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1 PBS-200-A Single entry power junction box Installation Instructions PBS-200-A Single entry power junction box with cold applied connection technology for use with BARTEC PSB / HSB trace heaters Consignes d installation Boîte de raccordement à une entrée PBS-200-A à technologie de connexion froide pour utilisation avec les câbles chauffants de type BARTEC PSB / HSB

3 Table of contents Overview 2 Certifications / Approvals 2 Technical data 2 Safety 2 Kit contents 3 Accessories 4 Installation 5 Preparation 5 Heating circuit length (PSB trace heaters) 5 Heating circuit length (HSB trace heaters) 5 Required tools 6 Cautions and warnings 6 Unrolling the trace heater 6 Installation on pipes 6 Fastening 7 Preparation of the trace heater 7 Installation of the mounting stand 12 Cable connection 13 Wiring 15 Installation of the end seal 17 Troubleshooting 18

PBS-200-A Single entry power junction box Installation Instructions Overview Technical data This manual introduces the installation and operation of the BARTEC PBS-200-A Single entry power junction

4 PBS-200-A Single entry power junction box Installation Instructions Overview Technical data This manual introduces the installation and operation of the BARTEC PBS-200-A Single entry power junction box. The trace heating system uses a self-regulating trace heater. It features a temperature-dependant resistive element between two parallel copper conductors, that regulates and limits the heat output of the trace heater according to the ambient temperature. If the ambient temperature rises, the power output of the trace heater is reduced. This selfregulating property prevents overheating which would cause damage to the trace heater. Even crossing or overlapping with other trace heaters (or other portions of the same trace heater) are possible. The heating system is set up as a fixed equipment heating system for pipes in ordinary and hazardous areas. Thanks to the parallel design the trace heater can be cut and installed to any required length. The manual applies for the following trace heaters: BARTEC PSB BARTEC HSB The following terms describe the parts of the trace heater within these instructions: Certifications / Approvals bus wire PBS-200-A Single entry power junction box for BARTEC PSB / HSB trace heaters heating element insulation jacket grounding braid outer jacket Ambient temperatures -67 to 131 F / -55 to 55 C Operation temperatures Voltage Heat output Resistance Explosion protection Heater dimensions PSB HSB PSB HSB Minimum bending radius Maximum power conductor size Terminals Safety -40 to 150 F /-40 to 65 C -76 F to -250 F / -60 C to -120 C 110 to 254 VAC 3 to 20 W/ft Grounding braid: < 18.2 Ω/km Class I, Div 2 Group A, B, C, D Class II, Div 2 Group E, F, G Class III (for information on T-ratings see the design guide of the trace heater) 0.46 x 0.22 (11.6 x 5.6 mm) 0.40 x 0.19 (10.2 x 4.8 mm) 1 (25 mm) Do not bend on the narrow axis. 10 AWG (6 mm²) Spring clamp EX e 2x3 lines, 1x3 PE For safe installation and operation of the PBS-200-A Single entry power junction box the technical requirements and instructions given in this manual must be followed. WARNING Risk of fire or electrical shock. Follow these guidelines to avoid personal injury or material damage. All electrical systems and installations must comply with BARTEC GmbH requirements and be installed in accordance with the relevant electrical codes and any other applicable national and local codes. BARTEC GmbH, the US and Canadian electrical codes require ground fault protection to be provided for all trace heating circuits. Install the connection kit, trace heaters and end seals carefully. Use the trace heater in accordance with the intended purpose and strictly comply with the operational data specified in section Technical Data. The bending radius of the trace heater must be at least 1 (25 mm). Do not bend on the narrow axis. Any defective component of the kit must be replaced before installation. To avoid short circuits, do not connect the trace heater bus wires together. Keep all components and the trace heaters dry before and during installation. During installation silicone adhesive is used. Follow the safety instructions given on the packaging. Keep these instructions for future reference. If applicable, leave them with the end user. De-energize before installation or servicing. Use only original BARTEC accessories. Page 2 / 21

5 Kit contents The following table lists the kit contents for the PBS-200-A Single entry power junction box: PBS-200-A power junction box with cold applied connection technology 1 x Silicone pants 1 x End cap 1 x Green/yellow tube for grounding braid 3 x Ferrule 1 x Silicone adhesive 1 x Safety datasheet for silicone adhesive 1 x Trace heater grommet 1 x Blind plug 1 x M25 blind plug with lock nut 1 x Cover for junction box incl. 4 fixing screws 1 x Junction box with connection terminals 1 x Top unit of the mounting stand incl. sealing ring and lock nut 1 x Base unit of the mounting stand Page 3 / 21

PBS-200-A Single entry power junction box Installation Instructions Accessories The

On pipe cable gland kit and end seal spare parts kit for replacement of damaged or lost

: CAK-D5-A 3x Adhesive tapes for trace heater installation on pipes etc. Catalog No.

Aluminium adhesive tape application under trace heaters for better heat distribution

: AT80-164 (for up to 176 F / 80 C) AT150-164 (for up to 302 F / 150 C) Pipe straps for

6 PBS-200-A Single entry power junction box Installation Instructions Accessories The following accessories are available for the trace heating system. On pipe cable gland kit and end seal spare parts kit for replacement of damaged or lost parts Catalog No.: CAK-D5-A 3x Adhesive tapes for trace heater installation on pipes etc. Catalog No.: PT-164 (100706) (for up to 212 F / 100 C) GT-108 (392328) (for up to 356 F / 180 C) Aluminium adhesive tape application under trace heaters for better heat distribution Catalog No.: AT (for up to 176 F / 80 C) AT (for up to 302 F / 150 C) Pipe straps for fixation of mounting stands on pipes etc. Supplied upon request, contact your local BARTEC distributor Electrical warning label Warning label for trace heater circuits Catalog No.: HTWL-DE (German) HTWL-US (English) HTWL-FR (French) HTWL-RU (Russian) Page 4 / 21

7 Installation Preparation Before installing any electric trace heating, the person installing must check if the trace heating has been designed and planned correctly. It is particularly essential to verify the following points: complete project planning documentation, operating instructions and installation instructions. correct selection of the trace heater and accessories with respect to: calculation of heat losses max. permissible operating temperature max. permissible ambient temperature temperature class heating circuit length Before installing, make sure that all piping and equipment is properly installed and pressure tested. Heating circuit length (PSB trace heaters) The following table shows the maximum circuit lengths in ft (m) for the different PSB trace heater types with standard circuit breaker amperages. Breaker sizing should be based on the National Electrical Code, Canadian Electrical Code or any other local or applicable code. Trace heater type 3 PSB PSB PSB PSB Power output Start-up temperature F ( C) Maximum heating circuit length in ft. (m) Operating Voltage: 120 VAC Operating Voltage: 208 VAC Operating Voltage: 240 VAC 20 A 30 A 40 A 20 A 30 A 40 A 20 A 30 A 40 A +50 (+10) 312 (95) 312 (95) 312 (95) 591 (180) 591 (180) 591 (180) 673 (205) 673 (205) 673 (205) 0 (-18) 295 (90) 312 (95) 312 (95) 551 (168) 591 (180) 591 (180) 597 (182) 640 (195) 640 (195) -20 (-29) 246 (75) 312 (95) 312 (95) 476 (145) 591 (180) 591 (180) 505 (154) 623 (190) 640 (195) -40 (-40) 240 (73) 312 (95) 312 (95) 420 (128) 558 (170) 591 (180) 479 (146) 623 (190) 640 (195) +50 (+10) 262 (80) 262 (80) 262 (80) 486 (148) 492 (150) 492 (150) 525 (160) 525 (160) 525 (160) 0 (-18) 197 (60) 262 (80) 262 (80) 394 (120) 492 (150) 492 (150) 394 (120) 525 (160) 525 (160) -20 (-29) 161 (49) 262 (80) 262 (80) 328 (100) 443 (135) 476 (145) 328 (100) 525 (160) 525 (160) -40 (-40) 157 (48) 256 (78) 262 (80) 312 (95) 394 (120) 476 (145) 315 (96) 512 (156) 525 (160) +50 (+10) 190 (58) 207 (63) 207 (63) 344 (105) 377 (115) 377 (115) 381 (116) 413 (126) 413 (126) 0 (-18) 125 (38) 184 (56) 207 (63) 246 (75) 312 (95) 344 (105) 246 (75) 374 (114) 413 (126) -20 (-29) 105 (32) 177 (54) 207 (63) 203 (62) 289 (88) 322 (98) 210 (64) 348 (106) 404 (123) -40 (-40) 98 (30) 164 (50) 207 (63) 190 (58) 272 (83) 302 (92) 197 (60) 328 (100) 387 (118) +50 (+10) 148 (45) 167 (51) 180 (55) 262 (80) 312 (95) 312 (95) 295 (90) 335 (102) 361 (110) 0 (-18) 98 (30) 138 (42) 148 (45) 190 (58) 256 (78) 295 (90) 197 (60) 276 (84) 295 (90) -20 (-29) 85 (26) 125 (38) 131 (40) 164 (50) 230 (70) 269 (82) 171 (52) 236 (72) 262 (80) -40 (-40) 72 (22) 115 (35) 118 (36) 131 (40) 180 (55) 230 (70) 131 (40) 197 (60) 230 (70) Heating circuit length (HSB trace heaters) The following table shows the maximum circuit lengths in ft (m) for the different HSB trace heater types with standard circuit breaker amperages. Breaker sizing should be based on the National Electrical Code, Canadian Electrical Code or any other local or applicable code. Trace heater type 5 HSB HSB HSB HSB Power output Start-up temperature F ( C) Maximum heating circuit length in ft. (m) Operating Voltage: 120 VAC Operating Voltage: 208 VAC Operating Voltage: 240 VAC 20 A 30 A 40 A 20 A 30 A 40 A 20 A 30 A 40 A +50 (+10) 312 (95) 312 (95) 312 (95) 541 (165) 541 (165) 541 (165) 620 (189) 620 (189) 620 (189) 0 (-18) 262 (80) 312 (95) 312 (95) 492 (150) 541 (165) 541 (165) 502 (153) 620 (189) 620 (189) -20 (-29) 246 (75) 312 (95) 312 (95) 443 (135) 541 (165) 541 (165) 489 (149) 620 (189) 620 (189) -40 (-40) 246 (75) 312 (95) 312 (95) 427 (130) 541 (165) 541 (165) 472 (144) 620 (189) 620 (189) +50 (+10) 184 (56) 190 (58) 190 (58) 315 (96) 374 (114) 374 (114) 361 (110) 374 (114) 374 (114) 0 (-18) 154 (47) 190 (58) 190 (58) 279 (85) 374 (114) 374 (114) 312 (95) 374 (114) 374 (114) -20 (-29) 148 (45) 190 (58) 190 (58) 262 (80) 374 (114) 374 (114) 302 (92) 374 (114) 374 (114) -40 (-40) 141 (43) 190 (58) 190 (58) 256 (78) 367 (112) 374 (114) 279 (85) 367 (112) 374 (114) +50 (+10) 131 (40) 135 (41) 135 (41) 230 (70) 269 (82) 269 (82) 262 (80) 269 (82) 269 (82) 0 (-18) 112 (34) 135 (41) 135 (41) 203 (62) 269 (82) 269 (82) 223 (68) 269 (82) 269 (82) -20 (-29) 108 (33) 135 (41) 135 (41) 190 (58) 269 (82) 269 (82) 217 (66) 269 (82) 269 (82) -40 (-40) 98 (30) 135 (41) 135 (41) 187 (57) 262 (80) 269 (82) 210 (64) 262 (80) 269 (82) +50 (+10) 98 (30) 105 (32) 105 (32) 177 (54) 210 (64) 210 (64) 197 (60) 210 (64) 210 (64) 0 (-18) 89 (27) 105 (32) 105 (32) 154 (47) 210 (64) 210 (64) 174 (53) 210 (64) 210 (64) -20 (-29) 82 (25) 105 (32) 105 (32) 148 (45) 210 (64) 210 (64) 164 (50) 210 (64) 210 (64) -40 (-40) 75 (23) 105 (32) 105 (32) 141 (43) 203 (62) 210 (64) 157 (48) 203 (62) 210 (64) Page 5 / 21

PBS-200-A Single entry power junction box Installation Instructions Required

system: Wire cutters Flat screwdriver Cross-head screwdriver Electricians

pliers Crimping pliers Unrolling the trace heater WARNING Risk of short cuts

Keep the trace heater ends dry before and during installation.

Unroll the required trace heater in a straight line and cut to the correct

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

plastic pipes conduct heat less efficiently than metal pipes do.

2 x Place aluminium tape where the trace heater will be attached for better heat

De-energize all power circuits before installation or servicing.

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

Do not use it as a loop for stepping on.

This saves time, helps to avoid installation mistakes and prevents damage to the

8 PBS-200-A Single entry power junction box Installation Instructions Required tools The following tools are required for installation of the trace heating system: Wire cutters Flat screwdriver Cross-head screwdriver Electricians screwdriver Tape measure Utility knife Needle-nose pliers (2x) Tongue and groove pliers Crimping pliers Unrolling the trace heater WARNING Risk of short cuts and/or material damage. Keep the trace heater ends dry before and during installation. Observe the trace heater s installation instructions. Unroll the required trace heater in a straight line and cut to the correct length. Cut off the trace heater ensuring a straight cut. Do not bend or pinch the trace heater, or pull it over sharp edges. 3 2 x Installation on pipes This step is necessary for plastic pipes only since plastic pipes conduct heat less efficiently than metal pipes do. For metal pipes continue with step 5. 2 x Place aluminium tape where the trace heater will be attached for better heat distribution. 4 Cautions and warnings WARNING Risk of fire or electrical shock. De-energize all power circuits before installation or servicing. Always use ground fault equipment within the heat tracing system. Double-check that all power circuits are de-energized before you begin your work. Make sure that you do not exceed the maximum heating circuit length for the trace heater type you use. 1 2 CAUTION Risk of injury and/or material damage. Never tread on or drive over the trace heater. Do not use it as a loop for stepping on. Preferably install the trace heater in a straight line around the pipe. This saves time, helps to avoid installation mistakes and prevents damage to the trace heater during the thermal insulation work. Furthermore the trace heater can be easily localised later on. The trace heater should be installed spirally only if this is expressly specified in the project planning. NOTICE When installing allow for an additional length of trace heater for assembling splice connections, tee branches, end seals etc. (approx. 1.6 ft (0.5 m) for each). 5 Page 6 / 21

Preferably install the trace heater in the lower half of the pipe, but not on the lowest point.

Preparation of the trace heater For splice connections the following instructions apply for both trace heaters.

6 Fastening At first, select the correct fastening material: Always use polyester adhesive tape or glass cloth tape that suits the expected temperatures.

9 7 Slide the trace heater grommet onto the trace heater and into the seal seat. Slide the blind plug into the free seal seat.

9 Preferably install the trace heater in the lower half of the pipe, but not on the lowest point. This prevents mechanical damage and allows for better heat distribution. If you use multiple trace heaters, position them with an offset of 90. Preparation of the trace heater For splice connections the following instructions apply for both trace heaters. Pass the trace heater through the base unit of the mounting stand. Do not fix the mounting stand on the pipe yet. 6 Fastening At first, select the correct fastening material: Always use polyester adhesive tape or glass cloth tape that suits the expected temperatures. Preferably use BARTEC adhesive tapes. Never use PVC insulating tape or self-adhesive tapes containing PVC or VC. Do not use metal fixtures. 9 7 Slide the trace heater grommet onto the trace heater and into the seal seat. Slide the blind plug into the free seal seat. Make sure that the trace heater stands out approximately 10 (25 cm). This makes cable preparation easier. Fasten the trace heater with the adhesive tape or zip ties at intervals of at least 12" (300 mm) on plastic pipes or 36" (900 mm) on steel pipes. NOTICE In order to ensure good heat transmission the trace heater must have a flat, flush fit over the whole length. If necessary, reduce the distances between the fixing points Page 7 / 21

PBS-200-A Single entry power junction box Installation

Be careful not to damage the internal insulation jacket.

10 PBS-200-A Single entry power junction box Installation Instructions Slide the top unit of the mounting stand over the trace heater. Slightly tighten the 4 fixing screws using a crosshead screwdriver. Do not tighten them fully yet to allow the trace heater to be moved. Push the grounding braid back. Use the screwdriver to form an eyelet. Be careful not to damage the internal insulation jacket. 13 Bend the trace heater and pull the heating element out of the grounding braid Remove 5 3/4 (145 mm) of the outer jacket on the end of the trace heater. Twist the grounding braid in order to form a wire Page 8 / 21

11 Push the green/yellow tube onto the twisted grounding braid. Make a small cut over and under each bus wire. Take care not to damage the bus wires. Carefully make an incision into the edges of the heating element. Take care not to damage the bus wires. 16 Remove 4 1/2" (115 mm) of the internal insulation jacket Page 9 / 21

PBS-200-A Single entry power junction box Installation Instructions Pull

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

Before you continue, make sure that the bus wires are in a faultless

12 PBS-200-A Single entry power junction box Installation Instructions Pull off the bus wires while holding the heating element. 19 Remove any remaining heating element that sticks to the bus wires. CAUTION Risk of malfunction of the heating system. Before you continue, make sure that the bus wires are in a faultless condition. Twist the bus wires. 20 Remove the remaining heating element. Take care not to damage the bus wires. 21 Page 10 / 21

Carefully cut in a triangle (1/4 / 5 mm) between the

Thread the bus wires into the silicone pants.

22 WARNING The silicone adhesive may cause irritation

Avoid repeated or prolonged skin contact.

13 Carefully cut in a triangle (1/4 / 5 mm) between the bus wires. Take care not to damage the bus wires. Thread the bus wires into the silicone pants. You might add further silicone adhesive to ensure optimal sealing. Slide the silicone pants all the way onto the heating element. 24 Crimp a ferrule onto the twisted grounding braid. 22 WARNING The silicone adhesive may cause irritation to skin and eyes. Avoid eye contact. Avoid repeated or prolonged skin contact. Follow the safety instructions given on the packaging. Put silicone adhesive onto the exposed heating element and insulation jacket. 25 Crimp a ferrule onto each of the bus wires Page 11 / 21

14 PBS-200-A Single entry power junction box Installation Instructions Installation of the mounting stand Pull back the trace heater. For easy cable connection it is enough when the silicone pants stands out of the mounting stand. Now, tighten the 4 fixing screws of the top unit of the mounting stand using a cross-head screwdriver Page 12 / 21

Install the pipe straps and tighten them firmly using a

Feed the prepared trace heater into the junction box.

15 Install the pipe straps and tighten them firmly using a screwdriver. Cable connection Unscrew the lock nut of the top unit of the mounting stand. Feed the prepared trace heater into the junction box. Slide the junction box onto the top unit of the mounting stand. Install the lock nut and tighten it using tongue and groove pliers Page 13 / 21

PBS-200-A Single entry power junction box Installation Instructions For

31A For splice connections continue here: Insert the blind plug into the

16 PBS-200-A Single entry power junction box Installation Instructions For powered connections continue here, for splice connections continue with step 31B below. Install the conduit pipe and conduit hub according to the manufacturer s installation instructions. Feed the cold lead cable into the power connection box. 31A For splice connections continue here: Insert the blind plug into the free cable entry. Screw on the lock nut. Tighten the lock nut while locking the blind plug using 2 adjustable wrenches. Make sure that the final tightening torque is 7.5 lbf ft (10 Nm). 7.5 lbf ft 31B Page 14 / 21

17 Wiring For wire connection at the terminals insert a small screwdriver into the screwdriver slot, then insert the wire. Connect all wires as shown. Power connection wiring Splice wiring GND L1 L2 / N GND L1 L2 / N 32A 32B Page 15 / 21

33 Apply the pipe s insulation according to the manufacturer s installation

18 PBS-200-A Single entry power junction box Installation Instructions Mount the cover of the junction box and tighten the 4 fixing screws using a screwdriver. 33 Apply the pipe s insulation according to the manufacturer s installation instructions. Apply an electrical warning label every 10 ft. on a clearly visible place. 34 Page 16 / 21

Installation of the end seal Cut the trace heater off

WARNING The silicone adhesive may cause irritation to skin

Put silicone adhesive onto the exposed insulating jacket

36 38 Cut in a triangle (1/4 / 5 mm) between the bus wires.

19 Installation of the end seal Cut the trace heater off straight. Remove 3/4 (20 mm) of the outer jacket. WARNING The silicone adhesive may cause irritation to skin and eyes. Avoid eye contact. Avoid repeated or prolonged skin contact. Follow the safety instructions given on the packaging. Put silicone adhesive onto the exposed insulating jacket and into the end cap. 35 Remove the exposed grounding braid. Make sure that the insulation jacket is not damaged Cut in a triangle (1/4 / 5 mm) between the bus wires. Push the end cap over the end of the trace heater NOTICE Allow the adhesive to cure for 20 minutes, then visually inspect. Full strength is reached after 24 hours. Page 17 / 21

20 PBS-200-A Single entry power junction box Installation Instructions Troubleshooting Problem Possible cause Remedy Trace heater remains cold Automatic circuit breaker disengages Ground fault protection is disengaged No power supply Trace heater or cold lead cable not properly connected Control unit adjusted incorrectly Automatic circuit breaker defective Automatic circuit breaker has wrong tripping characteristics, e. g. B instead of C Nominal circuit breaker size is insufficient Maximum heating circuit length has been exceeded End seal has not been installed Short circuit Humidity inside the connection system or end seal Trace heater damaged Moisture in the junction box Maximum monitoring length of the ground fault protection has been exceeded Ground fault protection defective Check the supply line Connect the trace heater and cold lead cable according to the installation instructions Adjust the control unit according to the installation instructions Replace the automatic circuit breaker Install an automatic circuit breaker with Type-C tripping characteristics Install an automatic circuit breaker with higher capacity (max. C 30 A) Split the heating circuit into separate circuits Install the end seal according to the installation instructions Identify the cause and remedy the fault (e. g. ensure that tape tails are not twisted) Replace the connection system / end seal Replace the trace heater at the point where it is damaged Dry the junction box Be sure that the conduit drain is installed and breathing properly. Install additional ground fault protection devices Replace the ground fault protection device(s) Page 18 / 21

21 Notes Page 19 / 21

22 PBS-200-A Single entry power junction box Installation Instructions Page 20 / 21

23 Page 21 / 21

24 BARTEC GmbH Max-Eyth-Straße Bad Mergentheim Germany Phone: Fax: BARTEC US 650 Century Plaza Drive, Suite D120 Houston, Texas USA Phone: Fax:

HS-TSPLICE - HEATSHRINK TEE / SPLICE. Installation Instructions

HS-TSPLICE - HEATSHRINK TEE / SPLICE. Installation Instructions - HEATSHRINK TEE / SPLICE This kit is only for use with the following Drexan HeatTracer Self-Regulating heater products: PipeGuard Warm (PGW), MultiTrace (MT) and HotTape (HT). CAUTION: A ground fault