. Report damages to the carrier for settlement. 3. Identify parts against the packing list to ensure
the proper type and quantity have been received. 4. Store in a dry location.
Kit Contents
5
2 1
3 4
6
NOTE: Electrical lockout may be required before working on this line or removal of thermal insulation.
7
Installation Precautions
· To minimize the potential for arcing and fire caused by product damage or improper installation use ground-fault protection. The National Electrical Code (NEC) and Canadian Electrical Code (CEC) require ground-fault protection of equipment for each branch circuit supplying electric heat tracing.
· Installation must comply with Thermon requirements and be installed in accordance with the NEC, CEC, or any other applicable national and local codes.
· De-energize all power sources before opening enclosure.
· Keep ends of trace heater and kit components dry before and during installation.
· Component approvals and performance ratings are based on the use of Thermon specified parts only. User supplied power connection fittings must be listed or certified for intended use.
· The kit instructions should be used in conjunction with the installation instructions for the trace heater and other accessory items.
Dimensions
126 mm (4.97″)
92 mm (3.64″)
Item
1
2 3 4 5 6 7
Quantity
Description
Expediter Assembly
Locknut
1
Gasket 1″ NPT Threaded Cap
Grommet
Expediter Base
1
RTV Tube
1
End Cap ET-6
1
TBX-3L Power Connection Boot
1
Junction Box with Cover
1
End Termination Caution Label
3
Wire Nut
209 mm (8.23″)
Certifications/Approvals Tools Required
2
Power Connection for FLX and HSX
INSTALLATION PROCEDURES
1. For one, two or three trace heaters. Insert
trace heater into expediter, grommet, and NPT threaded cap.
2. Two trace heaters.
3. Three trace heaters.
Tape Provided Separately
152 mm (6″)
Braid
4. Slide expediter toward pipe and secure
cap to base with the captive screws.
5. Mount expediter to pipe using two (2)
circumferential bands of 13 mm (½”) wide FT-1L tape.
6. Cut and remove overjacket.
Do not cut metallic braid.
Aluminium Foil (HSX Cable Only)
7. Separate braid strands at edge of
overjacket and pull trace heater through opening.
8. Twist braid into a pigtail. Trim ends of
braid.
9. Gently score the aluminium foil layer and
peel away. (HSX trace heaters cables only).
3
PCA-COM
Primary Insulation
117 mm (4-5/8″)
Matrix
Bus Wire
10. Cut and remove primary insulation jacket. 11. Skive outside of black matrix.
Do not cut bus wire strands.
12. Cut V-Notch in matrix and pull bus wires
from matrix. Cut and remove center matrix.
13. Apply a liberal amount of RTV sealant to
trace heater.
14. Slide boot onto the end of the trace
heater.
End Termination for FLX and HSX
Overjacket
13 mm (1/2″)
ET-6
15. Cut and remove overjacket.
16. Trim ends of braid. Gently score the
aluminium foil layer (HSX tracer only) and peel away.
17. Apply a liberal amount of RTV sealant to
trace heater and inside end cap. Slide end cap onto end of trace heater.
4
Mount Junction Box and Make Connections
INSTALLATION PROCEDURES
Wire Nuts
18. Mount junction box on expediter using
gasket and locknut provided.
19. Install power connection fittings
(supplied by others) and pull in power and ground wires.
Ground Lead
Ground Lug
20. Complete system wiring (components
supplied by others). See typical wiring details below.
Typical Wiring Details
Ground
L2/N
Trace Heater
Trace Heater #1
Ground
Trace Heater #2
L2/N
Trace Heater #1
Ground
Trace Heater #2
L2/N
Power Supply L1
Power Connection1 Trace heater.
Power Supply
L1 L1
Trace Heater #3
Power Connection3 Trace heaters.
Trace Heater #3
In-Line Splice and T-Splice
21. Install junction box lid using 4 captive
screws.
5
PCA-COM
Trace Heater Take-off for FLX and HSX
INSTALLATION PROCEDURES
Primary Insulation
Heating Cable Overjacket
Bus Wires
Primary Insulation
Heating Cable Overjacket
Metallic Braid
For Power Connection Boot Termination
For End Cap Termination
NOTE: Images may not be printed to scale.
Corporate Headquarters: 7171 Southwest Parkway · Building 300, Suite 200 · Austin, TX 78735 · Phone: 512-690-0600 For the Thermon office nearest you visit us at . . . www.thermon.com
Form PN50400C-1221
© Thermon, Inc. · Printed in U.S.A. · Information subject to change.
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