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Commercial
Heat-Tracing
Installation and Maintenance Manual
Self-Regulating Heating Cable Systems
1 General information
2 Product data
3 Heating cable selection
4 Heating cable storage
5 Product checks
6 Components installation
7 Controls, thermal insulation and marking
8 Power supply and electrical connection
9 Heating cable testing
10 Operation, maintenance and pipe repairs
11 Heating cable damage
15
16
10
11
3
4
10
20
20
18
19
2 | nVent.com/RAYCHEM
1 GENERAL INFORMATION
Use of the manual
The Installation and Maintenance manual is for nVent's
Raychem self-regulating heating cable systems on thermally insulated pipes. For gutters and downpipes consult the technical handbook.
For self-regulating ground or surface snow melting consult the technical handbook.
For self-regulating floor heating consult the handbook for comfortable warm floors.
For information regarding other applications contact your nVent representative.
Self-Regulating Cables
L
N
Colder
Section
Warmer
Section
Power output varies with temperature.
As pipe temperature increases, power output decreases.
At high temperatures, the polymer expands, reducing the number of the conductive paths, and thus reducing current flow.
At low temperatures, there are many conductive paths,allowing current to flow between the conductors.
Important
For the nVent 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.
nVent.com/RAYCHEM | 3
2 PRODUCT DATA
Cable type
Nominal voltage
Nominal power output
(*on insulated metal pipes)
HWAT-L HWAT-M
Hot water temperature maintenance
230 VAC 230 VAC
7 W/m at 45°C 9 W/m at 55°C
C-type circuit-breaker according to selected kit
Max. circuit length
max. 20 A
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. 20 A
100 m
20 A
10 mm
65°C
85°C
Max. dimensions in mm
(W x H)
Weight
Approvals/Certification
Control units
13.8 x 6.8
0.12 kg/m
EAC / UKrSEPRO
13.7 x 7.6
0.12 kg/m
BS / ÖVE / VDE / SEV / CSTB / SVGW /
HWAT-T55
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
Connection system
Junction box
Connection and end seal
Support bracket
–
RayClic
–
RayClic
Included in the kit Included in the kit
HWAT-R FS-C10-2X
Pipe Freeze Protection for LPHW services
230 VAC 230 VAC
12 W/m at 70°C 10 W/m at 5°C max. 20 A
100 m
20 A
10 mm
80°C
90°C max. 25 A
180 m
20 A
10 mm
90°C
90°C
16.1 x 6.7
0.14 kg/m
16 x 6.8
0.14 kg/m
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS-30
*maximum circuit of 150m
–
RayClic
JB16-02
CE20-01
Included in the kit 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.
4 | nVent.com/RAYCHEM
Cable type
Nominal voltage
Nominal power output
(*on insulated metal pipes)
HWAT-L HWAT-M
Hot water temperature maintenance
230 VAC 230 VAC
7 W/m at 45°C 9 W/m at 55°C
C-type circuit-breaker according to selected kit
Max. circuit length
max. 20 A
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. 20 A
100 m
20 A
10 mm
65°C
85°C
Max. dimensions in mm
(W x H)
Weight
Approvals/Certification
Control units
13.8 x 6.8
0.12 kg/m
EAC / UKrSEPRO
13.7 x 7.6
0.12 kg/m
BS / ÖVE / VDE / SEV / CSTB / SVGW /
HWAT-T55
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
Connection system
Junction box
Connection and end seal
Support bracket
–
RayClic
–
RayClic
Included in the kit Included in the kit
HWAT-R FS-C10-2X
Pipe Freeze Protection for LPHW services
230 VAC 230 VAC
12 W/m at 70°C 10 W/m at 5°C max. 20 A
100 m
20 A
10 mm
80°C
90°C max. 25 A
180 m
20 A
10 mm
90°C
90°C
16.1 x 6.7
0.14 kg/m
16 x 6.8
0.14 kg/m
HWAT-ECO
SBS-xx-Hx-ECO panels
ACS-30
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS-30
*maximum circuit of 150m
–
RayClic
JB16-02
CE20-01
Included in the kit JB-SB-08
Do not connect heating cable conductors together as this will result in a short circuit.
Any unconnected heating cable end must be sealed with a nVent approved end seal.
nVent.com/RAYCHEM | 5
Cable type
Application
10XL2-ZH
Pipe Freeze Protection
15XL2-ZH
Pipe Freeze Protection
Nominal voltage
230 Vac
Nominal power output
10W/m @ 5°C.
C-Type circuit breaker size
Max circuit length
max. 20A
238m
Minimum bending radius
10 mm
Max. continuous exposure temperature
65°C
85°C
Max exposure temperature
(power off)
Dimensions
13.7 x 6.2 mm
Weight
Approvals
0.13kg/m
VDE/CSTB (IEC62395)
230 Vac
15W/m @ 5°C.
max. 20A
188m
10 mm
65°C
85°C
13.7 x 6.2 mm
0.13kg/m
VDE/CSTB (IEC62395)
Control Units
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 150m
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 150m
Connection system
Connection kit
RayClic RayClic
Support Bracket
Included in Kit Included in Kit
26XL2-ZH
Pipe Freeze Protection
230 Vac
26W/m @ 5°C.
max. 20A
142m
10 mm
65°C
85°C
31XL2-ZH
Pipe Freeze
Protection / Temperature maintenance for greasy waste pipes
230 Vac
31W/m @ 5°C.
max. 20A
114m
10 mm
85°C
90°C
13.7 x 6.2 mm
0.13kg/m
13.7 x 6.2 mm
0.13kg/m
VDE/CSTB (IEC62395) VDE/CSTB (IEC62395)
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 116m
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 91m
RayClic
Included in Kit
RayClic
Included in 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.
6 | nVent.com/RAYCHEM
Cable type
Application
10XL2-ZH
Pipe Freeze Protection
15XL2-ZH
Pipe Freeze Protection
Nominal voltage
230 Vac
Nominal power output
10W/m @ 5°C.
C-Type circuit breaker size
Max circuit length
max. 20A
238m
Minimum bending radius
10 mm
Max. continuous exposure temperature
65°C
85°C
Max exposure temperature
(power off)
Dimensions
13.7 x 6.2 mm
Weight
Approvals
0.13kg/m
VDE/CSTB (IEC62395)
230 Vac
15W/m @ 5°C.
max. 20A
188m
10 mm
65°C
85°C
13.7 x 6.2 mm
0.13kg/m
VDE/CSTB (IEC62395)
Control Units
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 150m
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 150m
Connection system
Connection kit
RayClic RayClic
Support Bracket
Included in Kit Included in Kit
26XL2-ZH
Pipe Freeze Protection
230 Vac
26W/m @ 5°C.
max. 20A
142m
10 mm
65°C
85°C
31XL2-ZH
Pipe Freeze
Protection / Temperature maintenance for greasy waste pipes
230 Vac
31W/m @ 5°C.
max. 20A
114m
10 mm
85°C
90°C
13.7 x 6.2 mm
0.13kg/m
13.7 x 6.2 mm
0.13kg/m
VDE/CSTB (IEC62395) VDE/CSTB (IEC62395)
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 116m
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS 30
*maximum circuit of 91m
RayClic
Included in Kit
RayClic
Included in Kit
Do not connect heating cable conductors together as this will result in a short circuit.
Any unconnected heating cable end must be sealed with a nVent approved end seal.
nVent.com/RAYCHEM | 7
Cable type FroStop-Black GM-2X (T) EM2-XR EM2-R
Product/
Application
Nominal voltage
Nominal power output
(on insulated metal pipes)
Max. dimensions in mm (W x H)
Weight
Approvals
Control units
Frost protection of pipes / Ice and snow protection of gutters and downpipes
230 Vac
16 W/m at 5°C
C-type circuit-breaker according to selected kit
max. 16 A
Max. circuit length
80 m
16 A
10 mm
Min. bending radius
Max. continous exposure temperature
Max. exposure temperature
(power-on condition – 800 h. cumulative)
65°C
65°C
12.5 x 5.3
0.13kg/m
VDE / Intertek
Semko
EMDR-10
GM-TA
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS-30
*maximum circuit of
150m
Connection system
Junction box
JB16-02
Connection kit
CE20-01
CCE-06-CR
Ice and snow protection of gutters and downpipes
230 VAC
36 W/m in ice and
18 W/m in air at 0°C max. 20 A
80 m
20 A
10 mm
65°C
85°C
13.7 x 6.2
0.13 kg/m
VDE
EMDR-10
GM-TA
RAYSTAT-M2
SBS-XX-EV panels
ACS-30
–
RayClic
CCE-04-CT
Ramp and accessway heating
230 VAC
90 W/m at 0°C in concrete max. 50 A
85 m
50 A
50 mm
100°C
110°C
18.9 x 9.5
0.27 kg/m
VIA-DU-20
RAYSTAT-M2
SBS-XX-VV panels
ACS-30
VIA-JB2
VIA-CE1
CE
Ramp and accessway heating
230 VAC
80 W/m at 0°C in concrete max. 32 A
75 m
32 A
50 mm
90°C
90°C
11.8 x 4.5
0.13 kg/m
VIA-DU-20
RAYSTAT-M2
SBS-XX-VV panels
ACS-30
JB-82
CCE-04-CT
Support bracket
JB-SB-08 Included with RayClic
– –
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.
8 | nVent.com/RAYCHEM
100 m
10 A
10 mm
65°C
65°C
R-ETL-A
Frost protection for pipes
R-ETL-B
Frost
Protection for pipes
R-ETL-A-CR
Frost Protection for pipes
R-ETL-B-CR
Frost Protection for pipes
230 VAC
10 W/m at 5°C on pipe
230 VAC
16W/m at 5DegC on pipe.
230 VAC
10W/m at 5DegC on pipe.
230 VAC
16W/m at 5DegC on pipe.
max. 10 A max. 16A max. 10A max. 16A
100 m
16A
10 mm
65°C
65°C
100 m
10A
10 mm
65°C
65°C
100 m
16A
10 mm
65°C
65°C
8.5 x 5.8
8.5 x 5.8
8.5 x 5.8
8.5 x 5.8
0.07 kg/m 0.07kg/m 0.07kg/m 0.07kg/m
VDE / Intertek Semko / CSTB VDE / CSTB
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
JB16-02
CE-ETL/T2Red
U-ACC-PP-07
CE20-03
JB-SB-08
JB16-02
CE-ETL/T2Red
CE20-03
U-ACC-PP-07
JB-SB-08
JB16-02
CE20-03
U-ACC-PP-07
JB-SB-08
JB16-02
CE20-03
U-ACC-PP-07
JB-SB-08
Cable type FroStop-Black GM-2X (T)
Included with RayClic
EM2-XR
–
EM2-R
Product/
Application
Nominal voltage
Nominal power output
(on insulated metal pipes)
Max. dimensions in mm (W x H)
Weight
Approvals
Control units
Frost protection of pipes / Ice and snow protection of gutters and downpipes
230 Vac
16 W/m at 5°C
C-type circuit-breaker according to selected kit
max. 16 A
Max. circuit length
80 m
16 A
10 mm
Min. bending radius
Max. continous exposure temperature
Max. exposure temperature
(power-on condition – 800 h. cumulative)
65°C
65°C
12.5 x 5.3
0.13kg/m
VDE / Intertek
Semko
EMDR-10
GM-TA
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN*
SBS-FP-xx panels
AT-TS-13*
AT-TS-14*
ACS-30
*maximum circuit of
150m
Connection system
Junction box
JB16-02
Connection kit
CE20-01
CCE-06-CR
Ice and snow protection of gutters and downpipes
230 VAC
36 W/m in ice and
18 W/m in air at 0°C max. 20 A
80 m
20 A
10 mm
65°C
85°C
13.7 x 6.2
0.13 kg/m
VDE
EMDR-10
GM-TA
RAYSTAT-M2
SBS-XX-EV panels
ACS-30
–
RayClic
CCE-04-CT
Ramp and accessway heating
230 VAC
90 W/m at 0°C in concrete max. 50 A
85 m
50 A
50 mm
100°C
110°C
18.9 x 9.5
0.27 kg/m
VIA-DU-20
RAYSTAT-M2
SBS-XX-VV panels
ACS-30
VIA-JB2
VIA-CE1
CE
Ramp and accessway heating
230 VAC
80 W/m at 0°C in concrete max. 32 A
75 m
32 A
50 mm
90°C
90°C
11.8 x 4.5
0.13 kg/m
VIA-DU-20
RAYSTAT-M2
SBS-XX-VV panels
ACS-30
JB-82
CCE-04-CT
Support bracket
JB-SB-08 –
R-ETL-A
Frost protection for pipes
230 VAC
10 W/m at 5°C on pipe
230 VAC
16W/m at 5DegC on pipe.
230 VAC
10W/m at 5DegC on pipe.
230 VAC
16W/m at 5DegC on pipe.
max. 10 A
100 m
10 A
10 mm
65°C
65°C
8.5 x 5.8
8.5 x 5.8
8.5 x 5.8
8.5 x 5.8
0.07 kg/m 0.07kg/m 0.07kg/m 0.07kg/m
VDE / Intertek Semko / CSTB VDE / CSTB
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
RAYSTAT V5
ELEXANT 450c
RAYSTAT-CONTROL-
11-DIN
SBS-FP-xx panels
AT-TS-13
AT-TS-14
SBS-R-FP panels
JB16-02
CE-ETL/T2Red
U-ACC-PP-07
CE20-03
JB-SB-08
R-ETL-B
Frost
Protection for pipes max. 16A
100 m
16A
10 mm
65°C
65°C
JB16-02
CE-ETL/T2Red
CE20-03
U-ACC-PP-07
JB-SB-08
R-ETL-A-CR
Frost Protection for pipes max. 10A
100 m
10A
10 mm
65°C
65°C
JB16-02
CE20-03
U-ACC-PP-07
JB-SB-08
R-ETL-B-CR
Frost Protection for pipes max. 16A
100 m
16A
10 mm
65°C
65°C
JB16-02
CE20-03
U-ACC-PP-07
JB-SB-08
Do not connect heating cable conductors together as this will result in a short circuit.
Any unconnected heating cable end must be sealed with a nVent approved end seal.
nVent.com/RAYCHEM | 9
3 HEATING CABLE SELECTION
Check the design specification to make sure the proper heating cable is selected for each pipe or surface.
Refer to nVent product literature or the TraceCalc Net
Construction software to select the proper heating cable for each application.
FS-C10-2X
FroStop-
Black
HWAT-L
HWAT-M
HWAT-R
GM-2X (T)
EM2-XR
EM2-R
R-ETL-A-CR
R-ETL-B-CR
R-ETL-A
R-ETL-B
Look-up Table: The following table shows which heating cables are suitable for use with specific applications.
Product/
Application
Frost
Protection for Pipes
Flow
Maintenance
Hot Water
Temperature
Maintenance
Ice/Snow
Protection of Gutters
Ice/Snow
Protection of Ground
Surfaces
10XL2-ZH
15XL2-ZH
26XL2-ZH
31XL2-ZH
4 HEATING CABLE STORAGE
Store in a dry and clean place.
Temperature range:
–40°C to +60°C.
Protect any cable ends with an end seal.
10 | nVent.com/RAYCHEM
5 PRODUCT CHECKS
5.1 Pre-installation checks
Check materials received:
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.
Temperature exposure must not exceed that specified in nVent' product literature. Exceeding these limits will impair product performance. Check that expected exposure is within these limits.
Ensure that the heating cable voltage rating is suitable for the service voltage available.
Do not energize cable when it is coiled or on the reel.
Inspect heating cable and components for in-transit damage. An insulation resistance test (Section 9) on each reel is recommended.
Check piping to be traced:
Ensure all pressure testing is complete and pipework has final paint coating.
Walk the system and plan the routing of the heating cable on the pipe.
Check pipework against specification drawing. If different consult design authority.
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.
nVent.com/RAYCHEM | 11
5.2 Heating cable handling
Heating cable handling tips:
Paint and pipe coatings must be dry to the touch before heating cable installation.
When pulling the heating cable,
avoid:
sharp edges
high tractive force
kinking and crushing
walking or driving over the cable
moisture at cable interfaces
Heating cable pulling tips:
Use a reel holder that pays out smoothly with little tension.
Keep heating cable strung loosely but close to the pipe being traced to avoid interference with supports and equipment.
Pay out designed length and mark (i.e. with fixing tape) on cable while still on reel.
Leave the appropriate amount of heating cable at all power connection, splice, tee and end seal locations.
(Refer to component installation instructions)
Add additional heating cable to trace the fittings and supports or for spiralling as required by the design specifications, or consult nVent product literature for design.
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
The heating cable may be installed straight (spiralled or in multiple runs as required by the design specification, nVent product literature or TraceCalc software).
Do not
use metal attachments, vinyl electrical tape or duct tape as heating cable damage may result.
Self-regulating technology allows for the multiple overlapping of the heating cable on to itself.
12 | nVent.com/RAYCHEM
5.3.2 Heating cable, non-pipe fixing recommendations
For snow and ice protection applications, the heating cable should be fixed in place using one of the nVent recommended fixing methods, including spacer rail or connection to a reinforcement grid.
For gutter applications, the heater should be held in place within the gutter using recommended fixing clips as supplied by the manufacturer.
For underfloor heating applications, the heater shall be installed using the fixing methods of the manufacture or installed in the T2Reflecta heat reflector product.
5.4 Straight tracing
Straight trace the pipe unless the design calls for spiralling.
On horizontal pipes, fix on lower quadrant (5 O’clock or 7 O’clock positioning on pipe) and not on bottom of pipe.
Read the kit installation instructions and plan the component location before permanently attaching the cable to the pipe.
Thermally insulate and weatherproof to specification.
300 mm
Top
Pipe
Glass cloth tape
(typical)
Tight on pipe
Thermal insulation
(typical)
45°
(nominal)
nVent attachment tapes:
GT66
ATE-180
Self-adhesive glass cloth tape General purpose tape. GS-54 Self-adhesive glass cloth tape for stainless-steel pipes.
KBL-10 cable ties
Aluminium fixing tape. Using only if required for the system design
(Typically for temperature maintenance applications such as HWAT on plastic pipes).
nVent.com/RAYCHEM | 13
5.5 Cutting the heating cable
Cut the heating cable to length after it is attached to the pipe. Before cutting it, confirm the tracing allowance as per Section 2.
Raychem heating cable can be cut-to-length without affecting the heat output per metre.
5.6 Installation details
Follow the recommendations for cutting and stripping heating cables; they are included in the component installation instructions.
Horizontal pipe Vertical pipe
Cut the heating cable at right angles
90
°
Smallest bending radius: 10 mm
Run the cable over pipe suspensions
Wall/Floor transit
The thickness of thermal insulation must be continuous otherwise compensate by adding heating cable.
Do not clamp the cable
14 | nVent.com/RAYCHEM
6 COMPONENTS INSTALLATION
General notes:
Select the required components from nVent product literature or use the TraceCalc Net Construction 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 iscorrect for the heating cable and environment.
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
For the installation of all components refer to the relevant component installation instructions.
Required for each heating cable run:
Power connection and end-seal.
As required:
Splice
Tee-splice: RayClic or junction box, three connection kits and three insulation entry kits, depending on heater.
Accessories (pipe straps, fixing tape, support brackets, labels, etc)
6.2 Component installation hints
Locate RayClic / junction boxes for easy access but not exposed to mechanical abuse.
Position junction boxes so that power cable and heating cable entries do not point upwards.
Fix lids in place where access not required.
Confirm junction box stopping plugs are correct for application and fixed firmly in place.
Route heating cable from RayClic / junction box to insulation entry so as to avoid possible mechanical damage.
Do not
strain heating cable as it exits/enters RayClic
/ junction boxes and insulation entries.
Ensure heating cable is fixed above pipe straps such as used for RayClic / junction box support brackets.
Fix all low profile components (e.g. heatshrink end seals) in place.
nVent.com/RAYCHEM | 15
7 THERMAL INSULATION AND MARKING
7.1 Pre-insulation checks
Visually inspect the heating cable and components for correct installation and damage.
(See Section 11 if damaged.)
Insulation resistance (Megger) testing
(as per Section 9) is recommended prior to covering the pipe with thermal insulation.
7.2 Thermostats and control systems
In temperature-sensitive applications, thermostatic control may be necessary. Furthermore, for maximum energy efficiency, nVent requires the installation and use of an approved controller for the application.
Follow the installation instructions supplied with the thermostat or control. Use the proper wiring diagram for for the heating cable layout and control method desired.
After switching on the heating cable, the cable ends must be warm after 5 to 10 minutes.
7.3 Insulation installation hints
Correct temperature maintenance requires properly installed and dry thermal insulation.
Thermally insulate and weatherproof to design specification.
Check insulation type and thickness against the design specification.
To minimize potential heating cable damage, insulate as soon as possible after tracing.
Check that all pipework, including fittings, wall penetrations and other areas, have been completely insulated.
Ensure that heating cable is not damaged during installation of cladding for example by drills, self-tapping screws and sharp edges of cladding.
Check that all insulation entry kits are fitted correctly and sealed.
Ensure that all areas where valve stems, support brackets etc. exit the insulation are appropriately insulated and sealed.
16 | nVent.com/RAYCHEM
7.4 Marking
Install “Electric Traced” signs along piping at suitable intervals (5 m intervals recommended) on alternate sides as a warning.
Mark on outside of insulation the location of heating cable components.
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.
nVent.com/RAYCHEM | 17
8 ELECTRICAL PROTECTION
8.1 Overcurrent protection
Size circuit breakers according to the design specification or applicable nVent product literature. If devices other than those specifically identified are used, consult the nVent representative for the appropriate sizing information.
8.2 Residual current (earth fault) protection
nVent requires the use of a 30 mA residual current device to provide maximum safety and protection from fire.
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.
18 | nVent.com/RAYCHEM
9 HEATING CABLE TESTING
9.1 Recommendations
nVent recommends insulation resistance (Megger) test before installing heating cable; before installing thermal insulation; prior to initial start-up (disconnected from the controls).
9.2 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 21).
Measurement A
Measurement B nVent.com/RAYCHEM | 19
10
OPERATION, MAINTENANCE AND PIPE
REPAIRS
10.1 Heating cable operation
Temperature exposure must not exceed that specified in nVent product literature. Exceeding those limitations will shorten the service life and may permanently damage the heating cable.
Pipe insulation must be complete and dry to maintain the correct temperature.
10.2 Inspection and maintenance
De-energise all power circuits before installation or servicing and maintenance.
Visual inspection: Exposed heating cable and pipe insulation should be checked periodically to make sure that no physical damage has occured.
Function testing of electrical protection and temperature control systems should be carried out before the winter months each year. Temperature maintenance systems should be tested at least twice a year.
The Periodic Inspection Record on the following pages should be filled out during maintenance of each circuit in your system.
10.3 Piping systems repair and maintenance
Isolate heating cable circuit.
Protect the heating cable from mechanical or thermal damage during pipe repair work.
Check heating cable installation after pipe repairs and restore thermal insulation following the recommendations in Section 7. Check correct functioning of electrical protection systems.
11 HEATING CABLE DAMAGE
Heating cable damage
Do not repair damaged heating cable.
Remove entire damaged section and splice in a new length using the appropriate Raychem splice kits.
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.
Heating cable exposed to fire or flame may cause further fire damage if powered.
Remove from service at once and replace before re-use.
20 | nVent.com/RAYCHEM
.
T NO
CIRCUI nVent.com/RAYCHEM | 21
.
T NO
CIRCUI
22 | nVent.com/RAYCHEM
In connection systems Heating cable and cable glands tight Connection terminals tight Ear
nVent.com/RAYCHEM | 23
TROUBLESHOOTING GUIDE
Symptom
Circuit Breaker overcurrent protection trips or blows.
Probable causes
Electrical fault at:
• damaged heating cable
• faulty splices or tees
• end seal
• connection
Circuit oversized
Start-up below design temperature
Symptom
RCD trips
Defective electrical protection
Probable causes
Earth fault at:
• damaged heating cable
• faulty splices or tees
• end seal
• connection
• junction boxes
• splices and tees
• end seals
High leakage currents due to a combination of excessive lengths of power cable and heating cable.
Mains borne disturbances
Defective RCD
Corrective action
Investigate and remedy (see note 1):
Resize or redesign within Technical Handbook
Guidelines. (If larger protection is required, ensure supply cables are compatible).
design for lower start-up temperatures.
reheat pipe from alternative heat source to within exposure temperatures given in Product Data.
energize part of circuit followed by remainder (e.g. in sequence).
Replace
Corrective action
Investigate and remedy (see note 1):
Dry out and reseal or remake immediately.
Perform insulation resistance test.
(100 MΩ minimum)
Redesign
Redesign distribution, guidance is available from nVent.
Replace
24 | nVent.com/RAYCHEM
TROUBLESHOOTING GUIDE
Symptom
Circuit Breaker overcurrent protection trips or blows.
Probable causes
Electrical fault at:
• damaged heating cable
• faulty splices or tees
• end seal
• connection
Circuit oversized
Start-up below design temperature
Symptom
RCD trips
Defective electrical protection
Probable causes
Earth fault at:
• damaged heating cable
• faulty splices or tees
• end seal
• connection
• junction boxes
• splices and tees
• end seals
High leakage currents due to a combination of excessive lengths of power cable and heating cable.
Mains borne disturbances
Defective RCD
Corrective action
Investigate and remedy (see note 1):
Resize or redesign within Technical Handbook
Guidelines. (If larger protection is required, ensure supply cables are compatible).
design for lower start-up temperatures.
reheat pipe from alternative heat source to within exposure temperatures given in Product Data.
energize part of circuit followed by remainder (e.g. in sequence).
Replace
Corrective action
Investigate and remedy (see note 1):
Dry out and reseal or remake immediately.
Perform insulation resistance test.
(100 MΩ minimum)
Redesign
Redesign distribution, guidance is available from nVent.
Replace nVent.com/RAYCHEM | 25
Symptom
No power output
Probable causes
Loss of supply voltage due to:
• overcurrent or residual current protection trip
• loose terminals in junction box
• loss of supply cable continuity (e.g., open
• ircuited from damage
Control thermostat is connected in the normally open position
High resistance connection at:
• junction box terminals
• splices and tees
Symptom
Low pipe temperature
Probable causes
Wet thermal insulation
Design error
Incorrect setting or operation of controls e.g., thermostats.
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.
Corrective action
Restore supply voltage
• following A and B (page 20)
• re-tighten terminals
NB: If excessive heating has occured due to high
resistance, replace terminals or crimps
• locate damage and repair
Reconnect to normally closed position
Locate and remedy by:
• re-tighten
• repair
NB: If excessive heating has occured due to high resistance, replace
terminals or crimps
Corrective action
Remove and replace with dry insulation of correct specification and ensure complete weatherproofing
• check with competent authority for design conditions
• modify to meet nVent recommendations
Repair or reset to correct level of operation
Replace
26 | nVent.com/RAYCHEM
Symptom
No power output
Probable causes
Loss of supply voltage due to:
• overcurrent or residual current protection trip
• loose terminals in junction box
• loss of supply cable continuity (e.g., open
• ircuited from damage
Control thermostat is connected in the normally open position
High resistance connection at:
• junction box terminals
• splices and tees
Symptom
Low pipe temperature
Probable causes
Wet thermal insulation
Design error
Incorrect setting or operation of controls e.g., thermostats.
Heating cable has been exposed to excessive temperature beyond rating.
Corrective action
Restore supply voltage
• following A and B (page 20)
• re-tighten terminals
NB: If excessive heating has occured due to high
resistance, replace terminals or crimps
• locate damage and repair
Reconnect to normally closed position
Locate and remedy by:
• re-tighten
• repair
NB: If excessive heating has occured due to high resistance, replace
terminals or crimps
Corrective action
Remove and replace with dry insulation of correct specification and ensure complete weatherproofing
• check with competent authority for design conditions
• modify to meet nVent recommendations
Repair or reset to correct level of operation
Replace
4 If after 1, 2 and 3 above the fault has not been located, then either: a) Consult nVent 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. nVent.com/RAYCHEM | 27
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