Trace Heating Guide - Cable Services · TRACE HEATING PRODUCTS 7 6 Self Regulating XTV Electric trace heating for process temperature maintenance applications up to 120OC which may

Trace

Heating

Guide

TRACE HEATING GUIDE

Distributor of

Trace Heating Products

for 25 Years

(Northwest) LtdTel 01978 356948

(UK) LtdTel 01978 340450

(Central) LtdTel 01782 274714

(Liverpool) LtdTel 0151 9339022

RS 21752RS 21753RS 22195RS 14517

4 Trace Heating Products Page 4 - 8

Tyco trace heating products including Raychem Isopad, Wintergard and Frostop. Systems for commercial and industrial freeze protection and process control. Also ice protection, floor warming and leak detection products.

Size of Pipe (ø):

Length of Pipe:

Material of Pipe:

Thickness & Type of Insulation:

Ambient Temperature:(surrounding air, min & max)

Temperature:(to be maintained, ie 5OC for frost protection)

Maximum Temperature:(on the pipe ie through steam cleaning etc)

Indoors Outdoors

Hazardous Non-Hazardous

Number of Valves:

Number of Pipe Supports:

Supply Voltage

Additional Information:(general description of project etc)

Name:

Company:

Tel No:

Fax No:

Data Input Sheet - Fax Back

For our FREE design proposal please complete the datainput sheet below and fax it to a Cable Services sales office.

SALES OFFICEFAX NUMBERS

Northwest LtdFax: 01978 310438

UK LtdFax: 01978 311315

Central LtdFax: 01782 280547

Liverpool LtdFax: 0151 9339765

CABLESERVICES

3

9 Industrial Trace Heating Guidelines Page 9 - 17

Page 9 General InformationPage 9 Heating Cable SelectionPage 9 - 13 Heating Cable InstallationPage 14 - 15 Pipe Heat Loss ChartPage 16 - 17 Heat Tracing Plastic Pipes with Chemelex Auto-Trace Self-Regulating Heaters

18 Domestic / Commercial Trace Heating Guidelines Page 18 - 19

Page 18 Raychem WintergardPage 19 Raychem HWAT Hot Water Temperature Maintenance

20 Troubleshooting Guide Page 20 - 21

22 Thermostats Page 22 - 23

23 Rule Of Thumb Page 23

Our History of Trace Heating

Cable Services started distributing the Raychem range of self

regulating Trace Heating cables in the late seventies and have

over the years acquired a wide expertise in the installation of

the whole range of Tyco Trace Heating products.

Our vast experience coupled with stocks unequalled anywhere in the

UK makes Cable Services the only choice for Trace Heating materials.

Ring our experienced sales staff on the numbers listed across or use

the fax back form opposite to send us details of your requirements.

An immediate response is our commitment.

Contents

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Electric Trace HeatingFor frost protection and temperature maintenance.

WinterGard™ and FrostopFor self regulating heating cable for domestic andcommercial freeze protection.

Cable Services have distributed Raychem Trace Heating products for over 20 years.

The extended range of products now available from Tyco Thermal Controls includes theRaychem, Pyrotenax and Isopad products many of which are stock items at Cable Services.

Products available include:

Wintergard™ and Frostop heating cables are safe and reliable. Self regulating technology prevents overheating and minimises energy consumption andparallel circuit configuration means cables can be cut to length on site.

Contact Cable Services with application requirementsfor a design recommendation and quotation.(See page 3 for our simple data input sheet).

HWAT™ PlusFor self regulating heating for hot water temperature maintenance.

Hot water temperature maintenance using HWAT™Plus self regulating trace heating cable combinesinstant hot water in large and small buildings withimproved energy efficiency over traditional hot watersystems.

Contact Cable Service for a free design proposal andquotation.

Floor HeatingFlexible, reliable and easy to install floor heating.

The T2 floor heating product range is designed to provide room heating from floor up, heating theroom much more evenly than traditional systems, and ensuring that the floor is the warmest place in the room.

Contact Cable Services for a free design proposal and quotation.

Self Regulating BTVElectric trace heating for frost protection inindustrial applications without steam cleaning.

The BTV family of self regulating parallel circuit heating cables is used for frost protection of pipes and vessels. It can be used for process temperaturemaintenance up to 65OC and has an unlimited T6 rating for hazardous areas.

Contact Cable Services with application details for a design recommendation and quotation.(See page 3 for our simple data input sheet).

Self Regulating QTVRElectric trace heating for industrial process temperature maintenance applications up to 110OC, not subject to steam cleaning.

The QTVR family of self regulating parallel circuit heating cables is used for process temperature maintenance of pipes and vessels in industrial environments. It can also be used for frost protectionon large diameter pipes and has a T4 rating for hazardous areas.

Contact Cable Services with application details for a design recommendation and quotation.(See page 3 for our simple data input sheet).

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Self Regulating XTVElectric trace heating for process temperaturemaintenance applications up to 120OC which may be subject to steam cleaning.

The XTV family of self regulating parallel circuit heatingcables is used for process temperature maintenanceof pipes and vessels in industrial environments wherethere may be a requirement to steam clean. It can alsobe used for frost protection of large diameter pipesand other applications requiring high temperatureexposure capability. XTV heaters are rated T3 and T2(20XTV2 - CT) for hazardous area applications.

Contact Cable Services with application details for a FREE design recommendation and quotation.(See page 3 for our simple data input sheet).

Self Regulating KTVElectric trace heating for process temperaturemaintenance applications up to 150OC which may be subject to steam cleaning.

The KTV family of self regulating parallel circuit heating cables is used for industrial process temperature maintenance of pipes and vessels, where there may be a requirement for a high temperature exposure capability. KTV heaters are rated T3 and T2 for hazardous area applications.


High TemperaturePower Limiting VPLElectric trace heating designed for hightemperature industrial applications up to250OC temperature exposure.

VPL is a family of power limiting cables which can beused for frost protection and process temperaturemaintenance requiring high power output and/orhigh temperature exposure. VPL can provide processtemperature up to 230OC and can withstand routineexposure to 250OC with power off. Power limitingcables are ‘parallel circuit’ heaters formed by a coiledresistor alloy heating element wrapped around twoparallel conductors. this parallel construction allows itto be cut to length on site.

Contact Cable Services with application details for a FREE design recommendation andquotation. (See page 3 for our simple data input sheet).

Constant Wattage IHTIHT parallel circuit medium power constant output heater for non hazardous areas.

IHT is designed for high temperature processmaintenance applications particularly in chemicallyaggressive environments such as animal fats.The parallel circuit zone construction enables IHTto be cut to length and terminated on site.


Constant Wattage FHTFHT constant wattage parallel circuit heating cables for high power industrial applications including hazardous areas.

FHT is designed for high temperature applications andcan provide process temperature maintenance up to150OC and can withstand exposure up to 260OC poweroff. The parallel construction allows it to be cut tolength on site and its round shape provides excellentflexibility during installation.


Constant Wattage FG220Versatile flexible parallel circuit heater for mediumpower applications in non hazardous areas.

FG220 is a family of silicone rubber jacketed highlyflexible constant wattage heaters suitable for avariety of industrial applications in non hazardous,non chemical aggressive industrial environments. A stainless steel overbraid is available as an option.


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Ice and snow protection for ramps,steps and footpaths.

Viagard self regulating cables buried in the concrete ortarmac surface keeps ramps etc clear of snow and iceallowing continuous safe access. The Viagard systemoffers toughness, versatility and reliability.

Contact Cable Services with details of your applicationfor a FREE design proposal and quotation.

ICESTOP SystemFor snow and ice prevention on roofs and in gutters.

The Icestop system features a self regulating heatingcable specially developed to prevent ice formation onalmost any type of roof. The heat output adjusts ateach point along the cable, with highest output insnow and icy water and decreasing in warmer, dryerareas. The self regulating construction ensures thecable cannot overheat and thus provides a safe andeconomical means of ice protection.

Contact Cable Services with details of your applicationfor a FREE design proposal and quotation.

Apart from the heating cables described, the range of products available nowincludes the ISOPAD series heaters for very high temperature applications andthe ISOPAD heated hoses and drum heaters. Please contact sales for details

TraceTekLeak detection cables.

Raychem also manufactures TRACETEK leak detectioncable. This cable is installed in sensitive areas where the consequence of an undetected flood could be disastrous.

Please contact the Cable Services sales office for further details.

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9GENERAL INFORMATION

This installation information is for Raychem Self-Regulating Heater Systems on thermallyinsulated pipes only. For information regarding other applications contact Cable Services.

Warning

As with any electrical equipment or wiring installation operating at line voltages, heatingcable and component damage or incorrect installation that allows the penetration ofmoisture or contamination can lead to electrical tracking, arcing and potential fire hazard.

Do not connect a heater’s conductors together or this will result in a short circuit.

Any unconnected heating cable end must be sealed with a Raychem approved end seal.

Heating Cable Selection

Check the design specification to make sure the proper heater is installed on eachpipe. Refer to Cable Services for help in selecting the proper heating cable for eachthermal, chemical, electrical and mechanical environment.

Heating Cable Installation

1.1 Heating Cable Storage

• Store the heating cable in a clean, dry place.• Temperature range: -40OC to +60OC.• Protect the heating cable from mechanical damage.

1.2 Pre-Installation Checks

Check materials received:

• Review the heating cable design and compare the list of materials to the cataloguenumbers of heating cables and electrical components received to confirm thatproper materials are on site. The heater type is printed on its jacket.

• Temperature exposure must not exceed that specified in Raychem product literature.Exceeding these limits will impair product performance. Check that expectedexposure is within these limits.

• Ensure that the heating cable voltage rating is suitable for the service voltage available.• Inspect heating cable and components for in-transit damage. An insulation resistance

test on each reel is recommended.

Check piping to be traced:

• Complete the pipe pressure test.• 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

heater. Smooth off or cover with layers of glass cloth tape or aluminium foil tape.

Apply glass tapebefore spiralling

cable on pipe

Pipe length

Pitch Pipe

Heatingcable

Glass tape(typical)

Wrap loops inopposite direction

Tape after spirallingcable on pipe

Heatingcable length

Pitch PipeAuto-Traceself-regulatingheater cable

Glass tape(typical)

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Heating Cable Installation Cont.

1.3 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:

(1) Sharp edges(2) Excessive pulling force(3) Kinking and crushing(4) Walking on it, or running over it with equipment

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 minimum length of heater before fixing to pipe.• Leave a 0.5m heating cable service loop at all power connection, splice, tee and end

seal locations.• Add additional heating cable to trace the fittings and supports or for spiralling as

required by the design specifications, or consult Raychem product literature for design.• Protect all heating cable ends from moisture, contamination and mechanical damage

or other interference if left exposed for long periods of time before componentinstallation.

1.4 Heating Cable Attachment Recommendations

• The heating cable may be installed straight, spiralled or in multiple runs as requiredby the design specification or Raychem product literature.

• Do not use metal attachments, vinyl electrical tape or duct tape as heating cabledamage may result.

• Plastic cable ties must have a temperature rating that matches the system exposuretemperature.

• Fix in place with glass cloth tape (see figure 1) at 300mm intervals and additionallywhere necessary.

1.4.1 Straight Tracing

• Straight trace the pipe unless the design call for spiralling (see 1.4.2).• On horizontal pipes fix on lower quadrant as shown in figure 1 and not on bottom

of pipe.• Thermally insulate and weatherproof to specification.

Raychem Attachment Tapes

• GT-66 Fibreglass TapeGeneral purpose tape

• GS-54 Fibreglass TapeRecommended for use on stainless-steelsurfaces and lower temperature installationsas specified in Raychem product catalogue.

• AT-180 Aluminium TapeUse only if the design requires it. AT-180improves the heat transfer and increases thepower output of the heating cable. Attach theheating cable to the pipe as shown in figure 2.

1.4.2 Spiral Tracing

• Alternative spiralling methods are shown in figures 2a and 2b.• Only spiral heater on pipe when called for by design.

Figure 2a

• Heater cable length:- pipe length x spiral ratio.

• Refer to design spec for spiral ratio.Step 1 - Make starting loop as shownStep 2 - Grasp loop and wind around pipeStep 3 - Space evenly and attach pipe

• Thermally insulate and weatherproof tospecification.

Spiral Pitch Chart

Figure 2b

• Refer to design specification forspiral pitch.

• Mark the pipe at the spiral pitch oruse a simple length gauge.

• Fix the heater as installationprogresses.

• Thermally insulate and weatherproofto specification.

Example

• For pipe of 80mm NB (3” NPS)requiring 1.3m of cable permetre of pipe, pitch is 350mm.

NB(mm)

253240506580100150200

NPS(inches)

111/4

11/2

221/2

3468

1.1

25031035043052063080011801520

1.2

1702102403003604305608101050

1.3

140170190240290350440650840

1.4

110140160200240290370550710

1.5

100130140180210260330480620

Spiral Ratio(Metres of Heater per Metre of Pipe)

Glass tape(typical)

Tight on pipe Thermal Insulation(typical)

45O

(normal)

Pipe

Top

300mm

Pitch (in mm)

Figure 2

Figure 1

Pipe

Self-regulatingheater cable

ThermalInsulation

Glass tape(typical)

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1.5 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 Sections 1.3 and 1.6.

• Self-regulating cable can be cut to length without affecting the heat output per metre.

1.6 Typical Installation Details

• Typical installation details for fixing heater to pipe fittings are shown below and across.

General Notes:

• Trace pipe fittings as shown to allow easy maintenance.• Consult the design specification or Raychem product literature for the tracing

requirements for fittings and support.

1.6.1 Valve

• Refer to design specification for loop length.• Fix with glass cloth tape.• Thermally insulate and weatherproof to specification (including valve stem).

1.6.2 Elbow

• Fix heater to outside (long) radius of elbow.• Fix with glass cloth tape.• Thermally insulate and weatherproof to specification.

1.6.3 Flange

• Additional heating cable is2 times diameter of pipe.

• Fix with glass cloth tape.• Thermally insulate and

weatherproof to specification.

1.6.4 Pipe Bar Hanger

• Do not clamp heating cable withsupport. Heater must be over thesupport.

• No additional heating cable isrequired for bar or rod pipehangers.



1.6.5 Pipe Support Shoe



Heating Cable Installation Cont.

Pipe

See design recommendationfor specific heatercable length needed

Glass tape(typical)

Valve Body

Glass tape(typical)

This drawing shows the general installationmethod. The heating cable configurationwill vary for different valve shapes andheater cable lengths.

Glass tape(typical)

Self-regulatingheater cable

Figure 3

Figure 4

Self-regulatingheating cable

Glass tape(typical)

Pipe

Orifice plate

Figure 5

Glass tape(typical)

Sealer

Bar Hanger

Bar Hanger

Sealer



Pipe

Thermal Insulation

Weatherproofing

Figure 6


Side View

View From UnderSupport shoe

Glass tape(typical)

Pipe

Pipe3 times length of shoe

Figure 7

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InsulationThickness(mm)

10

20

25

30

40

50

80

ΔT(OC)

203040203040602030406080

1002030406080

100120140160180

2030406080

100120140160180

2030406080

100120140160180

2030406080

100120140160180

502

60

16.424.933.7

9.514.519.630.2

8.112.316.625.635.145.4

7.110.814.622.530.939.849.359.469.980.9

5.88.9

12.018.525.432.840.648.857.466.5

5.07.7

10.416.022.028.435.142.349.857.6

3.85.87.9

12.116.621.526.632.037.743.7

4011/2

48

13.620.727.9

8.012.216.525.5

6.910.414.121.829.938.6

6.19.2

12.519.226.434.142.250.859.869.2

5.07.7

10.416.021.928.335.142.249.757.5

4.46.79.1

14.019.124.730.636.843.450.2

3.45.27.0

10.814.819.123.628.433.438.7

3211/4

42

12.118.525.0

7.311.115.023.1

6.29.5

12.919.827.235.1

5.58.4

11.417.624.131.138.646.454.663.2

4.67.09.5

14.720.226.032.238.845.652.9

4.16.28.4

12.917.722.828.334.040.146.4

3.24.86.5

10.013.817.822.026.531.236.1

251

34

10.115.420.8

6.29.4

12.719.6

5.38.1

11.017.023.330.1

4.87.39.8

15.120.826.833.240.047.154.5

4.06.18.3

12.817.622.728.133.839.846.0

3.65.47.3

11.315.520.124.829.935.240.7

2.84.35.89.0

12.315.919.723.627.832.2

203/4

27

8.512.917.5

5.38.1

10.916.9

4.67.19.5

14.720.226.1

4.26.38.6

13.218.223.429.034.941.147.6

3.65.47.3

11.315.520.024.829.835.140.6

3.24.86.5

10.113.817.822.126.631.336.2

2.63.95.28.1

11.114.317.821.425.129.1

151/2

21

7.211.014.9

4.67.09.5

14.74.16.28.4

12.917.722.8

3.75.67.6

11.716.020.725.630.836.242.0

3.24.86.5

10.113.817.822.126.531.236.2

2.84.35.99.0

12.416.019.823.828.132.5

2.33.54.87.4

10.113.016.119.422.926.5

81/4

14

6.29.4

12.74.06.28.3

12.83.65.47.4

11.415.620.1

3.35.06.7

10.314.218.322.727.232.137.1

2.84.35.89.0

12.315.919.723.727.932.3

2.63.95.38.1

11.214.417.821.525.329.2

2.13.24.46.79.2

11.914.717.720.924.1

60024

610

139.7212.6287.474.6

113.4153.4236.560.792.4

124.9192.6264.5341.551.378.1

105.6162.9223.6288.7357.5430.1506.2586.239.460.081.1

125.1171.7221.7274.5330.2388.7450.132.248.966.2

102.1140.1180.9224.0269.4317.2367.221.132.143.567.092.0

118.8147.1176.9208.3241.2

50020

508

117.2178.3241.162.695.3

128.9198.751.177.7

105.1162.0222.4287.243.265.888.9

137.1188.3243.1301.0362.1426.3493.533.350.668.5

105.6144.9187.1231.7278.7328.1379.927.241.456.086.3

118.5153.0189.5227.9268.3310.718.027.437.057.178.3

101.2125.3150.7177.4205.4

45018

457

105.9161.1217.9

56.786.2

116.6179.7

46.270.395.1

146.7201.4260.0

39.259.680.6

124.3170.6220.3272.8328.1386.2447.1

30.245.962.195.8

131.5169.8210.3252.9297.7344.7

24.737.650.978.5

107.7139.1172.2207.2243.9282.4

16.425.033.852.171.592.3

114.3137.5161.9187.5

40016

406

94.6143.9194.6

50.777.1

104.3160.8

41.463.085.2

131.3180.3232.8

35.153.472.2

111.4152.9197.4244.4294.0346.1400.7

27.141.355.886.0

118.1152.4188.8227.1267.3309.5

22.333.945.870.696.9

125.1154.9186.4219.4254.0

14.922.630.647.164.783.5

103.4124.4146.4169.5

35014

356

83.3126.7171.3

44.768.092.0

141.836.555.675.2

115.9159.2205.5

31.047.263.898.4

135.1174.5216.1259.9306.0354.2

24.036.649.476.2

104.6135.1167.3201.2236.9274.3

19.830.140.762.786.1

111.1137.6165.5194.9225.6

13.320.227.342.157.874.692.4

111.2130.9151.5

30012

324

76.1115.8156.6

40.962.384.2

129.933.551.069.0

106.3146.0188.5

28.543.358.690.4

124.0160.2198.3238.6280.8325.2

22.133.645.570.196.2

124.2153.9185.1217.9252.2

18.227.737.557.879.3

102.4126.8152.5179.5207.9

12.318.725.339.053.569.185.5

102.9121.1140.3

25010

273

64.798.5

132.234.953.271.9

110.828.743.659.090.9

124.8161.1

24.437.150.277.4

106.3137.2169.9204.4240.6278.6

19.028.939.160.382.7

106.8132.3159.1187.3216.9

15.723.932.349.968.488.3

109.4131.6154.9179.4

10.716.322.034.046.660.274.589.6

105.5122.2

2008

219

52.680.0

108.228.543.458.790.523.535.748.374.5

102.3132.0

20.130.541.363.687.3

112.8139.6168.0197.7228.9

15.723.932.349.868.488.3

109.3131.5154.8179.3

13.119.926.941.456.873.490.9

109.3128.7149.0

9.013.718.528.639.250.662.775.488.8

102.8

1506

168

41.162.5

84.522.534.246.371.418.628.338.259.081.0

104.515.924.332.850.669.489.7

111.0133.5157.2182.0

12.619.125.939.954.870.887.6

105.4124.1143.7

10.516.021.733.445.959.273.388.2

103.9120.3

7.411.315.223.532.241.651.561.972.984.4

1004

114

28.843.859.216.024.433.050.913.420.327.542.458.275.211.617.623.836.650.365.080.496.8

113.9131.9

9.214.119.029.340.252.064.477.491.1

105.57.8

11.916.124.834.144.054.565.677.289.45.78.6

11.617.924.631.839.347.355.764.5

803

89

23.035.047.313.019.826.741.210.916.622.434.547.461.29.5

14.419.530.041.253.265.979.393.3

108.17.6

11.615.724.333.343.053.364.175.487.36.59.9

13.420.728.536.745.554.764.474.64.87.39.9

15.320.927.033.540.347.454.9

652

1/2

76

19.329.439.711.116.822.835.1

9.314.219.229.640.652.5

8.112.416.825.935.545.856.768.380.493.0

6.610.113.721.128.937.346.255.665.575.8

5.78.7

11.818.124.932.139.847.956.365.2

4.36.58.8

13.518.624.029.735.742.148.7

Pipe SizeNB (mm)NPS (inches)OD (mm)

• Pipe heat loss (Qs) is shown in watts per minute (W/m).• Heat loss calculation is based on metal pipes insulated with glass fibre and located

outdoors in a 8.9 m/s wind.• A 10% safety factor has been included.• For indoor applications multiply heat loss by 0.9.

Pipe Heat Loss

Pipe Insulation

Glass FibreMineral Wool (Rockwool)Mineral Fibre BlanketFoamed ElastomerRigid Cellular PolyurethaneCalcium Silicate BlockCellular GlassExpanded Perlite

1 W/mK = 0.86kcal/mhK

Insulation

1.01.061.201.170.671.501.611.50

Thermal Conductivity At10OC Mean Temp (W/mK)

0.0360.0380.0430.0420.0240.0540.0580.054

Insulation Factors Valve Type

GateButterflyBallGlobe

Heat Loss(Metre Equivalent)

1.30.70.81.2

Valve Heat Loss Factor

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General Information

Raychem self-regulating heaters are ideal for heat tracing plastic pipes. The self-regulatingfeature of Raychem cable enables the heater to vary its response to sensed temperaturesat each point along the circuit. This means the heater’s power output will not overheatthe pipe, even where overlapped.

Raychem BTV-CR and BTV-CT can be used safely and without over-heating on any ofthe common plastic pipe materials. These products have a tinned copper braid whichprovides the earth path in the case of an earth fault. Consult Cable Services regardingother applications and the use of other Auto-Trace products on plastic pipes.

Table 1The following table lists generally accepted maximumallowable temperature for various plastic pipe materials:

Caution:These are typical values. The temperature ratings ofplastic pipes depend upon operating pressure, so servicetemperature ratings may be lower (consult the pipemanufacturer’s literature).

Design

The thermal conductivity of plastics is much lower than that of carbon steel (approximately 150 times less). This lower thermal conductivity does not appreciablyaffect the heat loss from the system, but does affect the thermal environment aroundthe Auto-Trace heater. The increased resistance to heat transfer from the heater necessitates compensation of the heater’s power output.

Factors which affect the thermal output of Raychem heaters are the heater geometry,plastic pipe wall thickness, and the use of heat transfer aids, e.g. aluminium tape.

Extensive testing of Raychem products has determined the effect for these factors on heater power output. Power output adjustment factors for typical applications are shown in Table 2. These adjustment factors are applied to the power output for insulated steel pipes to give output for insulated plastic pipes.

ATE-180 aluminium tape may be used to increase the output of Raychem’s heaters onplastic pipes. The design may consider installation with glass cloth tape (not ATE-180)with ATE-180 over the Raychem heater, or with ATE-180 both under and over theheater. Power output adjustment factors for these alternatives are included in Table 2.

Table 2Power output adjustment factors (pipe wall thickness 6mm or less).

Approval authorities worldwide have permitted the installation of the braided versionsof Raychem products in hazardous areas without thermostatic controls.For specific approvals information, see the product data sheets or contact Cable Services.

**20 bars saturated steam (maximum cumulative exposure 1000 hours)

Heat Tracing Plastic Pipes With Self-Regulating Heaters

CatalogueNumber

3 BTV15 BTV18 BTV1

10 BTV110 QTV115 QTV120 QTV15 KTV-18 KTV-1

15 KTV-120 KTV-13 BTV25 BTV28 BTV2

10 BTV210 QTV215 QTV220 QTV24 XTV28 XTV2

12 XTV215 XTV220 XTV25 KTV-28 KTV-2

15 KTV-220 KTV-2

Maximum ExposureTemperaturesContinuous

65OC65OC65OC65OC

110OC110OC110OC150OC150OC150OC150OC65OC65OC65OC65OC

110OC110OC110OC120OC120OC120OC120OC120OC150OC150OC150OC150OC

MaximumCircuit Length

100m80m65m55m50m60m55m

115m90m65m55m

200m165m130m105m115m100m110m250m180m145m130m110m225m180m130m110m

NominalSupplyVoltage Vac

110110110110110110110110110110110230230230230230230230230230230230230230230230230

For TemperatureMaintenance Up To (OC) Intermittent

85OC85OC85OC85OC

135OC135OC135OC215OC **215OC **215OC **215OC **85OC85OC85OC85OC

135OC135OC135OC215OC **215OC **215OC **215OC **215OC **215OC **215OC **215OC **215OC **

MaximumCircuit Length

225m160m130m110m120m90m75m

200m150m120m160m or 80m100m or 50m90m or 40m60m

NominalSupplyVoltage Vac

230230230230230230230230230230230 or 110230 or 110230 or 110230

For TemperatureMaintenance Up To (OC) Power Off

250OC250OC250OC250OC200OC200OC200OC260OC260OC260OC260OC260OC260OC260OC

Chart Ratings (Industrial Heaters)Self Regulating Heaters

CatalogueNumber

5 VPL10 VPL15 VPL20 VPLIHT / 2 / 10-CTIHT / 2 / 20-CTIHT / 2 / 30-CTFHT / 2 / 10-CTFHT / 2 / 20-CTFHT / 2 / 30-CTFG 260 - 10FG 260 - 20FG 260 - 30FG 260 - 40

Non-Self Regulating Heaters

Ratings for other products (PYRO etc.) available on request.

230

125

200

200

65

110

150

65

110

120

150

Polyethylene 50OCPVC 60OCABS 70OCPolypropylene 70OCCPVC 80OCFRP 95OC

Without ATE-180 With ATE-180 aluminium With ATE-180 aluminiumaluminium tape tape* over heater tape* under & over heater

3BTV2 0.60 0.75 0.855BTV2 0.50 0.75 0.808BTV2 0.45 0.65 0.7510BTV2 0.45 0.70 0.75

*Applied longitudinally along heater length

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Application

Frost protection for pipework at max. 65OC operating temperature.FS-A-2X 10 W/m at 5OCFS-B-2X 26 W/m at 5OC

Frost protection for pipework at max. 95OC operating temperature and temperaturemaintenance for metal waste pipes with fatty waste water.FS-C-2X 31 W/m at 5OC

22 W/m at 40OC

Heater Selection

Frost protection up to -20OC.

Frost protection cables FS-A-2X and FS-B-2X are suitable for any pipe material (copper, threaded pipes, stainless steel, plastic pipes and composite metal pipes withoutrestriction).

For plastic pipes, please use aluminium adhesive tape ATE-180. The frost protectioncable should be covered along its entire length. Heat insulation λ = 0.035 W/(m.K) orbetter.

WINTERGARD

2008

FS-B-2X

FS-B-2X

FS-B-2X

(mm)(inches)

1506

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

1255

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

1084

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

FS-A-2X

763

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

FS-A-2X

FS-A-2X

6721/2

FS-B-2X

FS-B-2X

FS-B-2X

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

542

FS-B-2X

FS-B-2X

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

4211/2

FS-B-2X

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

351/4

FS-B-2X

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

281

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

223/4

FS-B-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

151/2

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

CableType

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

FS-A-2X

PipeDiameter

10mm

15mm

20mm

25mm

30mm

40mm

50mm

Insulation Thickness

Application

Optimum water temperature maintenance for single family houses, flats, offices, hotels,hospitals, convalescent homes, sports centres, etc.

Heating Cable Type HWAT-L HWAT-M HWAT-R

Maintenance Temperature Typically 45OC Typically 55OC Variable 50-70OC

Max. Exposure Temperature 65OC 65OC 80OC

Outer Jacket Colour Yellow Orange Red

Control unit HWAT-ECO - Compatible Essential

Timer QWT-04 Recommended - -

Legionella Prevention Possibility ofthermal legionellaprevention up tothe draw off points

Insulation Thickness

Pipe Size (mm) 15 22 28 35 42 54

Insulation Thickness (mm) 20 20 25 30 40 50

Ambient Temperature: 18OCThermal conductivity λ = 0.035 W/(m.K)For other thermal conductivity insulation materials, contact Cable Services.

HWAT(Hot Water Temperature Maintenance)Design Guide

Electrical Protection

• The total length of heating cable determines the number and size of the circuit breakers.

• Residual current device (rcd): 30 mA required.• The power connection must be carried out by an approved electrical installer.

Circuit-breaker to BSEN 60898 (type C): the maximum length of the heating circuit isbased on a minimum start-up temperature of +12OC, 230 VAC.

HWAT-L HWAT-M HWAT-R

10 A 80m 50m 50m

13 A 110m 65m 65m

16 A 140m 80m 80m

20 A 180m 100m 100m

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Troubleshooting Guide

Symptoms

A Overcurrent protection trips or blows

Probable Cause Corrective Action

1 Electrical fault at: 1 Investigate and remedy (see note 1):a damaged heaterb faulty splices or teesc end seald connection

2 Circuit oversized. 2 Resize or design within Electrical Protection Bulletin Guidelines. (If larger protection required, ensure supply cables are compatible).

3 Start-up below design temperature. 3 a Redesign for lower start-up temperatures.b Preheat pipes from alternative heat source to

within exposure temperature given inProduct Data Sheet.

c Energise part of circuit followed byreminder (e.g. in sequence).

4 Defective protection. 4 Replace.

Symptoms

B RCCB trips


1 Electrical fault at: 1 Investigate and remedy (see note 1):a damaged heaterb faulty splices or teesc end seald connection

2 Excessive moisture in: 2 Dry out and reseal or remake immediately.a junction boxes Perform insulation test (10 M Ω minimum).b splices or teesc end seal

3 High capacitance leakage due to excessive 3 Redesign within Electrical Protectionpower cable and Auto Trace lengths. Bulletin Guidelines.

4 Main borne disturbances. 3 Redesign within Guidelines availablefrom Raychem.

5 Defective RCCB. 5 Replace.

Symptoms

C No power output


1 Loss of supply voltage due to: 1 Restore supply voltage:a Overcurrent or residual current protection operating. a Following A and B across page.b Loose terminals in junction boxes. b Re-tighten terminals

NB. If excessive heating has occurred due to highresistance, replace terminals or crimps.

c Loss of supply cable continuity c Locate damage and repair.(e.g. open circuited from damage).

2 Control thermostat is connected in the 2 Re-connect to normally closed position. normally open position.

3 High resistance connection at: 3 Locate and remedy by:a Junction box terminals. a Re-tighten.b Splices or tees b Repair.

NB. If excessive heating has occurred due to highresistance, replace terminals or crimps.

Symptoms

D Low pipe temperature


1 Wet thermal insulation. 1 Remove and replace with dry insulation ofcorrect specification and ensure completeweatherproofing.

2 Design error. 2 a Check with competent authority fordesign conditions.

b Modify to meet Raychem recommendations.

3 Incorrect setting or operation of controls 3 Repair or reset to correct level of operation.e.g. thermostat.

4 Heater has been exposed to excessive 4 Replace.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.

4. If after 1, 2 and 3 above the fault has not been located, then either:

(a) Consult Cable Services for further assistance.

(b) Where local practices and conditions allow (e.g. non-hazardous areas) isolate one section of heater from another by cutting or

half and testing (e.g. Insulation Resistance) both halves until general area of damage is found. Remove insulation and expose fault.

Surface Sensing - OrdinaryTemp.Setting Exposure

Description Controller Temp. Sensor Voltage

ElectronicAT-TS-13 -5OC +15OC -20OC +160OC 230V

AT-TS-14 0OC +120OC -20OC +160OC 230V

RAYSTAT-CONTROL-10 0OC +150OC -40OC +150OC 230V

PanelmountTCONTROL-CONT-02 Configurable Depending

between -1999 on type ofand +9999 sensor used* 110 / 240V

TCON-CSD/07/0-100C Ranges 0OC +100OC Depending on typeof sensor used* 230V

TCON-CSD/07/0-200C Ranges 0OC +200OC Depending on typeof sensor used* 230V

MechanicalT-M-10-S/0+50C 0OC +50OC -40OC +60OC Upto 230V

T-M-10-S/0+200C 0OC +200OC -20OC +230OC Upto 230V

T-M-10-S/0+50+300C +50OC +300OC -20OC +345OC Upto 230V

MechanicalDual Sensing



T-M-20-S/0+50+300C +50OC +300OC -20OC +345OC Upto 230V

Surface Sensing - HazardousTemp.Setting Exposure


ElectronicRAYSTAT-EX-03 0OC +499OC -50OC +585OC 110 / 240V

MechanicalRAYSTAT-EX-02 -4OC +163OC -50OC +215OC 240V

MechanicalDual Sensing

T-M-20-S/+5+215C/EX +5OC +215OC -30OC +250OC Upto 400V

T-M-20-S/+70+350C/EX +70OC +350OC -30OC +380OC Upto 400V

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Rule of Thumb!

Useful Design Information

Calculating Heat Losses On Uninsulated Pipes

Indoors9.4 watts X surface area in metres squared X OC of Delta T.

Outdoors30 watts X surface area in metres squared X OC of Delta T.(assuming 20mph wind)

Add a least 10% margin for error(Delta T = required maintained temperature minus the minimum ambient temperature.)

NB: Heater output halved in free air.

Calculating Surface Areas

Cylindrical = π x D x HCircle = π R2

Sphere = 4 π R2

Hemisphere = 2 π R2

Cone = π x (R + r) x (R - r)2 + H2

(*) These systems can depending on the application be used with the following sensors: MONI-PT100-EXE and MONI-PT100-EXE-SENSOR (hazardous area), MONI-PT100-NH (ordinaryarea), MONI-PT100-4/20MA (intrinsic safe, TCONTROL-CONT-02 only).

DigiTrace Thermostats

Ambient Sensing - OrdinaryTemp.Setting Exposure


ElectronicAT-TS-13 -5OC +15OC 230V

RAYSTAT-ECO-10 0OC +30OC 230V

MechanicalT-M-10-S/0+50C 0OC +50OC Upto 230V

Ambient Sensing - HazardousTemp.Setting Exposure


ElectronicRAYSTAT-EX-04 0OC +49OC 110 / 240V

DigiTrace Thermostats

(Northwest) LtdRhosddu Industrial Estate,

Rhosrobin, Wrexham LL11 4YZ.

Tel: 01978 356948Fax: 01978 310438

Email: [email protected] 21753

(UK) LtdRhosddu Industrial Estate,

Rhosrobin, Wrexham LL11 4YZ.

Tel: 01978 340450Fax: 01978 311315


(Central) Ltd2 Windermere Street, Cobridge-Hanley,

Stoke-on-Trent ST1 5EG

Tel: 01782 274714Fax: 01782 280547

Email [email protected] 14517

(Liverpool) Ltd43 St. Johns Road, Liverpool L20 8AZ.

Tel: 0151 9339022Fax: 0151 9339765


RS 21752RS 21753RS 22195RS 14517

Documents

Trace Heating Guide - Cable Services · TRACE HEATING PRODUCTS 7 6 Self Regulating XTV Electric trace heating for process temperature maintenance applications up to 120OC which may