STEP 4 HOW TO ASSEMBLE AND INSTALL
THE CABLE AND FUSED PLUG KIT
INSTALLING THE END SEAL
4a.
CLEANLY cut off the end of the cable.
4b.
1. Use a pencil or screwdriver
to unravel the braid back 1"
from the cable end.
2. Twist the braid
into a tight
pigtail.
4c.
1. Tape the braid pigtail back on top of
the braided cable.
2. Pushing firmly, insert the cable into
the end seal all the way (at least
3
/
4
").
Some gel may ooze out. Do not
attempt to wipe off.
DO NOT TWIST THE END SEAL DURING OR AFTER INSERTION. DO
NOT REUSE AN END SEAL.
To avoid short circuits, NEVER twist the wires inside the Freeze
d
Free
Cable together OR allow them to touch each other or the outer braid.
Example
You have 12 feet of plastic pipe length
1 ball valve
You need 2.5 feet of cable per foot of plastic pipe as determined
in Step 2 above.
Calculate (12 feet x 2.5) + 1 foot for ball valve
Total cable length = 31 feet
MAXIMUM CABLE LENGTH IS 75 FEET. USE OF LONGER LENGTH
MAY CAUSE THE INTERNAL FUSE TO BLOW.
STEP 2 REFER TO THE LENGTH SELECTION CHARTS
These charts will tell you the length of the cable you need per foot
of pipe and also the recommended distance to leave between each
spiral wrap of cable on the pipe.
HOW TO USE THE LENGTH SELECTION CHART
Choose either Chart #1 or Chart #2 for your type of pipe (plastic or
metal). Read down to find your pipe diameter, then read across to the
box below your lowest expected temperature. The first number ap
-
pearing in the box will tell you the length (feet) of cable you need per
foot of pipe. The second number indicates the recommended distance
between each spiral wrap of cable on the pipe. The abbreviation “str”
indicates that the cable should be run in a straight line instead of spiral
wrap (see Step #6).
Example
• Your pipe diameter is 1
1
/
2
"
• Your lowest expected temperature is -20°F (-29°C)
• Your pipe length is 12 feet
From Chart #1
• You need 2.5 feet of cable per foot of pipe for plastic pipes.
From Chart #2
• You need 1.8 feet of cable per foot of pipe for metal pipes.
Cable Length Required
per foot of
pipe
Distance
between
Spiral wraps
“str” denotes
straight
cable
(not spiraled)
Chart #1 Length Selection for Plastic Pipes
(based on the use of
1
/
2
" insulation)
Pipe
Lowest Expected Temperature
Dia.
+20°F/-7°C
0°F/-18°C
-20°F/-29°C
-40°F/-40°C -60°F/-51°C
1
/
2
"
1'
1'
1.5'
2'
2.4'
str
str
2
3
/
8
"
1
1
/
2
"
1
1
/
4
"
3
/
4
"
1'
1.1'
1.7'
2.3'
2.9'
str
7
1
/
4
"
2
3
/
8
"
1
1
/
2
"
1
1
/
4
"
1"
1'
1.3'
2'
2.7'
3.3'
str
5"
2
3
/
8
"
1
5
/
8
"
1
3
/
8
"
1
1
/
4
"
1'
1.6'
2.3'
3.2'
4.1'
str
4
1
/
4
"
2
1
/
2
"
1
3
/
4
"
1
3
/
8
"
1
1
/
2
"
1'
1.8'
2.5'
3.6'
4.7'
str
4"
2
5
/
8
"
1
3
/
4
"
1
3
/
8
"
2"
1'
2.1'
3'
4.3'
5.4'
str
4"
2
5
/
8
"
1
3
/
4
"
1
1
/
8
"
Chart #2 Length Selection for Metal Pipes
(based on the use of 1/2" insulation)
Pipe
Lowest Expected Temperature
Dia.
+20°F/-7°C
0°F/-18°C
-20°F/-29°C
-40°F/-40°C -60°F/-51°C
1
/
2
"
1'
1'
1'
1.3'
1.7'
str
str
str
3
1
/
8
"
2"
3
/
4
"
1'
1'
1.1'
1.5'
2'
str
str
7
1
/
4
"
3"
2"
1"
1'
1'
1.3'
1.8'
2.4'
str
5"
5"
2
3
/
4
"
1
7
/
8
"
1
1
/
4
"
1'
1.1'
1.6'
2.1'
2.9'
str
11
1
/
2
"
4
1
/
4
"
2
7
/
8
"
1
7
/
8
"
1
1
/
2
"
1'
1.2'
1.8'
2.4'
3.2'
str
9"
4"
2
3
/
4
"
1
7
/
8
"
2"
1'
1.5'
2.2'
2.8'
3.9'
str
6
5
/
8
"
3
3
/
4
"
2
7
/
8
"
2"
STEP 3 CALCULATE EXACT HEATER LENGTH NEEDED
Multiply the cable length required per foot of pipe by the length of
your pipe. Add one extra foot for each valve located in your line.
Maximum cable length is 75 feet. For cable lengths longer than
75 feet, use two cables.
(Cable length required per foot of pipe x pipe length)
+ one foot for each valve or spigot
= total cable length
a
STEP 5 INSTALLING THE PLUG
NEVER ATTEMPT TO MAKE PLUG/END SEAL ASSEMBLY
WHILE PLUG IS CONNECTED TO POWER.
Before removing the cover screws, plug the power cord into 120 volt
power outlet to check for the function of the Power Light Indicator.
If the light is not lit, do not install the cable; return the plug to your
dealer for a replacement.
5b.
1. Loosen two assembly screws (approximately 1/4").
2. DO NOT fully remove the assembly screws (see
figure 2a).
Figure 1
power light
Cover Screws (2)
5a.
1. R e m o v e t h e
power cord from
the outlet.
Remove two cov
-
er screws. (See
Figure 1)
Figure 2a
braided
cable
assembly
screws (2)
Ground Strip
cable
assembly
screw fixture
3. Push until the yellow jacket is seen from the opening
as shown in Figure 2b.
4. The ground braid MUST NOT enter the assem
-
bly screw fixture opening where it can contact an
assembly screw which will be a live part when the plug
is reassembled and the system is operating.
Figure 2b
5d.
Tighten the two assembly screws until they are each
snug against the metal surfaces on top of the assembly
screw fixture (5" lb. in torque).
5c.
1. Cleanly cut 1" off
cable.
2. I n s e r t b r a i d e d
cable into assem
-
bly screw fixture
o p e n i n g ( t u n
-
nel). Allow braid
to slide back as
cable is inserted.
