Commercial heat-tracing:
Installation and
Maintenance Manual
Self-Regulating
Heating Cable Systems
11
12
1
General information
2
Conditions for safe use
3
Heating cable selection
4
Heating cable storage
5
Product checks
6
Components installation
7
Thermostats and control systems
8
Thermal insulation and marking
9
Power supply and electrical connection
10
Heating cable testing
Operation, maintenance and pipe repairs
Heating cable damage
Pg. 16
Pg. 17
Pg. 18
Pg. 11
Pg. 12
Pg. 13
Pg. 15
Pg. 1
Pg. 3
Pg. 6
Pg. 6
Pg. 7
1
General information
Use of the manual
The Installation and Maintenance manual is for Tyco
Thermal Controls self-regulating heating cable systems on thermally insulated pipes. For gutters and downpipes, consult the Technical Handbook (Ref. CDE-0518).
For self-regulating ground or surface snow melting consult
INST-159 only.
For information regarding other applications contact your
Tyco Thermal Controls representative.
Self-Regulating Cables
L
N
Colder
Section
Warmer
Section
D
Power output varies with temperature.
D
As pipe temperature increases, power output decreases.
D
At high temperatures, the polymer expands, reducing the number of the conductive paths, and thus reducing current flow.
D
At low temperatures, there are many conductive paths,allowing current to flow between the conductors.
Important
For the Tyco Thermal Controls warranty to apply, the
instructions that are included in this manual and product
packages must be followed. The installation must be compatible with local requirements applicable to electric heat-tracing systems.
1
2
Conditions for safe use
Cable type HWAT-L HWAT-M
Hot water temperature maintenance
Nominal voltage
Nominal power output
(*on insulated metal pipes)
230 VAC
7 W/m at 45°C max. 20 A
C-type circuit-breaker according to selected kit
Max. circuit length
Min. bending radius
Max. continous exposure temperature
180 m
20 A
10 mm
65°C
Max. exposure temperature
(power-on condition – 800 h. cumulative)
85°C
Max. dimensions in mm
(W x H)
Weight
13.8 x 6.8
0.12 kg/m
Approvals
Control units
QWT-05
HWAT-ECO
230 VAC
9 W/m at 55°C max. 20 A
100 m
20 A
10 mm
65°C
85°C
13.7 x 7.6
HWAT-R
230 VAC
12 W/m at 70°C max. 20 A
100 m
20 A
10 mm
80°C
90°C
16.1 x 6.7
FS-A-2X FS-B-2X
Frost protection for pipes
230 VAC
10 W/m at 5°C max. 16 A
150 m
16 A
10 mm
65°C
85°C
13.7 x 6.2
230 VAC
26 W/m at 5°C max. 16 A
105 m
16 A
10 mm
65°C
85°C
13.7 x 6.2
FS-C-2X FS-C10-2X
Frost protection of pipes/ Temperature maintenance
Frost protection for pipes
230 VAC
31 W/m at 5°C
22 W/m at 40°C max. 16 A
90 m
16 A
10 mm
95°C
95°C
12.7 x 5.3
230 VAC
10 W/m at 5°C max. 25 A
180 m
20 A
10 mm
90°C
90°C
16 x 6.8
Connection system
Junction box
Connection kit
–
RayClic
0.12 kg/m 0.14 kg/m 0.13 kg/m 0.13 kg/m 0.13 kg/m 0.14 kg/m
BS / ÖVE / VDE / SEV / CSTB / SVGW / DVGW / CE / VDE
HWAT-ECO HWAT-ECO AT-TS-13
AT-TS-14
RAYSTAT-CONTROL
RAYSTAT-ECO
RAYSTAT-
CONTROL-11-DIN
AT-TS-13
AT-TS-14
RAYSTAT-CONTROL
RAYSTAT-ECO
RAYSTAT-
CONTROL-11-DIN
AT-TS-13
AT-TS-14
RAYSTAT-CONTROL
RAYSTAT-
CONTROL-11-DIN
RAYSTAT-CONTROL-10
RAYSTAT-ECO-10
RAYSTAT-
CONTROL-11-DIN
AT-TS-13*
AT-TS-14*
*maximum circuit
of 150m
–
RayClic
–
RayClic
–
RayClic included in the kit
–
RayClic included in the kit
JB16-02
CE20-01
JB-SB-08
JB16-02
CE20-01
CE25-21
JB-SB-08
Support bracket
included in the kit included in the kit included in the kit
Warning
As with any electrical equipment or wiring installation operating at line voltages, heating cable and component damage or incorrect installation that allows the penetration of moisture or contamination can lead to electrical tracking, arcing and potential fire hazard.
Do not connect heating cable conductors together or this will result in a short circuit.
Any unconnected heating cable end must be sealed with a
Tyco Thermal Controls approved end seal.
2 3
Cable type
Nominal voltage
Nominal power output
(on insulated metal pipes)
FroStop-Green FroStop-Black
Frost Protection for pipes
Frost protection of pipes / Ice and snow protection of gutters and downpipes
GM-2X
Ice and snow protection of gutters and downpipes
230 VAC 230 Vac 230 VAC
10 W/m at 5°C max. 16 A
16 W/m at 5°C max. 16 A
8BTV2-CT
Drain heating for ramp drainage systems
EM2-XR
Ramp and accessway heating
EM2-R
Ramp and accessway heating
R-ETL-A
Frost protection for pipes
T2Red
Underfloor heating
230 VAC 230 VAC 230 VAC 230 VAC 230 VAC
36 W/m in ice and
18 W/m in air at 0°C
26W/m at 5°C 90 W/m at 0°C max. 20 A max. 16 A
80 W/m at 0°C
10 W/m at 5°C 60-100 W/m max. 50 A max. 32 A max. 10 A max. 20 A
2
C-type circuit-breaker according to selected kit
Max. circuit length
Min. bending radius
Max. continous exposure temperature
10 mm
65°C
Max. exposure temperature
(power-on condition – 800 h. cumulative)
65°C
Max. dimensions in mm
(W x H)
12.5 x 5.3
Weight
Approvals
Control units
100 m
16 A
0.13 kg/m
AT-TS-13
AT-TS-14
RAYSTAT-ECO-10
RAYSTAT-
CONTROL-10
RAYSTAT-
CONTROL-11-DIN
80 m
16 A
10 mm
65°C
65°C
12.5 x 5.3
80 m
20 A
10 mm
65°C
85°C
13.7 x 6.2
80 m
16 A 0°C startup
10 mm
65°C
85°C
13.7 x 6.2
85 m
50 A
50 mm
100°C
110°C
75 m
32 A
50 mm
90°C
90°C
18.9 x 9.5 13.7 x 6.2
100 m
10 A
35 mm
65°C
65°C
8,5 x 5,8
100 m
35 mm
65°C
65°C
6,0 x 8,7
0.13kg/m 0.13 kg/m 0.13kg/m 0.27 kg/m 0.13 kg/m 0.07 kg/m
BS / ÖVE / VDE / SEV / CSTB / SVGW / DVGW / CE / VDE
–
CE / VDE
EMDR-10 / HTS-D
AT-TS-13
AT-TS-14
RAYSTAT-ECO-10
RAYSTAT-
CONTROL-10
RAYSTAT-
CONTROL-11-DIN
EMDR-10
HTS-D
VIA-DU-20
EMDR-10
VIA-DU-20 VIA-DU-20 AT-TS-13
AT-TS-14
RAYSTAT-
CONTROL
RAYSTAT-ECO
Raychem TA
Raychem TC
Connection system
Junction box
JB16-02 JB16-02 – VIA-JB2 JB-82 JB16-02 –
Connection kit
CE20-01 CE20-01 RayClic
CCE-03-CR
JB16-02
C25-21
E-06
CE25-21
JB-SB-08
VIA-CE1
–
CCE-04-CT
–
CE-ETL/T2Red CE-ETL/T2Red
– –
Support bracket
JB-SB-08 JB-SB-08
Warning
As with any electrical equipment or wiring installation operating at line voltages, heating cable and component damage or incorrect installation that allows the penetration of moisture or contamination can lead to electrical tracking, arcing and potential fire hazard.
included in the kit
Do not connect heating cable conductors together or this will result in a short circuit.
Any unconnected heating cable end must be sealed with a
Tyco Thermal Controls approved end seal.
4 5
3
Heating cable selection
Check the design specification to make sure the proper heating cable is installed on each pipe or surface. Refer to
Tyco Thermal Controls product literature or the TraceCalc software to select the proper heating cable for each application.
Look-up Table: The following table shows which heating cables are suitable for use with specific applications.
Application Protection for Pipes
Temperature
Maintenance
Protection of Gutters
Ice/Snow
Protection of
Ground Surfaces
Underfloor heating/ warming
FS-A-2X
FS-B-2X
FS-C-2X
FS-C10-2X
FroStop-
Green
FroStop-
Black
HWAT-L
HWAT-M
HWAT-R
GM-2X
8BTV2-CT
EM2-XR
EM2-R
R-ETL-A
T2-Red
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
4
Heating cable storage
Heating cable storage
D
Store the heating cable in a clean, dry place
D
Temperature range: –40°C to +60°C
D
Protect the heating cable from mechanical damage
6
5
Product checks
5.1 Pre-installation checks
Check materials received:
D
Review the heating cable design and compare the list of materials to the catalogue numbers of heating cables and electrical components received to confirm that proper materials are on site. The heating cable type is printed on its outer jacket.
D
Temperature exposure must not exceed that specified in Tyco Thermal Controls’ product literature. Exceeding these limits will impair product performance. Check that expected exposure is within these limits.
D
Ensure that the heating cable voltage rating is suitable for the service voltage available.
D
Do not energize cable when it is coiled or on the reel.
D
Inspect heating cable and components for in-transit damage. An insulation resistance test (see section 8) on each reel is recommended.
Check piping to be traced:
D
Ensure all pressure testing is complete and pipework has final paint coating.
D
Walk the system and plan the routing of the heating cable on the pipe.
D
Check pipework against specification drawing. If different consult design authority.
D
Inspect piping for burrs, rough surfaces, sharp edges etc. which could damage the heating cable. Smooth off or cover with layers of glass cloth tape or aluminium foil.
7
5.2 Heating cable handling
Heating cable handling tips:
D
Paint and pipe coatings must be dry to the touch before heating cable installation.
D
When pulling the heating cable, avoid: d
sharp edges d
excessive pulling force d
kinking and crushing d
walking on it, or running over it with equipment.
Heating cable pulling tips:
D
Use a reel holder that pays out smoothly with little tension.
D
Keep heating cable strung loosely but close to the pipe being traced to avoid interference with supports and equipment.
D
Pay out designed length and mark (i.e. with fixing tape) on cable while still on reel.
D
Leave the appropriate amount of heating cable at all power connection, splice, tee and end seal locations. (Refer to component installation instructions) d
Add additional heating cable to trace the fittings and
supports or for spiralling as required by the design specifications, or consult Tyco Thermal Controls product literature for design.
D
Protect all heating cable ends from moisture, contamination and mechanical damage or other interference if left exposed before component installation.
5.3.1 Heating cable on pipe attachment recommendations
D
The heating cable may be installed straight, spiralled or in multiple runs as required by the design specification, Tyco
Thermal Controls’ product literature or TraceCalc software.
d
Do not use metal attachments, vinyl electrical tape or duct tape as heating cable damage may result.
d
Self-regulating technology allows for the multiple overlapping of the heating cable on to itself.
8
5.3.2 Heating cable, non-pipe fixing recommendations
D
For snow and ice protection applications, the heating cable should be fixed in place using one of the Tyco Thermal
Controls recommended fixing methods, including spacer rail or connection to a reinforcement grid.
D
For gutter applications, the heater should be held in place within the gutter using recommended fixing clips as supplied by the manufacturer.
D
For underfloor heating applications, the heater shall be installed using the fixing devices of the manufacture or installed in the T2Reflecta heat reflector product.
5.4 Straight tracing
D
Straight trace the pipe unless the design calls for spiralling.
D
On horizontal pipes, fix on lower quadrant (5 O’clock or
7 O’clock positioning on pipe) and not on bottom of pipe.
D
Read the kit installation instructions and plan the component location before permanently attaching the cable to the pipe.
D
Thermally insulate and weatherproof to specification.
300 mm
Top
Pipe
Glass cloth tape
(typical)
Tight on pipe
Thermal insulation
(typical)
45°
(nominal)
Tyco Thermal Controls attachment tapes:
GT66 Self-adhesive glass cloth tape General purpose tape.
ATE-180 Aluminium fixing tape. Using only if required for the system design (Typically for temperature maintenance applications such as HWAT.)
9
5.5 Cutting the heating cable
D
Cut the heating cable to length after it is attached to the pipe. Before cutting it, confirm the tracing allowance as per
Sections 3.3 and 3.6.
D
Raychem heating cable can be cut-to-length without affecting the heat output per metre.
5.6 Typical installation details
D
Typical installation details for fixing heating cable to pipe fittings are shown hereafter.
General notes:
D
Trace pipe fittings as shown to allow easy maintenance.
D
Consult the design specification or Tyco Thermal Controls product literature or TraceCalc software for the tracing requirements for fittings and supports.
D
Follow the recommendations for cutting and stripping heating cables; they are included in the component installation instructions.
6
Components installation
General notes:
Select the required components from Tyco Thermal
Controls product literature or use the TraceCalc software.
Raychem component kits (including power connections, splices and end seals) must be used to satisfy Standards and Approval Body requirements.
Installation instructions included in the kit must be followed, including those for preparation of the heating cable conductors for connections. Before assembly, use the guide given in the instructions to ensure that the kit is correct for the heating cable and environment.
d
Raychem self-regulating and power-limiting heating cables are parallel circuit design. Do not twist the conductors together as this will result in a short circuit.
6.1 Components required
D
For the installation of all components refer to the relevant component installation instructions.
D
Required for each heating cable run:
Power connection and end-seal.
D
As required:
Splice
Tee-splice: junction box, three connection kits and three insulation entry kits.
Accessories (pipe straps, fixing tape, support brackets, labels, etc)
10 11
6.2 Component installation hints
D
On horizontal pipes locate junction boxes below pipe wherever possible.
D
Locate junction boxes for easy access but not exposed to mechanical abuse.
D
Position junction boxes so that power cable and heating cable entries do not point upwards.
D
Fix lids in place where access not required.
D
Confirm junction box stopping plugs are correct for application and fixed firmly in place.
D
Route heating cable from junction box to insulation entry so as to avoid possible mechanical damage.
d
Do not strain heating cable as it exits/enters junction boxes and insulation entries.
D
Ensure heating cable is fixed above pipe straps such as used for junction box support brackets.
D
Fix all low profile components (e.g. heatshrink end seals) in place with self-adhesive glass cloth tape.
7
Thermostats and control systems
D
In temperature-sensitive applications, thermostatic control may be necessary. Furthermore, for maximum energy efficiency, Tyco Thermal Controls require the installation and use of an approved controller for the application.
D
Follow the installation instructions supplied with the thermostat or control. Use the proper wiring diagram for the heating cable layout and control method desired.
8
8.1
Thermal insulation and marking
Pre-insulation checks
D
Visually inspect the heating cable and components for correct installation and damage. (See Section 10 if damaged.)
D
Insulation resistance (Megger) testing (as per Section 8) is recommended prior to covering the pipe with thermal insulation.
8.2 Insulation installation hints
D
Correct temperature maintenance requires properly installed and dry thermal insulation.
D
Thermally insulate and weatherproof to design specification.
D
Check insulation type and thickness against the design specification.
D
To minimize potential heating cable damage, insulate as soon as possible after tracing.
D
Check that all pipework, including fittings, wall penetrations and other areas, have been completely insulated.
D
Ensure that heating cable is not damaged during installation of cladding for example by drills, self-tapping screws and sharp edges of cladding.
D
Check that all insulation entry kits are fitted correctly and sealed.
D
Ensure that all areas where valve stems, support brackets etc. exit the insulation are appropriately insulated and sealed.
12 13
8.3 Marking
D
Install “Electric Traced” signs along piping at suitable intervals (5 m intervals recommended) on alternate sides
as a warning.
D
Mark on outside of insulation the location of heating cable components.
D
For outdoor de-icing and snow melting applications, the presence of heat-tracing shall be made evident by the posting of caution signs or marking where clearly visible.
9
9.1
Power supply and electrical connection
Electrical loading
Size overcurrent protective devices according to the design specification or applicable Tyco Thermal Controls product literature. If devices other than those specifically identified are used, consult the Tyco Thermal Controls representative for the appropriate sizing information.
9.2 Residual current (earth fault) protection
Tyco Thermal Controls requires the use of a 30 mA residual current device to provide maximum safety and protection from fire. Where design results in a higher leakage current, a maximum 300 mA residual current device may be used. Ground fault protection is required in any installation.
The metal braid covering the trace heater shall be connected to an earth terminal for electrical protection of the circuit.
14 15
10
10.1
Heating cable testing
Recommendations
Tyco Thermal Controls recommends insulation resistance test before installing heating cable; before installing thermal insulation; prior to initial start-up; and as part of the periodic maintenance.
10.2 Test method
After completing heating cable installation, the insulation resistance between the conductors and the braid should be checked using a 2.500 VDC megger tester. Minimum readings should be 100 Megohms regardless of the heating cable length. The installer should record the original values for each circuit on the installation record sheet
(see page 17).
11
Operation, maintenance and pipe repairs
11.1 Heating cable operation
D
Temperature exposure must not exceed that specified
in Tyco Thermal Controls product literature. Exceeding those limitations will shorten the service life and may permanently damage the heating cable.
D
Pipe insulation must be complete and dry to maintain the correct temperature.
11.2 Inspection and maintenance
De-energise all power circuits before installation or ser-
vicing and maintenance.
D
Visual inspection: Exposed heating cable and pipe insulation should be checked periodically to make sure that no physical damage has occured.
D
Meggering: The system should be meggered regularly.
When meggering the insulation resistance from the main supply panel, it is recommended that the test is performed between L/N (together) and PE. Freeze protection systems should be meggered before the winter months each year
(see section 8). Temperature maintenance systems should be tested at least twice a year. Function testing of electrical protection and temperature control systems should be carried out at regular intervals.
D
The Periodic Inspection Record on the following pages should be filled out during maintenance of each circuit in your system.
11.3 Piping systems repair and maintenance
D
Isolate heating cable circuit.
D
Protect the heating cable from mechanical or thermal damage during pipe repair work.
D
Check heating cable installation after pipe repairs and restore thermal insulation following the recommendations in Section 8. Check correct functioning of electrical protection systems.
17 16
12
Heating cable damage
Heating cable damage
D
Do not repair damaged heating cable.
Remove entire damaged section and splice in a new length using the appropriate Raychem splice kits.
D
Replace damaged heating cable at once.
Damage allowing moisture and contamination to enter the heating cable may result in arcing earth faults and potential fire hazards.
D
Heating cable exposed to fire or flame may cause further fire damage if powered.
Remove from service at once and replace before re-use.
18
CIRCUIT NO.
19 20
CIRCUIT NO.
21
A
Troubleshooting guide
Symptom:
Overcurrent protection trips or blows.
Probable Causes
1
Electrical fault at:
a
damaged heating cable
b
faulty splices or tees
c
end seal
d
connection
2
Circuit oversized
Corrective Actions
1
Investigate and remedy (see note 1):
B
3
Start-up below design temperature
4
Defective electrical protection
Symptom: RCD trips.
Probable Causes
1
Earth fault at:
a damaged heating cable
b
faulty splices or tees
c end seal
d connection
2
Excessive moisture in:
a junction boxes
b splices and tees
c end seals
3
High leakage currents due to a combination of excessive
lengths of power cable and heating cable.
4
Mains borne disturbances
5
Defective RCD
2
Resize or redesign within Technical Databook
Guidelines. (If larger protection is required, ensure supply cables are compatible).
3 a
design for lower start-up temperatures.
b reheat pipe from alternative heat source to
within exposure temperatures given in Product
Data Sheets.
c energize part of circuit followed by remainder (e.g. in
sequence.
4
Replace.
Corrective Actions
1
Investigate and remedy (see note 1):
2
Dry out and reseal or remake immediately.
3
Perform insulation resistance test.
(100 M Ω minimum)
Redesign
4
Redesign distribution, guidance is available from
Tyco thermal controls.
5
Replace.
22 23
C Symptom:
No power output.
Probable Causes
1
Loss of supply voltage due to:
a
overcurrent or residual current protection operating
b
loose terminals in junction box
c
loss of supply cable continuity (e.g., open circuited from damage
2
Control thermostat is connected in the normally open position
3
High resistance connection at:
a junction box terminals
b splices and tees
Corrective Actions
1
Restore supply voltage
a
following A and B (page 20)
b
re-tighten terminals
NB: If excessive heating has occured due to high
resistance, replace terminals or crimps
c locate damage and repair
2
Reconnect to normally closed position
3
Locate and remedy by:
a
re-tighten
b
repair
NB: If excessive heating has occured due to high resistance, replace terminals or crimps
D Symptom:
Low pipe temperature.
Probable Causes
1
Wet thermal insulation
2
Design error
3
Incorrect setting or operation of controls e.g., thermostats.
4
Heating cable has been exposed to excessive temperature
beyond rating.
Note:
Locate faults by the following steps:
1 Visually inspect the power connections, splices and end seals for correct installation.
2 Look for signs of damage at:
a) Valves, pumps, flanges and supports.
b) Areas where repairs or maintenance work has been carried out.
3 Look for crushed or damaged insulation and cladding along the pipe.
24
4 If after 1, 2 and 3 above the fault has not been located, then either: a) Consult Tyco Thermal Controls for futher assistance. b) Where local practices and conditions allow (e.g., non hazardous areas) isolate one section of heating cable from another by cutting in half and testing (e.g., Insulation Resistance) both halves until general area of damage is found.
Remove insulation and expose fault.
25
Corrective Actions
1
Remove and replace with dry insulation of correct
specification and ensure complete weatherproofing
2
a check with competent authority for design conditions
b modify to meet Tyco Thermal Controls recommendations
3
4
Repair or reset to correct level of operation
Replace
Raychem is a trademark of Tyco Thermal Controls, LLC or its affiliates .
Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal
Controls’ only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuse of the product. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to make changes, without notification to the
Buyer, to processing or materials that do not affect compliance with any applicable specification.
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141407, Mосковская обл., г. Химки ул. Панфилова, 19, 11 этаж,
Деловой Центр Кантри Парк
Тел. +7 (495) 926 18 85
Факс +7 (495) 926 18 86
Serbia and Montenegro
Keying d.o.o.
Vuka KaradΩiça 79
23300 Kikinda
Tel. (230) 401 770
Fax (230) 401 790
Schweiz / Suisse
Tyco Thermal Controls N.V.
Office Baar
Haldenstrasse 5
Postfach 2724
6342 Baar
Tel. (041) 766 30 80
Fax (041) 766 30 81
Suomi
Tyco Thermal Controls Nordic AB
Flöjelbergsgatan 20B
SE-431 37 Mölndal
Puh. 0800 11 67 99
Telekopio 0800 11 86 74
Sverige
Tyco Thermal Controls Nordic AB
Kanalvägen 3 A
SE-194 61 Upplands Väsby
Tel. 08-590 094 60
Fax 08-590 925 70
Türkiye
SAMM Dış Ticaret A.Ş.
Yeniyol Sk. Etap İş Merkezi C Blok
No : 10 Kat : 6
34722 Acıbadem - Kadıköy
İSTANBUL
Tel . +0216-325 61 62 (Pbx)
Faks +0216-325 22 24
United Kingdom
Tyco Thermal Controls (UK) Ltd
3 Rutherford Road,
Stephenson Industrial Estate
Washington, Tyne & Wear
NE37 3HX
Tel. 0800 969013
Fax 0800 968624 [email protected]
www.tycothermal.com
