Chromalox Installation, Operation Industrial Heating Cable Products MAINTENANCE INSTRUCTIONS

Chromalox Installation, Operation Industrial Heating Cable Products MAINTENANCE INSTRUCTIONS
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
Chromalox
410-795-2223
®
Installation, Operation
SERVICE REFERENCE
DIVISION
and
4
SALES
REFERENCE
MAINTENANCE INSTRUCTIONS
SECTION
RT
PJ438-18
(Supersedes PJ438-16)
161-057884-001
DATE
JULY, 2010
Industrial Heating Cable Products
IMPORTANT GENERAL INSTRUCTIONS
These instructions are to be followed when installing
Chromalox Heating cables on pipes in ordinary locations. Consult
factory for installation of braided cable in hazardous locations.
Chromalox has three basic types of heating cables: Self-Regulating,
Constant Wattage and Mineral Insulated. Although they are all
resistance type cables, they each have different operating charac-
teristics. These characteristics may make one type of cable more
suitable for a particular application than another. This manual,
however, is not intended as a product selection manual. Refer to
bulletin PJ304 “Chromalox Design for Heat Tracing Products” for
product selection guidelines. Below is a chart highlighting certain
characteristics for Chromalox heating cables.
Self-Regulating
Hazardous ratings available
Usable on plastic pipe
Can be cut to length in field
Can be single over lapped
Constant Wattage Mineral Insulated
Yes
Yes*
Yes
Yes
Yes
No
Yes
No
Yes
No
No
No
* Low temperature cables only. UL listing only applies to 3W/Ft. cables
Jacket
Heavy-Duty
Metal Sheath
Overcoat Over Braid
(Optional)
Resistance Wire
Densely Compacted
Mineral Insulation
Binder
Module Point
Buss Wires
Buss Wires
Tinned Copper Braid
(Optional)
Jacket
Primary Insulation
Tinned Copper Braid (Optional)
Overcoat Over Braid (Optional)
Conductive Matrix
Self-Regulating
Constant Wattage
Twin (Shown) or Single
Resistance Wires
Mineral Insulated
INCOMING INSPECTION
1. Open package and visually check for breaks or nicks in the
cable jacket. File claim with carrier if any damage is found.
2. Never energize the cable when it’s coiled or on a reel. Test
only when it is laid out straight.
3. After removing the cable from the carton or wrapping, check
the resistance of the unit from buss wires to braid or metal
sheath with a 500VDC megger to assure the cables have not
been damaged during shipping and handling. If the cable has
no braid or metal sheath, uncoil the cable onto a metal surface
and check resistance between the buss wires and the metal surface.
ELECTRIC SHOCK HAZARD. Any cable with an insulation resistance reading less than 10 megohms
before installation should not be installed. Contact
your local Chromalox representative.
4. The heating cables should be stored in their shipping cartons or
on reels in a dry atmosphere until they are ready to be installed.
© 2010 Chromalox, Inc.
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
INSTALLATION
A. IMPORTANT — GENERAL NOTES REGARDING
INSTALLATION OF HEAT TRACING SYSTEMS.
with the piping on the inflow end. The cable on the pump or
vessel should be physically separate to permit disconnection
during maintenance or removal.
16. Use aluminum foil tape to cover the heating cable whenever the
cable is not in good contact with the pipe (i.e. at supports,
valves, pumps, etc.) or whenever its use is specified by the
Chromalox Design Guide PJ304.
17. Separately controlled circuits should be provided on dead end
legs and closed bypasses.
18. No heat tracing circuit should extend more than two feet beyond
a point where two or more pipes join when such junctions permit optional flow paths. In such cases, separately controlled
traces should be used.
19. The minimum installation temperature for all Chromalox heating cables is -40˚F (-40˚C).
20. Chromalox Type SRL heating cables are well suited for heat
tracing plastic pipes. Consult bulletin PJ304 “Chromalox
Design Guide for Heat Tracing Products” for design recommendations. Installation details AD1 through AD17 apply for
plastic pipe only when Type SRL heating cable is used. Consult
factory for applications involving other products.
FIRE HAZARD. Failure to follow these guidelines
could result in property damage or personal injury.
1.
2.
3.
4.
5.
Read this instruction sheet and those enclosed with the accessories to familiarize yourself with the products.
Selection of heating cable type and rating should be in accordance with the procedures located in the “Chromalox Design
Guide for Heat Tracing Products” (PJ304).
Ensure all pipes, tanks etc. have been hydrostatically tested
prior to the installation of the heating cable.
Always install tracing at the 5 or 7 o’clock position on a pipe.
Installation Guidelines for fire protection systems:
a. For use on insulated UL listed steel schedules 5, 10, 20 and
40 standpipe and sprinkler system pipe up to and including
6 in. size. Includes use on elbows, tees, flanges, hangers
and valves as shown. (show figures of heating cable
installed to various equipment as mentioned above). UL
listed fiberglass insulation with a minimum k-factor of
0.25 BTU/hr -˚F-ft2 -in with weatherproof cladding must
be used.
b. For systems having piping which connects between buildings in unheated areas, coolers and freezers.
c. For systems having sprinkler piping that is installed in
coolers or freezers where the temperature is -40˚F or
greater.
B. INSTALLING A SINGLE RUN OF CABLE ON A PIPE.
1. Mount the reel of cable on a holder and place near one end of
the pipe run to be traced. Choose the end from which it will be
the easiest to pay out the cable.
2. Pay out the cable from the reel and loosely string along the piping, making sure the cable is always next to the pipe when
crossing obstacles. For example, if the heater is on the wrong
side of a crossing pipe, you will have to restring the cable or cut
and splice it.
Not intended to be used as the means to prevent freezing of
sprinkler branch lines including all accessories for these lines
and automatic (deluge, preaction, dry pipe, alarm, etc.) valves
as referenced in NFPA 13.
To prevent damage to cable, avoid such things as:
— Pulling the cable over sharp edges.
— Forcibly pulling the cable free if it snags while
being paid out.
— Allowing the cable to be walked on or subjeced to other abuse which could cause mechanical damage.
3. When you reach the end of the circuit, secure the heater cable
to the pipe using glass tape or plastic cable tie with a temperature rating compatible with the heater cable.
For use in Ordinary Hazard Occupancies only as specified in
NFPA 13 the standard for the installation of sprinkler systems.
Fire suppression system heater circuits must be connected to
monitoring equipment. A listed power supply relay with the
appropriate voltage coil shall be connected in parallel prior to
the heat tracing (should show figure with typical installation).
The output contacts of the listed power supervisory relay
should be connected to a listed fire control panel which has
provisions for supervisory circuits.
6. Do not attempt to heat trace any piece of equipment which will not be insulated.
7. Do not install heating cable on equipment which
could become hotter than the heating cable’s
maximum exposure temperature.
8. Do not install heating cable in an area or on
equipment which contains potentially corrosive
materials without having a suitable protective
jacket on the cable.
9. The minimum bending radius for all Chromalox
heating cables is six times the minor diameter.
10. Allow a minimum of 2” between cable runs.
11. Always install heat tracing on the outside radius
of elbows.
12. Never install heat tracing over expansion joints
without leaving slack in the cable.
13. Never use tie-wire or pipe straps to secure SelfRegulating Maximum Circuit length or Constant
Wattage heating cables.
14. Observe all published specifications. Do not
expose cables to temperatures above their specified maximums. Do not run cables longer than
specified maximum circuit lengths. See table 3
for details.
15. Pumps and small vessels should be heat traced and controlled
If this end is to have an end seal installed, remember to leave
about a foot of extra cable. If it is a power connection, leave
about two feet of extra heater cable.
4. (If the heater cable is to be spiralled, go to step 4A.)
Begin attaching the cable to the pipe about every foot (.3
meters).
Place the cable on the bottom half of the pipe at the 5 or 7
o’clock position. Refer to installation detail AD1. Go to step 5.
a. Note the path of the heater cable and the spiral factor of the
design. A simple way to think about spiral factor is: A1.1
spiral factor means install 11 feet of heating cable on every
10 feet of pipe, etc. At about every 10 feet of pipe, pull the
required amount of cable and let hang in a loop, and attach
the cable to the pipe.
b. Rotate the loops around the pipe until all the slack has been
taken up. Even out the spirals of the heater cable and secure
to the pipe as necessary to obtain good contact. The entire
circuit can be installed with hanging loops with the spiralling on the pipe being done when you trace the heat sinks.
Refer to installation detail AD3.
5. At a heat sink (pipe supports, valves, pumps, reducers, gauges,
bucket strainers, etc.), attach the heater cable to the pipe just
before the heat sink. Refer to the design specs to determine the
amount of heater cable you need to install on the heat sink. Pull
this amount of cable into a loop, attach the heater cable on the
other side of the heat sink and continue attaching the cable
down the pipe as before.
2
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
INSTALLATION
6. When you reach the heater cable reel, you should have the
heater cable attached all along the pipe, with the correct amount
of heater cable pulled in loops at all heat sinks. Attach the cable
to the pipe, (leave an extra foot if at an end seal, two feet if at a
power connection) and cut the heater cable from the reel.
7. Install the heater cable loops on the heat sinks. Refer to the
proper installation detail (AD5-AD12) for a general idea of how
to install the cable, but remember:
• It is important to get the proper amount of heater cable on
the heat sink, rather than exactly as the detail shows. The
detail is just a guide.
• Self-Regulating heater cables are very flexible and can be
single overlapped for installation ease. Feel free to use this
feature when you can.
i. At each heat sink, the easiest thing to do is supply the
extra heater called for by the design drawing from only
one heater cable. This avoids having to measure out half
of the requirement from each cable.
ii. When doing the previous step, leave a small loop other
cable at equipment which may be serviced, such as
pumps, valves, instruments, etc. This is so both heater
cables may be removed enough for future access.
b. Supply heater cables from one reel.
The general procedure is the same as given earlier, but there
are a few things to do to make sure the system is correctly
done.
i. With this method, a loop is pulled for the entire circuit.
To do this, attach the end of the heater cable to the pipe
near the heater cable reel. Remember to leave enough
extra cable for the type of connection to be installed.
ii. Begin pulling the cable off the reel in a large loop down
the piping run. Be sure to keep the cable next to the pipe.
Moving down the run, continue attaching the cable to the
pipe, leaving the side of the loop going back to the reel
unattached.
iii.You will want both sides of the loop to be about the
same length to avoid future problems. Also, it is easier to
install the extra cable required at each heat sink from only
one cable. Therefore, pull the right amount of extra heater
cable needed at every second heat sink from the side of
the loop you are attaching to the pipe. At the remaining
serviceable heat sinks (pumps, valves, instruments, etc.)
don’t forget to leave a short loop of cable for slack when
access to the equipment is needed.
iv. When the end of the piping run is reached, pull the proper amount of extra cable for the connection to be installed.
v. Now, begin working the remaining side of the loop back
toward the reel, installing it on the pipe and heat sinks as
required.
2. Installation for Backup (Redundant) Systems.
The purpose of a backup system is to provide the proper amount
of heat from the second heater cable if there are problems with
the first. Therefore, each cable must be installed so it can do the
job alone. The simplest way to do this is to install the first heater
cable as given in Section B. Then, go back and install the backup heater cable the same way.
There are several things to keep in mind:
• The power connections and end seals for the two cables are
often designed to be at opposite ends of the run in a redundant system. Remember to leave the proper amount of extra
cable for the connection to be installed on each cable at that
end.
• On piping one inch IPS or smaller, it can be difficult to
apply both heater cables with good contact at all places. The
main thing is to get the correct amount of cable installed.
However, try to get as much contact with the piping and heat
sinks from both cables as possible.
FIRE HAZARD. Do not overlap constant wattage or
mineral insulated heating cables.
• By having the cable installed this way, it can be removed
easily from the heat sink without cutting if access to, or
removal of the heat sink is required.
Note: If a tee is designed into the system, or if you are using two or
more short cable lengths to complete a circuit, allow two or three
feet of each cable to overlap. This will allow flexibility in assembling the connection kit and locating it on the pipe.
C. INSTALLING MORE THAN ONE HEATING CABLE
ON A PIPE.
There are two cases where you will need to install more than
one heater cable on a pipe:
• When the design calls for more than one cable.
• When the lines being heat traced are considered important
enough to install a backup (redundant) heat tracing system.
The installation requirements are different for these cases.
1. Installing multiple heater cables for design requirements.
The most common multiple cable requirement is two cables
on a pipe. Below are the recommended techniques for the two
cable systems. They also apply to installations where three or
more cables are to be installed on a pipe.
There are two ways of paying out two heater cables along a
pipe. The first is to locate two reels of heater cable and supply
one cable from each. This method works for all types of piping
runs.
However, it may increase material waste by leaving unusable
lengths from two reels. The second way is to supply both cables
from one reel. This method is generally the easiest for relatively straight, simple piping runs. For each circuit, decide which
method to use and then go to the appropriate part below.
a. Supplying cable from two reels.
The general procedure here is the same as given earlier, but
there are a few things to do to make sure the system is correctly done.
3
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
SUPPLEMENTAL INSTRUCTIONS FOR ATEX AND IECEx APPLICATIONS
SRL, SRP and SRM/E self-regulating heating cables, U Series
connection accessories Type UPC, UMC, UES and RTES
1. Do not bend the cable for a length of 300mm from the cable
gland inlet.
2. Connection and termination of Chromalox ATEX and IECEx
certified cable must be carried out by using the U Series of certified cable connection kits as supplied by Chromalox Inc.
These are only to be used for the operations for which they
were designed.
3. The supply circuit to the heating cables must be protected by a
safety differential device or equivalent ground fault protection.
4. The earthing braid of the heat trace cable must be bonded to a
suitable earth terminal.
5. The minimum cable installation temperature for SRL, SRP and
SRM/E cable is -40˚C (-40˚F).
6. The certified minimum cable exposure temperature for SRL,
SRP and SRM/E cable is -60˚C (-76˚F).
7. The presence of heat trace cables under insulation on pipelines
or vessels must be marked by the attachment of Caution labels
at regular intervals on the installation.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heating cable. Failure
to do so could result in personal injury or property
damage. Heaters must be installed by a qualified
person in accordance with IEC 62086-2:2001.
Any installation involving electric heating cables
must be performed by a qualified person and must
be effectively grounded in accordance with IEC
62086-2:2001 to eliminate shock hazard.
TYPICAL INSTALLATION DETAIL
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Metallic Pipe
Tape or Banding
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Metallic Pipe
Top
Top
45˚
45˚
45˚
12”
12”
Weatherproof Jacket
Typical
Weatherproof Jacket
Note: Cable located at nominal
45˚ below horizontal centerline.
Note: Cable located at nominal 45˚ below
horizontal centerline on either side.
Thermal Insulation
AD1 - One Run of Cable
Note:
1. Do not spiral if ratio
of heater length to pipe
length is greater than
1.5. Instead, use two
cables or choose a higher wattage heater.
Tape or Banding
Typical
Thermal Insulation
AD2 - Two Runs of Cable
Heating Cable
Self Regulating, Constant Wattage,
Mineral Insulated
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Tape or
Banding
12”
Typical
Note: Heating cable is
applied to the outside (long)
radius of the pipe elbow.
Metallic Pipe
Tape or Banding
Metallic Pipe
Note:
2. Refer to pitch chart in design
data section on circuit drawing
for proper pitch length.
Pitch
Weatherproof Jacket
Thermal Insulation
Weatherproof
Jacket
Thermal Insulation
AD3 - One Cable-Spiralling Method
AD4 - One Run of Cable at Pipe Elbow
4
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
TYPICAL INSTALLATION DETAIL
Flange Position with Pipe Expanded
Expansion Joint
Orifice Plate
Tape or Banding
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Tape or Banding
Flexible conduit junction box may be
required if a splice is necessary
Conduit connection fitting to be suitable for area classification. Heating cable may be run continuously
through the conduit.
Note: Insulate over flanges & orifice plate and
weatherseal. All piping must be fully insulated
and weathersealed.
Note: All piping must be fully insulated and weathersealed.
AD5 - Orifice Flange
AD6 - Expansion Joint
Tape or Banding
Metallic Pipe
Tape or Banding
Metallic Pipe
A
A
Support Shoe
3”
Typical
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
3 inches (Typical)
Pipe Support
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Note: Pipe Support to be insulated two feet
below pipe and weathersealed. All piping
must be fully insulated and weathersealed.
AD7 - Welded Support
Section A-A
Note: Insulate and weatherseal support. All piping must be fully insulated and weathersealed.
AD8 - Shoe Support
Pressure Gauge
Tape or Banding
Shut-Off
Valve
Front View
Rear View
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
Tape or Banding
Note: Completely insulate & weatherseal line and
gauge. All piping must be fully insulated and
weathersealed.
Note: All piping must be fully insulated and
weathersealed.
AD9 - Valve
Metallic Pipe
AD10 - Pressure Gauge
5
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
TYPICAL INSTALLATION DETAIL
Heating Cable
Self Regulating, Constant Wattage,
Mineral Insulated
Pressure Gauge
A
Diaphragm
Housing
Shut-Off
Valve
Level
Gauge
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
A
Tape or Banding
Note: Completely insulate & weatherseal line. All
piping must be fully insulated and weathersealed.
Tape or Banding
Metallic Pipe
Note: All piping must be fully insulated and weathersealed.
AD12 - Level Gauge
AD11 - Diaphragm Pressure Gauge
UPC Junction Box Connection
(See Instruction Sheet PJ495 for
Installation Instructions)
Splice Connection using
UMC Kit. (See Instruction
Sheet PJ497 for Installation
Instructions)
Conduit Connection
Hub (not included)
Tape or Banding
Junction Box
(not included)
Pipe Strap
Grounded
Braid
Connect to bracket with
grounding screw
Metallic Pipe
Heating Cable
Pipe Strap
Metallic Pipe
Heating Cable
Tape or Banding
Note: All piping must be fully insulated and weathersealed.
Note: All piping must be fully insulated and weathersealed.
AD13 - U Series Power Connection
AD14 - U Series Splice & Tee Connection
6
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
TYPICAL INSTALLATION DETAIL
Junction Box Connection
(See Instruction Sheets PJ442 or
PJ444 for Installation Instructions)
Conduit Connection
Hub (not included)
Tape or Banding
Splice Connection
(See Instruction Sheets
PJ445 or PJ446 for
Installation Instructions)
Junction Box
(not included)
Grounded
Braid
Connect to bracket with
grounding screw
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage
Pipe Strap
Heating Cable
Self Regulating
Constant Wattage
Metallic Pipe
Tape or Banding
Note: All piping must be fully insulated and weathersealed.
Note: All piping must be fully insulated and weathersealed.
AD13 - EL Series Power Connection
AD14 - EL Series Splice & Tee Connection
Metallic Pipe
Heating Cable
Self Regulating
Constant Wattage
Conduit Connection
Hub (not included) RTPC Power Connection Kit
(See Instruction Sheet PJ451 for
Installation Instructions)
End Seal Kit
(See Instruction Sheets
PJ441, PJ443 or PJ450 for
Installation Instructions)
Heating Cable
Self Regulating
Constant Wattage
Tape or Banding
Tape or Banding
Pipe Strap
Metallic Pipe
Note: All piping must be fully insulated and weathersealed.
Note: All piping must be fully insulated and weathersealed.
AD15 - End Seal
AD16 - DL Series Power Connection
RTST Splice and Tee Kit
(See Instruction Sheet PJ452
for Installation Instructions)
Note:
1. For multiple heaters place
control sensor 90˚ from nearest
heater or centered between
equally spaced heaters.
2. Place high-limit sensor
approximately 15” from heater
and mount in the same manner
as shown below.
Tape or Banding
Pipe Strap
Weatherproof
Jacket
Heating Cable
Self Regulating
Constant Wattage
Thermal Insulating
Heating Cable
Self Regulating
Constant Wattage
Mineral Insulated
90˚
Section A-A
Control Sensor
Metallic Pipe
Metallic Pipe
Tape or Banding to hold
heating cable
3 Foot
Minimum
Nearest pipe support
or other heat sink
Note: All piping must be fully insulated and weathersealed.
Tape Bulb
tight against pipe
AD18 - Sensor Placement
AD17 - DL Series Splice & Tee Connection
7
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
WIRING
To prevent equipment damage, Circuits fed from
overhead lines should be protected by secondary
lighting arrestors.
CONTROLS:
1. All heating circuits should have temperature controls. Temperature control of the pipeline can be obtained through various
Chromalox temperature controls. Refer to Chromalox bulletins
PJ304 and PJ310 for recommendations.
2. Contactors must be used when load currents exceed the rating of
the thermostat contacts. Equipment protection ground fault (30
mA EPD) thermal breakers are recommended with type SRL and
SRP.
3. The temperature control should be mounted in a location where
it will not be subjected to excessive shock or vibration.
4. Line sensing temperature sensors should be mounted in accordance with Installation Detail AD18 (see Detail on previous
page).
5. Ambient sensing temperature sensors should be located at a
point where the lowest ambient temperature is expected.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heating cable. Failure
to do so could result in personal injury or property
damage. Heater must be installed by a qualified
person in accordance with the National Electrical
Code, NFPA 70.
ELECTRIC SHOCK HAZARD. Any installation involving electric heating cables must be performed by a
qualified person and must be effectively grounded
in accordance with the National Electrical Code to
eliminate shock hazard.
ACCESSORIES:
1. Selection of Installation Accessories should be in accordance
with Chromalox bulletin PJ309 and PJ304.
2. Only use Chromalox installation kits and use them only for the
operations for which they are designed.
3. The instructions included in the Chromalox installation accessories must be followed in order for the third party approvals
(UL, FM, CSA, ATEX, IECEx, etc.) to apply.
4. Junction boxes must be in accordance with the requirements of
the area classification.
5. All outdoor junction boxes must be located above grade level.
Covers should be kept on the boxes at all time when not being
worked in.
6. All terminations must be protected from the weather and from
physical damage by locating them either under the weatherproof
insulation or inside an appropriate junction box.
7. All equipment must be properly grounded.
8. Install installation accessories according to the instructions
included in the kits and per installation details AD13 through
AD17.
To prevent equipment damage, handle and secure
temperature sensors, especially thermostat bulbs
and capillaries with care to avoid distortion or
crimping which might impair control accuracy.
6. Exposed thermostat capillaries should have mechanical protection.
End Cap
End Cap
Heat Resistance Wire
Heat Generating Matrix
L2
Power Supply
L1
L2
Power Supply
L1
Buss Wire
Buss Wire
Thermostat
Thermostat
Contactor
Contactor
Heat Resistance Wire
Heat Generating Matrix
L2 Power
L1 Supply
L2 Power
L1 Supply
End Cap
Buss Wire
End Cap
Buss Wire
Control
Circuit
Control
Circuit
Thermostat
Thermostat
I. Self-Regulating
II. Constant Wattage
Typical Wiring Diagrams
Contactor
End Cap
Heat Resistance Wire
Heat Resistance Wire
Cold Lead
Typical Wiring Diagrams
L2
Power Supply
L1
L2 Power
L1 Supply
End Cap
Thermostat
Control
Circuit
OR
L1
L2
III. Mineral Insulated
Thermostat
Thermostat
Typical Wiring Diagrams
8
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
INSTALLATION TESTING
When the heater cable and connections for a circuit have been
completed, immediately perform the following checks.
3. Inspect the insulation resistance of the circuit using a 500VDC
megger. Always perform this test at the power connection. Any
cable with an insulation resistance of less than 10 megohms
should be removed and discarded.
4. Check voltage at end of circuit and record in log. (Please see
Page 11)
1. Visually inspect the heater cable and temperature controls for
signs of mechanical damage. If damage is seen, either replace the
complete heater cable, or cut out the damaged section and
replace using the proper splice connection for the area and cable
you are using.
2. Inspect all connections to be sure they are correctly assembled.
Be sure each heater cable entry to a connection has a grommet
and the compression plates and caps are properly tightened.
THERMAL INSULATION
An installed heating circuit should be thermally insulated immediately to provide protection from damage from ongoing work.
Things to remember about insulating:
7. Insulation must be covered by a weatherproof barrier, such as an
aluminum jacket.
8. If you are using metal jacketing and sheet metal screws, be sure
the screws are not long enough to penetrate the thermal insulation and damage the heater cable.
9. Again, perform the megger test on the circuit immediately after
the thermal insulation is installed to detect if any mechanical
damage may have occurred.
10. When the insulation and the weatherproofing is complete, attach
“Electric Traced” labels on the outside of the insulation. These
should be installed where they are visible from normal operations, usually on alternating sides about every 10 feet. It is also
useful to mark the location of any connections buried under the
insulation.
1. Insulate the equipment being heat traced as soon as possible after
the heating cable is installed. This will protect the cable from
possible physical damage.
2. The type and thickness of thermal insulation specified on the
design drawing must be used. If you use another type or thickness, the heater cable type or amount may have to be changed.
3. Never install wet insulation. Both the piping and the insulation
must be dry when thermally insulating a circuit. Wet insulation
may cause start-up or operational problems.
4. Properly weatherproof the thermal insulation. All places where
valve stems, conduits, pipe supports, connection housing, thermal capillary tubes, etc. extend outside the insulation jacketing
must be sealed with a suitable compound to keep water out.
5. Insulate valves fully up to, and including, the packing gland.
6. Heat trace and fully insulate the face of all non-diaphragm pressure instruments.
Additional requirements for rigid thermal insulations:
1. In the standard single heater cable installation, rigid insulations
do not need to be oversized. However, they should be carved so
there is no gap in the insulation.
2. In case of redundant or multiple heater cables, rigid insulations
which are .500 inches oversized should be used.
COMMISSION TESTING
1. Again, visually inspect the piping, insulation and connections for
the heater cable to make sure no physical damage has occurred
if some time period has elapsed since the installation and startup.
2. Megger the system again to determine if damage not readily visible has occurred.
3. Turn all branch circuit breakers to the OFF position.
For systems controlled by line-sensing thermostats:
1. Set the thermostat to the desired control temperature.
2. Turn the main circuit breaker ON.
3. Turn ON the branch circuit breakers controlled by the thermostat.
4. Allow the pipe temperatures to be raised to the control point.
This may take up to four hours for most circuits (large full pipes
may take longer).
5. Measure the amperage draw. ambient temperature, and pipe temperature for each circuit and record in the installation log. This
information may be needed for future maintenance and troubleshooting.
For systems controlled by ambient-sensing thermostats:
1. If the actual ambient temperature is higher than the desired thermostat setting, turn the thermostat setting up high enough to turn
the system ON or (some models) turn the selector switch to the
ON position.
2. Turn the main circuit breaker ON.
3. Turn the branch breakers ON one-by-one until all are on.
4. Allow system to run at least four hours in order to let all pipes
reach steady-state.
5. Measure the amperage draw, ambient temperature and pipe temperature for each circuit and record in the installation log. This
information may be needed for future maintenance and troubleshooting.
6. When the system is completely checked out, reset the thermostat
to the proper temperature.
For redundant systems:
Follow the procedure above for the type of control system you
have, but commission the systems one at a time. Start up the primary system, qualify it and shut it down. Then start up the backup system, qualify it and shut it down.
9
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
SPECIFICATIONS
Table 1 – Maximum Temperatures
CABLE TYPE
SRL / HSRL
SRM/E / HSRM
CWM
SRF
SRP
MAX. MAINTAIN (POWER ON)
150˚F
302˚F
See table below
150˚F
230˚F
MAX EXPOSURE (POWER OFF)
185˚F
420˚F
See table below
185˚F
275˚F
Table 2 – Maximum Maintenance Temperatures
Temperatures (°F)
Output(W/Ft.)
3
4
6
6.7
8
9
10.1
10.6
12
w/o AT-1 Tape
340
325
293
282
262
246
229
222
200
w/ AT-1 Tape
350
344
332
328
320
314
307
304
296
Table 3 – Maximum Circuit Lengths
SRL / HSRL Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
50°F Start-Up (Ft.)
Cable Rating
SRL / HSRL3-1C
SRL / HSRL3-2C
SRL / HSRL5-1C
SRL / HSRL5-2C
SRL / HSRL8-1C
SRL / HSRL8-2C
SRL / HSRL10-1C
SRL / HSRL10-2C
10A 15A 20A
205 305 360
400 600 660
125 185 250
250 375 505
100 150 200
185 285 375
60 95 130
100 160 210
25A
NR
NR
270
540
215
420
160
260
0°F Start-Up (Ft.)
30A 40A
NR NR
NR NR
NR NR
NR NR
NR NR
NR NR
180 NR
315 360
10A
135
275
90
180
70
135
50
80
15A
200
415
135
270
110
200
80
125
20A
270
555
180
360
145
265
105
170
25A
330
660
225
450
180
335
130
210
-20°F Start-Up (Ft.)
30A
360
NR
270
540
215
395
155
255
40A
NR
NR
NR
NR
NR
420
180
340
10A
120
245
80
160
65
120
45
75
50A
NR
NR
NR
NR
NR
NR
NR
NR
210
420
160
350
15A
265
525
155
310
130
245
85
155
60
115
45
90
15A
185
370
120
245
100
175
70
120
20A
245
495
160
325
130
235
95
160
25A
300
600
205
405
165
300
120
195
30A
360
660
245
490
200
350
140
240
40A
NR
NR
270
540
210
420
180
320
SRM/E / HSRM Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
50°F Start-Up (Ft.)
Cable Rating
SRM/E / HSRM 3-1
SRM/E / HSRM 3-2
SRM/E / HSRM 5-1
SRM/E / HSRM 5-2
SRM/E / HSRM 8-1
SRM/E / HSRM 8-2
SRM/E / HSRM 10-1
SRM/E / HSRM 10-2
SRM/E / HSRM 15-1
SRM/E / HSRM 15-2
SRM/E / HSRM 20-1
SRM/E / HSRM 20-2
15A
285
575
180
360
145
285
95
190
70
145
60
115
20A
385
770
240
480
190
380
125
255
95
190
75
155
30A
NR
780
360
720
285
575
190
385
145
290
115
230
40A
NR
NR
375
750
325
650
250
490
190
385
155
305
0°F Start-Up (Ft.)
50A
NR
NR
NR
NR
NR
NR
NR
NR
210
420
160
350
15A
275
540
165
325
135
255
90
165
65
120
50
100
20A
375
750
220
430
175
345
110
225
85
175
65
135
30A
385
780
330
645
265
520
175
345
125
270
105
200
40A
NR
NR
375
750
325
650
250
490
165
360
140
270
-20°F Start-Up (Ft.)
20A
365
740
210
415
165
335
100
215
80
165
65
130
30A
385
780
310
620
250
490
170
330
120
260
100
195
40A
NR
NR
375
750
325
650
245
470
150
340
135
255
50A
NR
NR
NR
NR
NR
NR
250
490
210
420
160
335
SRP Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
50°F Start-Up (Ft.)
Cable Rating
SRP 5/1
SRP 10/1
SRP 15/1
SRP 5/2
SRP 10/2
SRP 15/2
15A
145
100
75
295
200
150
20A
195
135
100
385
270
195
30A
295
200
150
580
400
295
40A
390
270
200
750
530
390
0°F Start-Up (Ft.)
50A
490
330
250
750
665
500
15A
110
70
60
220
145
120
20A
145
95
80
290
190
160
30A
215
145
120
430
290
235
40A
295
190
160
580
380
320
-20°F Start-Up (Ft.)
50A
360
240
200
720
480
400
15A
70
65
55
135
130
110
20A
90
85
70
180
175
145
30A
135
130
110
270
260
220
40A
180
175
145
360
350
290
10
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
50A
225
215
180
450
440
360
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
SPECIFICATIONS (cont’d)
CWM Specifications
SRF Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
40°F Start-Up (Ft.)
0°F Start-Up (Ft.)
Circuit Load
Max. Circuit Length
Model
(Amps/Ft.)
(Ft.)
Cable Rating
20A
30A
40A
20A
30A
40A
CWM 4-1CT
0.033
350
SRF 3-1C
350
360
NR
270
360
NR
CWM 8-1CT
0.067
240
SRF 3-2C
660
NR
NR
555
660
NR
CWM 12-1CT
0.100
200
SRF 5-1C
230
270
NR
180
270
NR
CWM 4-2CT
0.017
700
SRF 5-2C
450
540
NR
360
540
NR
CWM 8-2CT
0.033
480
SRF 8-1C
180
215
NR
145
215
NR
CWM 12-2CT
0.050
400
SRF 8-2C
330
420
420
265
395
420
CWM 12-4CT
0.025
780
NR = Not Required. Maximum circuit length has been reached in a smaller breaker size.
Note — Thermal magnetic circuit breakers are recommended since magnetic circuit breakers could "nuisance trip" at low temperature.
MAINTENANCE
Recommended maintenance for Chromalox heat tracing systems consists of performing the steps involved in the commission testing on a
regular basis. For those systems controlled by line sensing thermostats, Chromalox recommends checking the system at least twice
per year. Systems controlled by an ambient-sensing thermostat should
be checked when the season requiring their use is approaching.
Repair or replace all damaged heater cable, connections, thermal
insulation and weatherproofing using only Chromalox connections
and methods before testing the system.
Record all repairs made and measurements taken in the installation and maintenance log.
11
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
INSTALLATION AND MAINTENANCE LOG
Reference Information
Circuit Number
Circuit Breaker Number
Drawing Number
Circuit Length
Heat Tracing Visual Checks
No Signs of Moisture, Corrosion or Damage
Proper Electrical Connection
Proper Grounding of the Braid
Initial
Date
Initial
Date
Initial
Date
Heat Tracing Electrical Checks
Megger Test (500 VDC)
(Bypass Controls)
Amperage Draw Test
Compare to design Amperage Draw
Voltage at end of Circuit*
Meg Ohms
Date
Amperage
Amb. Temp.
Date
Voltage
Date
Accessories/Control Checks
Temperature Control Properly Set
Sensors Protected and Undamaged
All Enclosures and Kits Closed and Sealed
Set Point
Date
Initial
Date
Initial
Date
Thermal Insulation Checks
Location of Kits Visible on
Outside of Insulation
Insulation is Complete, Dry and Weatherproof
Initial
Date
Initial
Date
* This test must be performed at installation or at any time the cable is cut or damaged in any way.
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
1347 HEIL QUAKER BLVD., LAVERGNE, TN 37086
Phone: (615) 793-3900
www.chromalox.com
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
410-795-2223
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement