+44 (0)1293 547361 crj - luckinslive.com

BN Thermic Ltd34 Stephenson WayThree Bridges, Crawley, West Sussex RH10 1TNEngland

Tel: +44 (0)1293 547361Fax: +44 (0)1293 531432

BNTMCRJT-03

BNInstallation instructions for

CRJself limiting frost protection heating cable

Please read and follow these instructions carefully to ensure an efficient and safe installation.The CRJ heating cable is intended for use in non hazardous areas and should only be used on pipes containing water for the prevention of the pipe contents from freezing.It should not be used if the pipe is likely to be heated above 65 degrees C internally e.g. internal steam cleaning etc.Never use the cable whilst still in a coil.Protect the cable from the likelihood of mechanical damage or such things as being chewed by animals.Only use the approved termination and jointing kits, the use of any other components will void the warranty.

InstallationBefore applying the cable ensure the area and pipe work is clean and free of any sharp surfaces and combustible materials.Secure the cable to the pipe with PF-T insulating tape at intervals of no more than 200mm, with the cable run straight along the pipe or evenly spiralled.The cable should also be wrapped around flanges, valves or vulnerable pumps to compensate for the extra heat loss, the cable may be allowed to touch or cross if necessary.The system, when complete, should be fully insulated and protected from the weather and any mechanical damage. Warning labels should be placed on the outside of the insulationWhere the circuit is to start, sufficient cable should be left outside of the insulation (approximately 300mm to facilitate connection to a suitable junction box using the 20mm packing gland supplied.All terminations and connections must be completed by a qualified electrician and carried out in accordance with current regulations.

Termination CRJ T1 kit contains:1 black cable gland 20mm1 red 40mm x 3.2mm diam heat shrink1 blue 40mm x 3.2mm diam heat shrink1 green/yellow 65mm x 3mm diam sleeve1 black 70mm x 16.4mm diam heat shrink1 black 50mm x 16.4mm diam heat shrink1 black 35mm x 16.4mm diam heat shrink2 insulated barrel connectors1 warning label

Tools requiredSharp knifeSide cuttersLong nose pliersSmall screwdriverHeat gunCrimp toolSpanner

80mm

75mm

50mm

Preparation for termination

First slide the cable gland and then the 70mm heat shrink onto the cable. Cut around the outer cable sheath 80mm from the end the gently bend the cable to break the sheath free.

Gently bend the cable and feed the inner core through the braid opening.

Pull the braid tight to form a ‘pig tail’

Carefully score around the inner sheath 50mm from the end. Gently bend the cable to break this section of the sheath free.

Carefully cut along the centre of the inner jacket as shown gently bend the inner jacket, remove and discard.

Carefully cut along the centre of the outer sheath as shown. Discard the 80mm length of the outer sheath.

Push back the earth braid to create a bulge .

Then using a small screwdriver make an opening at the bulge.

STEP

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30mm

BlueRed

Taking care not to cut into the two conductors, working from the outside, expose the conductors (Buss wires).

Slide the black adhesive lined 50mm long x 16mm diameter heat shrink over the cable leaving 10mm over the exposed red and blue insulated Buss wires. Have on hand the long nose pliers. Using the heat gun shrink this sleeve.

As the heat shrink reduces down immediately squeeze the overhung portion with the pliers for 20 seconds to form a fork like arrangement. (The heat shrink has an inner glue like material to ensure good adhesion.)

Crimp, using a suitable tool, the two insulated barrel connectors to the conductors to facilitate connection to the power feed cable.

Slide the 70mm length back over the terminated section including the green/yellow covered earth wire to the base of the forked conductors and shrink into place. Finally slide the gland over the assembly in preparation for connection into a suitable junction box. Tighten the cable gland.

Starting from the ends pull each Buss wire away from the inner core material.

Remove and discard the inner core material leaving the two bare Buss wires exposed.

Slide the red 40mm long x 3mm diameter heat shrink over either of the exposed Buss wires and using a suitably rated heat shrink gun shrink into place. Repeat using the blue sleeve on the other exposed wire. Slide the green/yellow sleeve over the earth wire.

STEP

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END

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15mm

4mm

Using the same method to expose and separate the earth braid as shown in the termination detail, strip the outer, inner and earth braid back 15mm from the cable end. Fold the earth wire around the sheath. DO NOT EXPOSE THE BUSS WIRES.

Slide the 35mm length of black heat shrink over the cable end so that there is 15mm overhanging the cable end.

Apply heat to the shrink tubing and when the overhanging portion is fully shrunk squeeze the ends together to enable the inner glue to adhere to itself. A bead of the clear colour glue should be visible at the end.

Using a pair of side cutters cut down the centre of the 15mm length of inner core and then remove 4mm of one of the Buss wires so as to form a notch. This ensures that there is no way in which the Buss wires can come into contact with each other.

STEP

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Pipe Diameter

(mm)

INSULATION THICKNESS (mm) Allowance for increased cable length

12 25 50 Pair of flanges Valve Support

12 CRJ-10 Straight CRJ-10 Straight CRJ-10 Straight 0.23 0.10 0.10



75 CRJ-25 1.3m cable/1m pipe

CRJ-25 Straight CRJ-10 Straight 0.45 0.40 0.15

100 CRJ-25 1.8m cable/1m pipe

CRJ-25 Straight CRJ-25 Straight 0.60 0.50 0.20

150 CRJ-25 3m cable/1m pipe

CRJ-25 1.4m cable/1m pipe

CRJ-25 1.2m cable/1m pipe

0.80 0.60 0.25

Maximum circuit length for CRJ-10: 205m. Maximum circuit length for CRJ-25: 126m.

END

BN Thermic Ltd. 34 Stephenson Way, Three Bridges, Crawley, West Sussex RH10 1TN England

Tel: +44 (0)1293 547361 Fax: +44 (0)1293 531432

BN

Remote End Preparation

Breaker Cable Length (m)

CRJ-10 CRJ-25

10A 1 to 116 1 to 60

13A 116 to 150 60 to 78

16A 150 to 205 78 to 88

30A - 88 to 126

• Use type C breaker

Breaker selection for CRJ Self Regulating Cable

BN Thermic Ltd34 Stephenson WayThree Bridges, Crawley, West Sussex RH10 1TNEngland

Tel: +44 (0)1293 547361Fax: +44 (0)1293 531432

BN

Installation instructions for

CRJ-Ssplice/tee kit

Before commencing this procedure please read the notes on the termination kit instructions.

CRJ-S kit contains: 1 black 150mm x 16.4 diam heat shrink 3 red 40mm x 3.2mm diam heat shrink 3 blue 40mm x 3.2mm diam heat shrink 2 blue insulated barrel connectors 1 piece mastic tape 1 green/yellow 65mm x 3mm sleeve 1 black 70mm x 16.4 mm heat shrink 3 black 35mm x 16.4mm heat shrink 1 uninsulated barrel connector 1 cable tie

BNTMCRJS-02

70mm

75mm

50mm

Preparation for jointing/splice

Prepare each end of the cable in a similar manner for each cable to be spliced (or tee connected). First slide both the 150mm and the 70mm length of black heat shrink onto one side of the cable. Then carefully cut around the outer cable jacket 70mm from the end.

Taking care not to cut into the two conductors, working from the outside, expose the conductors (Buss wires).

Gently bend the cable and feed the inner core through the braid opening.

Pull the braid tight to form a ‘pig tail’

Carefully score around the inner sheath 50mm from the end. Gently bend the cable to break this section of the sheath free.

Carefully cut along the centre of the inner jacket as shown gently bend the inner jacket, remove and discard.

Carefully cut along the centre of the outer sheath as shown. Discard the 70mm length of the outer sheath.

Push back the earth braid to create a bulge .

Then using a small screwdriver make an opening at the bulge.

STEP

1

STEP

9

STEP

5

STEP

6

STEP

7

STEP

8

STEP

2

STEP

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4

30mm

BlueRed

To make the splice

Slide the black adhesive lined 50mm long x 16mm diameter heat shrink over the cable leaving 10mm over the exposed red and blue insulated Buss wires. Have on hand the long nose pliers. Using the heat gun shrink this sleeve.

As the heat shrink reduces down immediately squeeze the overhung portion with the pliers for 20 seconds to form a fork like arrangement. (The heat shrink has an inner glue like material to ensure good adhesion.)

Starting from the ends pull each Buss wire away from the inner core material.

Remove and discard the inner core material leaving the two bare Buss wires exposed.

Slide the red 40mm long x 3mm diameter heat shrink over either of the exposed Buss wires and using a suitably rated heat shrink gun shrink into place. Repeat using the blue sleeve on the other exposed wire. Slide the green/yellow sleeve over the earth ‘pigtail’.

Using the 2 blue insulated barrel connectors’ crimp the Buss conductors together red to red and blue to blue.

Slide the 70mm heat shrink so that it is centred over the joint and shrink into position. Using the un-insulated barrel connector, butt the earth ‘pigtails’ into the connector and crimp.

Now slide the 150mm length of heat shrink over the entire joint area and, again using the heat gun, shrink into position. The splice is now complete.

STEP

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90mm

cable tie

Mastic Tape

Prepare all 3 cable ends as previously described, remembering to slide both the 150mm and the 70mm black heat shrink onto one of the cables. Before crimping the conductors together fit the cable tie as shown to support the cable that is to form the tee. Then crimp all the red Buss wires together followed by the blue wires using the 2 blue insulated barrel connectors provided.

Slide a small strip of mastic tape 25mm long under the 2 cables and wrap around both cables stretching the tape so as to bring them together tightly.

Slide the 150mm black heat shrink over the entire joint and shrink into position. A bead of adhesive should be visible where the heat shrink and cable outer sheath meet.

The termination (feed) and the 2 remote ends should be completed in accordance with the instructions provided in that kit.

Slide the 70mm heat shrink over the joint and shrink into position. Now using the un-insulated barrel connector join the earth braids together and crimp.

STEP

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BN Thermic Ltd. 34 Stephenson Way, Three Bridges, Crawley, West Sussex RH10 1TN EnglandTel: +44 (0)1293 547361 Fax: +44 (0)1293 531432

BN

Tee Joint

+44 (0)1293 547361 crj - luckinslive.com

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