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TT-5000-CK-MC-M/F-10   TT-5000-CK-MC-MTT-5000-CK-MC-F   TT-5000-HUV-CK-MC-M/F-10

Field installed connectors installation instructions

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13

DEScRIpTIONField Installed connectors for TraceTek 5000, 5000-HS, 5000-HUV, 5001, 5001-HS and 5001-HUV Bulk cableThese instructions describe field connecting of TT5000, TT5000-HS, TT5000-HUV, TT5001, TT5001-HS and TT5001-HUV bulk sensing cable.For technical support, call Pentair Thermal Management at (800) 545-6258.

TOOLS REqUIRED• Needlenosepliers • Razorbladeorutilityknife• Smallpairofwirecutters • 3/4-inchmaskingtape• TT-ULTRA-TORCH(PN390067-000)flamelessheatingtool(Ultratorch200)orsuitableheatgunwithconcentratortip.

• Highimpedanceohmmeter(Fluke87orequivalent;metermustbecapable of measuring to at least 20 megohms)

• Greenleestrippers(1917or1918)orequivalentfor24AWGand26AWGwire

• Permanentinkmarker• TT-CT-SCTcrimpingtool(PN644333-000)

ADDITIONAL MATERIALS REqUIRED• TT-Test-Tool-Pin&Socket(PN986291-000)• TT-MET-MC(PN571293-000)• TT-FET-MC(PN383017-000)

NOTES• Donotuseanopenflameheatingtool.• Thepinconnectorshouldalwaysbeinstalledonthecableendpointedtowardsthealarmmodule.

• UsewithTT5000,TT5000-HS,TT5000-HUV,TT5001,TT5001-HSandTT5001-HUVsensingcableonly.ThiskitisnotcompatiblewithotherTraceTek sensing cables.

Fire Hazard. Heat guns and flameless heating tools can cause fire or explosion in hazardous areas. Be sure there are no flammable materials or vapors in the area before using these tools. Follow all site safety guidelines when working in hazardous areas.

Component approvals and performance are based on the use of specified parts only.

HealtH Hazard. Overheating heat-shrinkable tubing or SolderSleeves will produce fumes that may cause irritation. Use adequate ventilation and avoid charring or burning. Consult MSDS RAY3122 and RAY5103 for further information.

CHEMTREC 24-hour emergency telephone: (800) 424-9300

Non-emergency health and safety information: (800) 545-6258.

WARNING: CAUTION:

BSCT

F

E

C

D

A

TT-5000-cK-Mc-M/F-10 (p000000711)TT-5000-HUV-cK-Mc-M/F-10 (p000000712)KIT cONTENTS: (10 M and 10 F connectors)Item qty Description

A 10 TT-CK-MC-Mpinconnectorwithspinnerring

B 10 TT-CK-MC-Fsocketconnector

C 22 Whitespacers(2extra)

D 125 SolderSleeve®splices(5extra)

E 21 Heat-shrinkabletubing,labeledSCT(1extra)

F 21 Heat-shrinkabletubing,unlabeled(1extra)

TT-5000-cK-Mc-M or (pN 961207-000) (1 M connector)TT-5000-cK-Mc-F (pN 880841-000) (1 F connector)KIT cONTENTS:

Item qty Description (Either A or B present in kit)

A 1 TT-CK-MC-Mpinconnectorwithspinnerring

B 1 TT-CK-MC-Fsocketconnector

C 2 Whitespacers(1extra)

D 7 SolderSleevesplices(1extra)

E 1 Heat-shrinkabletubing,labeledSCT(0extra)

F 1 Heat-shrinkabletubing,unlabeled(0extra)

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13 2 / 8

Cut

2 1/

4 in

HS-1

HS-2 HUV-22

1/2

in

HUV-1

• Graspropebraidabout25mm(1in)behindthetapedendnear the looped end of the pull rope. Feel for the sealed end of the sensor cable beneath the rope braid. Bend the ropebraidtoa90degreeangleandlocatesealedendofthe sensor cable.

• Spreadtheropebraidfibersaparttoexposethesealedend of the sensor cable.

• Graspthesealedendandpullabout30cm(12in)ofsensorcableoutwhileholdingtheropebraidinplace.

• Tapetheropebraidtosensorcabletopreventtheropefrom springing back.

•UsingGreenleestrippers,cutoffthesealedendofcableabout 6 mm (1/4 in) from the seal itself.

• Locatethesealedcableendandwrap19mm(3/4in)maskingtapeonblackoverbraid2½inches from the start of the sealed end.

• Cutoffsealedendofcable about 6 mm (1/4 inch) from the seal itself.

•Unraveltheblackoverbraidfiberstotapeedge, then trim fibers to tape edge

TT5000 & TT5001 cableTT5000-HS, TT5001-HS cableGo

to S

tep

HS-

1

Go to

Ste

p H

UV-

1

TT5000Outer braid of red,

white & black fibers

TT5001Outer braid of

white & black fibersTT5000-HS

White overbraid

TT5001-HSWhite overbraid

with purple thread

Go to Step 1Page 3TT5000-HUV

Black overbraidwith red thread

TT5001-HUVBlack overbraid

with purple thread

TT5000-HUV, TT5001-HUV cable

Sensing cable and Overbraid Identification

3/8THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13

1 1/2 in

19 mm(3/4 in)

End view of razorblade

Do not cut through the black jacket

19 mm(3/4 in)

13 mm(1/2 in)

1

3

5 6

19 mm(3/4 in)

Don’t slit between

here

Part CWhite spacer1/16 in minimum

2

4

•Wrap19mm(3/4in)maskingtape38mm(1-1/2in)fromthe end of the cable.

•Wrapasecondpieceadjacenttothefirst.• Foldtheendsofeachpieceoftapeforeasyremoval.

• Verylightlyscoreallthewayaroundtheblackjacketwitharazorbladeorutilityknife.

• Removethe19mm(3/4in)jacketsectionbytwistingclockwiseandpulling.

• Unbraidthecorewires.• Cutoffthe2smallwhitewiresand4bluebraidfibers.Leavethelargediameterwhitewireintact.

Avoid nicking the remaining wires.

• Slit19mm(3/4in)oftheouterbraidlengthwise.• Removeseveredstrands.• Twistandpushtheremainingbraidbacktothetape.• Usecutterstocutoffbraidstrandsatthetape.

• Bendthecoresharplyinalldirectionstoflaretheblackjacketandinspectthewiresfordamageatthecut.

• SliptheWhitespaceroverthecorebundleandunderthejacket.

•Whitespacershouldprotrudeabout1/16into2mm.Do not fold or tear the jacket.

• Trimawayanyjacketshardsthatmaybepresent.

• Straightentheremainingwiresbypullingslightlyandflexing.

• Trimall5wiresto19mm(3/4in)long.• Donotstripthelargediameterwhitewire.• Carefullystriptheinsulationonthefoursmallcoloredwires.Toavoidbreakingthewires,striptheinsulationinsmallsectionsuntil13mm(1/2in)hasbeenremoved.Usethe26AWG(0.15mm2)slotfortheblackwiresandthe24AWG(0.24mm2)slotfortheredandyellowwires.

Do not break wire strands.

Note:SubsequentillustrationsshowTT5000cablebutapplytoTT5001 also.

Note: For–HUVcable,thetapesegmentbelowwasalreadyappliedonoverbraidin step HUV-2.

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13 4 / 8

Lightly touch ohmmeter lead to the black jacket.

Do not clip ontothe black jacket.

Part DSolderSleeve

Yellow (large tab)

Black

TT-FET-MC TT-MET-MC

Black

Red

Spinnerring

Pin Connector(Part A)

Yellow (large tab)

BlackBlack

Red

Socket Connector (Part B)

7

8

9

• Settheohmmetertoitshighestresistancescale.Measuretheresistancebetweentheblackwiresandjacketasfollows:Lightlytouchoneohmmeterleadtotheblackjacket–Do not clip the lead to the black jacket. Cliptheotherleadtoeachoftheblackwires(oneatatime).Ifbothmeasurementsareover20megohms(metermayread:∞,O.L.,etc.),proceedtothenextstep.

• Ifeithermeasurementislessthan20megohms,checkthatthejacketdoesnottouchtheblackwireateithercableend.Checkthatwhitespacerisproperlylocatedandblackjacketisnotbuckled.Ifnoshortscanbefound,donotusethecablesection.ContactTraceTek for help.

Foreitherconnectortype,theredandyellowwiresneedtobepre-tinned.• Twisttogetheranyloosestrandsoftheredoryellowwires.• SlideaSolderSleevesplice(PartD)ontotheredoryellowwire.• HeatthesolderbandinthecenteroftheSolderSleeveuntilitflowsontothebarewire.

• UseplierstoremovetheSolderSleevefromthewirewhilestillhot.• Repeattheprocesswiththeotherstrandedwire.• DiscardtheusedSolderSleeves.

•Notethelargetabcutoutaroundrim of connector. Position the large tap at 12 o’clock position, see below.

• Usepermanentinkmarkertomark flat portion of connector bodybehindthelargetab.

• Forthepinconnector(PartA)only,slip the spinner ring, large hole first, onto the connector.

• AttachTT-MET-MCandTT-FET-MCtosocketandpinconnector(PartsBandA)touseasaholdertoavoidburningfingerswhileapplyingheat.

Locate the Yellow Wire connector post

5 / 8THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13

Leave a 1.5 mm (1/16 in) gap 6 mm

(1/4 in)

TT-FET-MC

SCT

14

Small end

Large end

SolderSleeveTT-MET-MC

TT-MET-MC

SolderSleeve endsmust be inside connector

TT-MET-MC

Align the tube end with the ribbed section of the connector

Part ESCT heat-shrinkabletubing

SCT

TT-FET-MC

10 11

12 13

• Keepwiresinthesameorderthattheyexitfrom the cable end.

• SlideaSolderSleevesplice(smallendfirst)ontoeachwire,allthewaytothecableend.

• Thesolderringmustlieoverbareconductor,not insulation.

• Wireendsmustextendbeyondthesolderrings.

• HeattheSolderSleevesuntiltheyhaveshrunkfullyandthesolderringshavemeltedandflowed.Keep the heat source moving to avoid charring the connector.

• Carefullyremoveassemblyfromheat.Holdconnectorandcablesteadyandallowtocool.Movingsolderjointwhenhotcanweakentheconnection.

• Removethetapethatisclosesttothecableend.

• SlideSCTlabeledheat-shrinkable tubeovertheassembly.

• Heatshrink6mm(1/4in)ofthetubeontotheconnector,movingtheheatsourcearoundthetubetoheatevenly.

• Leaveasmall1.5mm(1/16in)gapbetweenthetubeandthe ribbed section of the connector.

• Do not overheat. Thetubemayslipoffoftheconnectorifitisoverheated.

• Allow to cool before proceeding.

• TheSCTtubeusedwithTT5000-HUVconnector kit is designed to be longer,andwillcoverthetapesegment on braided cable.Donotremovethetapesegment securing theblackoverbraidbefore shrinking the SCTtube.

• Onceyellowwireisalignedcorrectlytothemarkonconnectorbody,theredwirewillbeoppositetoitandallwireswillbeintheircorrectpositions.

• Orienttheconnectorandpush aligned connector posts into the SolderSleeves.

• VerifytheSolderSleeveendsareinsidetheback of the connector.

• Makesurethesolderbandsareincontactwithconnectorpostsandthewires.

THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13 6 / 8

Do notheat fibers

SCT

Do not reheat this area

SCT

Adhesive willflow from the

end of the tube

SCT

TT-FET-MC

TT-FET-MC

TT-FET-MC

TT-FET-MC

SCT

TT-FET-MC

SCT

15

16

• Finishshrinkingthetube,startingattheendopposite the connector.

• Donotapplyheatdirectlytothebraidfibers.• Heatthetubingenduntiladhesivemeltsand

beads on the braid fibers.• Inspecttheexposedadhesiveatthetubing/braidfiberinterface.Ifavoidisvisible,useagloveorragtosqueezethetubeslightlyandfillthevoidwithmoltenadhesive.

• Keepheatingthetubingsectioninthemiddleoftubeuntilfullyrecovered.

• Avoidreheatingthealreadyshrunksectionontheconnectorbody.

• Removethelastpieceoftapewhiletheadhesiveisstillwarm.

• Proceedtothenextstepbeforethetubecools.

•Whilethetubingisstillhot,placetubinginthelargeropeningofthecrimptool.Alignendofcrimptoolwithendofshrinktube.CrimpSCTtubingtocoolandseal.Openandrotatecrimptool90degreesandcrimpagaintoensure proper adherence to the cable.

• Ifthetubinghasmovedmorethan3mm(1/8in)offthethreaded connector, push the hot tubing back to the origi-nalpositionwhilesupportingassemblyusing“holder”endtermination.Youmayhavetoreheatthetube.Holdthecrimptoolinplacewhileitcoolsthetube.

• Applyheattotubingonelasttimetosoftenthecreasesmadebythecrimptool.Donotoverheat.

• Removethecrimpingtoolandlettheassemblyfinishcooling.

•Allow the assembly to fully cool.

• Removetheendtermination.• Forthepinconnector,thespinnerringmustturnfreely.Ifnecessary,gentlyuseplierstobreakitfree.

cAUTION: Burn Hazard Do not get hot adhesive on your bare skin.

The hot adhesive will burn your skin.

7/8THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13

Yellow (1) Yellow (1)

Red (4)

Black (3)Black (2)

Red (4)

Black (2)Black (3)

Wire orientation atcable end oppositesocket connector

Wire orientation atcable end opposite

pin connector

SCT

TT-FET-MC

SCT

17

18

• Attachthematingtest-tool-halftotheconnectortobetested.

• Ifbothcableendshaveconnectors,attachamatingendtermination at the opposite end. If there is no connector on the opposite cable end, prepare it according to steps 1 through6andtwisttogetherwires1&2.Alsojoinwires3&4.

• Useanohmmetertomeasuretheresistancebetweenthetest tool posts.

• Theresistancebetweenthe2longestpostsorthe2shortestpostsshouldbe≈4xcablelength(ft)(i.e.A100ft.(30m)cableshouldmeasure≈400Ωbetweenthetwolongestpostsand≈400Ωbetweenthetwoshortestposts.)

• Theresistancebetweenthe2intermediatelengthpostsshould be greater than 20 megohms.

• Iftheassemblyfailsanyoftheresistancetests;1) Checkthetwistedwiresattheoppositecableend.2) Checkforanypinchesinthesensingcableatthe

access points.3) Ifnecessary,cutoffanddiscardtheconnectorand

installanewone.

FOR HS cable only:• Removetapefromropebraid.• Slideropebraidtoabout25mm(1in)fromconnectoronend

of sensing cable.• Attachendterminationtosensingcableorimmediatelyproceedtomakeconnectiontonextlengthofsensorcableandapplyenvironmentalseal.

• Leavetheloopedendofpullingropeinplace.Donotcutthepullrope,itmaybeneededinthefuture.

Test the connector Assembly

8 / 8THERMAL MANAGEMENT SOLUTIONS EN-TraceTekTT5000connectors-IM-H54830      01/13

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©2005-2013Pentair. PN770575-000

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SCT

SCT

SCT

Part FUnlabeledheat-shrinkabletube

19

• Beforematingtheconnectorassemblies,slidetheunlabeledshrinktubeonto(PartF)oneofthecables.Connectthepinandsocketconnectorstogetherfirmly.Centertheunlabeledshrinktubeoverthepin/socketconnection.Heatshrinkthetubeovertheconnection,beginninginthecenterandshrinkingtowardstheendsuntilthetubefullyconformstotheshapeofthecon-nectionandadhesiveflowsfromeachendofthetube.

• AvoidoverheatingpartF.ThethinwallunlabeledshrinktubingrequireslessheatthantheSCTcableshrinktubing.

•Let the entire connector area cool before handling the cable.

Note: Donotleaveconnectoropentoenvironment.Ifthecon-nectorbecomeswetorcontaminated,itwillneedtobereplaced.

Note: WhenarranginganyTT5000Seriescablesdonotuseabend radius less than 51 mm (2 in).

cAUTION: Burn Hazard Do not get hot adhesive on your bare skin.

The hot adhesive will burn your skin.

Apply Environmental Seal