Trace Heating Guide - Cable Services

TraceHeatingGuide

TRACE HEATING PRODUCTSThermal ControlsElectric Trace HeatingFor frost protection and temperature maintenance.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 FrostopFor self regulating heating cable for domestic andcommercial freeze protection.Wintergard and Frostop heating cables are safeand reliable. Self regulating technology preventsoverheating and minimises energy consumption andparallel circuit configuration means cables can becut to length on site.Contact Cable Services with application requirementsfor a design recommendation and quotation.(See page 3 for our simple data input sheet).Thermal ControlsFloor HeatingFlexible, reliable and easy to install floor heating.The T2 floor heating product range is designed toprovide room heating from floor up, heating theroom much more evenly than traditional systems,and ensuring that the floor is the warmest placein the room.Contact Cable Services for a free design proposaland quotation.Self Regulating BTVElectric trace heating for frost protection inindustrial applications without steam cleaning.The BTV family of self regulating parallel circuitheating cables is used for frost protection of pipesand vessels. It can be used for process temperaturemaintenance up to 65 O C and has an unlimited T6rating for hazardous areas.Contact Cable Services with application details fora design recommendation and quotation.(See page 3 for our simple data input sheet).54HWAT PlusFor self regulating heating for hot watertemperature maintenance.Hot water temperature maintenance using HWATPlus 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.Self Regulating QTVRElectric trace heating for industrial processtemperature maintenance applications upto 110 O C, not subject to steam cleaning.The QTVR family of self regulating parallel circuitheating cables is used for process temperaturemaintenance of pipes and vessels in industrialenvironments. It can also be used for frost protectionon large diameter pipes and has a T4 rating forhazardous areas.Contact Cable Services with application details fora design recommendation and quotation.(See page 3 for our simple data input sheet).TRACE HEATING PRODUCTS

TRACE HEATING PRODUCTSThermal ControlsSelf Regulating XTVElectric trace heating for process temperaturemaintenance applications up to 120 O C which maybe 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 fora FREE design recommendation and quotation.(See page 3 for our simple data input sheet).Thermal ControlsConstant Wattage IHTIHT parallel circuit medium power constantoutput 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.Contact Cable Services with application details fora FREE design recommendation and quotation.(See page 3 for our simple data input sheet).7Self Regulating KTVElectric trace heating for process temperaturemaintenance applications up to 150 O C which maybe subject to steam cleaning.Constant Wattage FHTFHT constant wattage parallel circuit heatingcables for high power industrial applicationsincluding hazardous areas.6The KTV family of self regulating parallel circuitheating cables is used for industrial processtemperature maintenance of pipes and vessels,where there may be a requirement for a hightemperature exposure capability. KTV heaters arerated T3 and T2 for hazardous area applications.Contact Cable Services with application details fora FREE design recommendation and quotation.(See page 3 for our simple data input sheet).High TemperaturePower Limiting VPLElectric trace heating designed for hightemperature industrial applications up to250 O C 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 230 O C and can withstand routineexposure to 250 O C 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).FHT is designed for high temperature applications andcan provide process temperature maintenance up to150 O C and can withstand exposure up to 260 O C poweroff. The parallel construction allows it to be cut tolength on site and its round shape provides excellentflexibility during installation.Contact Cable Services with application details fora FREE design recommendation and quotation.(See page 3 for our simple data input sheet).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.Contact Cable Services with application details fora FREE design recommendation and quotation.(See page 3 for our simple data input sheet).TRACE HEATING PRODUCTS

TRACE HEATING PRODUCTS8Thermal ControlsVIAGARD SystemIce 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 detailsTraceTekLeak detection cables.Raychem also manufactures TRACETEK leak detectioncable. This cable is installed in sensitive areas wherethe consequence of an undetected flood could bedisastrous.Please contact the Cable Services sales office forfurther details.GENERAL INFORMATIONThis installation information is for Raychem Self-Regulating Heater Systems on thermallyinsulated pipes only. For information regarding other applications contact Cable Services.WarningAs 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 SelectionCheck 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 Installation1.1 Heating Cable Storage• Store the heating cable in a clean, dry place.• Temperature range: -40 O C to +60 O C.• Protect the heating cable from mechanical damage.1.2 Pre-Installation ChecksCheck 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 resistancetest 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 theheater. Smooth off or cover with layers of glass cloth tape or aluminium foil tape.9INDUSTRIAL TRACE HEATING GUIDELINES

INDUSTRIAL TRACE HEATING GUIDELINES12Heating Cable Installation Cont.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 tracingrequirements 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).PipeValve BodySee design recommendationfor specific heatercable length needed1.6.2 ElbowGlass tape(typical)Figure 3• Fix heater to outside (long) radius of elbow.• Fix with glass cloth tape.• Thermally insulate and weatherproof to specification.Figure 4Self-regulatingheater cableGlass tape(typical)Glass tape(typical)This drawing shows the general installationmethod. The heating cable configurationwill vary for different valve shapes andheater cable lengths.PipeGlass tape(typical)Self-regulatingheater cableThermalInsulation1.6.3 Flange• Additional heating cable is2 times diameter of pipe.• Fix with glass cloth tape.• Thermally insulate andweatherproof 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.• Fix with glass cloth tape.• Thermally insulate andweatherproof to specification.1.6.5 Pipe Support Shoe• Fix with glass cloth tape.• Thermally insulate andweatherproof to specification.PipeGlass tape(typical)Self-regulatingheating cableFigure 5SealerGlass tape(typical)Figure 6Side ViewBar HangerOrifice plateWeatherproofingPipeSelf-regulatingheating cableSupport shoeView From UnderSelf-regulatingheating cableFigure 7Glass tape(typical)Thermal Insulation3 times length of shoeBar HangerSealerPipePipeSelf-regulatingheating cable13INDUSTRIAL TRACE HEATING GUIDELINES

INDUSTRIAL TRACE HEATING GUIDELINES15INDUSTRIAL TRACE HEATING GUIDELINES14InsulationThickness(mm)10202530405080ΔT( O C)20304020304060203040608010020304060801001201401601802030406080100120140160180203040608010012014016018020304060801001201401601805026016.424.933.79.514.519.630.28.112.316.625.635.145.47.110.814.622.530.939.849.359.469.980.95.88.912.018.525.432.840.648.857.466.55.07.710.416.022.028.435.142.349.857.63.85.87.912.116.621.526.632.037.743.7401 1 /24813.620.727.98.012.216.525.56.910.414.121.829.938.66.19.212.519.226.434.142.250.859.869.25.07.710.416.021.928.335.142.249.757.54.46.79.114.019.124.730.636.843.450.23.45.27.010.814.819.123.628.433.438.7321 1 /44212.118.525.07.311.115.023.16.29.512.919.827.235.15.58.411.417.624.131.138.646.454.663.24.67.09.514.720.226.032.238.845.652.94.16.28.412.917.722.828.334.040.146.43.24.86.510.013.817.822.026.531.236.12513410.115.420.86.29.412.719.65.38.111.017.023.330.14.87.39.815.120.826.833.240.047.154.54.06.18.312.817.622.728.133.839.846.03.65.47.311.315.520.124.829.935.240.72.84.35.89.012.315.919.723.627.832.2203 /4278.512.917.55.38.110.916.94.67.19.514.720.226.14.26.38.613.218.223.429.034.941.147.63.65.47.311.315.520.024.829.835.140.63.24.86.510.113.817.822.126.631.336.22.63.95.28.111.114.317.821.425.129.1151 /2217.211.014.94.67.09.514.74.16.28.412.917.722.83.75.67.611.716.020.725.630.836.242.03.24.86.510.113.817.822.126.531.236.22.84.35.99.012.416.019.823.828.132.52.33.54.87.410.113.016.119.422.926.581 /4146.29.412.74.06.28.312.83.65.47.411.415.620.13.35.06.710.314.218.322.727.232.137.12.84.35.89.012.315.919.723.727.932.32.63.95.38.111.214.417.821.525.329.22.13.24.46.79.211.914.717.720.924.160024610139.7212.6287.474.6113.4153.4236.560.792.4124.9192.6264.5341.551.378.1105.6162.9223.6288.7357.5430.1506.2586.239.460.081.1125.1171.7221.7274.5330.2388.7450.132.248.966.2102.1140.1180.9224.0269.4317.2367.221.132.143.567.092.0118.8147.1176.9208.3241.250020508117.2178.3241.162.695.3128.9198.751.177.7105.1162.0222.4287.243.265.888.9137.1188.3243.1301.0362.1426.3493.533.350.668.5105.6144.9187.1231.7278.7328.1379.927.241.456.086.3118.5153.0189.5227.9268.3310.718.027.437.057.178.3101.2125.3150.7177.4205.445018457105.9161.1217.956.786.2116.6179.746.270.395.1146.7201.4260.039.259.680.6124.3170.6220.3272.8328.1386.2447.130.245.962.195.8131.5169.8210.3252.9297.7344.724.737.650.978.5107.7139.1172.2207.2243.9282.416.425.033.852.171.592.3114.3137.5161.9187.54001640694.6143.9194.650.777.1104.3160.841.463.085.2131.3180.3232.835.153.472.2111.4152.9197.4244.4294.0346.1400.727.141.355.886.0118.1152.4188.8227.1267.3309.522.333.945.870.696.9125.1154.9186.4219.4254.014.922.630.647.164.783.5103.4124.4146.4169.53501435683.3126.7171.344.768.092.0141.836.555.675.2115.9159.2205.531.047.263.898.4135.1174.5216.1259.9306.0354.224.036.649.476.2104.6135.1167.3201.2236.9274.319.830.140.762.786.1111.1137.6165.5194.9225.613.320.227.342.157.874.692.4111.2130.9151.53001232476.1115.8156.640.962.384.2129.933.551.069.0106.3146.0188.528.543.358.690.4124.0160.2198.3238.6280.8325.222.133.645.570.196.2124.2153.9185.1217.9252.218.227.737.557.879.3102.4126.8152.5179.5207.912.318.725.339.053.569.185.5102.9121.1140.32501027364.798.5132.234.953.271.9110.828.743.659.090.9124.8161.124.437.150.277.4106.3137.2169.9204.4240.6278.619.028.939.160.382.7106.8132.3159.1187.3216.915.723.932.349.968.488.3109.4131.6154.9179.410.716.322.034.046.660.274.589.6105.5122.2200821952.680.0108.228.543.458.790.523.535.748.374.5102.3132.020.130.541.363.687.3112.8139.6168.0197.7228.915.723.932.349.868.488.3109.3131.5154.8179.313.119.926.941.456.873.490.9109.3128.7149.09.013.718.528.639.250.662.775.488.8102.8150616841.162.584.522.534.246.371.418.628.338.259.081.0104.515.924.332.850.669.489.7111.0133.5157.2182.012.619.125.939.954.870.887.6105.4124.1143.710.516.021.733.445.959.273.388.2103.9120.37.411.315.223.532.241.651.561.972.984.4100411428.843.859.216.024.433.050.913.420.327.542.458.275.211.617.623.836.650.365.080.496.8113.9131.99.214.119.029.340.252.064.477.491.1105.57.811.916.124.834.144.054.565.677.289.45.78.611.617.924.631.839.347.355.764.58038923.035.047.313.019.826.741.210.916.622.434.547.461.29.514.419.530.041.253.265.979.393.3108.17.611.615.724.333.343.053.364.175.487.36.59.913.420.728.536.745.554.764.474.64.87.39.915.320.927.033.540.347.454.9652 1 /27619.329.439.711.116.822.835.19.314.219.229.640.652.58.112.416.825.935.545.856.768.380.493.06.610.113.721.128.937.346.255.665.575.85.78.711.818.124.932.139.847.956.365.24.36.58.813.518.624.029.735.742.148.7Pipe SizeNB (mm)NPS (inches)OD (mm)• Pipe heat loss (Q s ) is shown in watts per minute (W/m).• Heat loss calculation is based on metal pipes insulated with glass fibre and locatedoutdoors 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 LossPipe InsulationGlass FibreMineral Wool (Rockwool)Mineral Fibre BlanketFoamed ElastomerRigid Cellular PolyurethaneCalcium Silicate BlockCellular GlassExpanded Perlite1 W/mK = 0.86kcal/mhKInsulation1.01.061.201.170.671.501.611.50Thermal Conductivity At10 O C Mean Temp (W/mK)0.0360.0380.0430.0420.0240.0540.0580.054Insulation FactorsValve TypeGateButterflyBallGlobeHeat Loss(Metre Equivalent)1.30.70.81.2Valve Heat Loss Factor

INDUSTRIAL TRACE HEATING GUIDELINES16Heat Tracing Plastic Pipes WithSelf-Regulating HeatersGeneral InformationRaychem 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).DesignThe 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 heaternecessitates 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 factorson heater power output. Power output adjustment factors for typical applicationsare shown in Table 2. These adjustment factors are applied to the power output forinsulated 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).PolyethylenePVCABSPolypropyleneCPVCFRP50 O C60 O C70 O C70 O C80 O C95 O CWithout ATE-180 With ATE-180 aluminium With ATE-180 aluminiumaluminium tape tape* over heater tape* under & over heater3BTV2 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 lengthChart Ratings (Industrial Heaters)Self Regulating HeatersCatalogueNumberFor TemperatureMaintenance Up To ( O C)NominalSupplyVoltage Vac3 BTV11105 BTV1110658 BTV111010 BTV111010 QTV111015 QTV111011020 QTV11105 KTV-11108 KTV-111015015 KTV-111020 KTV-11103 BTV22305 BTV2230658 BTV223010 BTV223010 QTV223015 QTV211023020 QTV22304 XTV22308 XTV223012 XTV212023015 XTV223020 XTV22305 KTV-22308 KTV-223015015 KTV-223020 KTV-2230**20 bars saturated steam (maximum cumulative exposure 1000 hours)MaximumCircuit Length100m80m65m55m50m60m55m115m90m65m55m200m165m130m105m115m100m110m250m180m145m130m110m225m180m130m110mMaximum ExposureTemperaturesContinuous Intermittent65 O C65 O C65 O C65 O C110 O C110 O C110 O C150 O C150 O C150 O C150 O C65 O C65 O C65 O C65 O C110 O C110 O C110 O C120 O C120 O C120 O C120 O C120 O C150 O C150 O C150 O C150 O C85 O C85 O C85 O C85 O C135 O C135 O C135 O C215 O C **215 O C **215 O C **215 O C **85 O C85 O C85 O C85 O C135 O C135 O C135 O C215 O C **215 O C **215 O C **215 O C **215 O C **215 O C **215 O C **215 O C **215 O C **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.Non-Self Regulating HeatersCatalogueNumber5 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 - 40For TemperatureMaintenance Up To ( O C)125230200200NominalSupplyVoltage Vac230230230230230230230230230230230 or 110230 or 110230 or 110230MaximumCircuit Length225m160m130m110m120m90m75m200m150m120m160m or 80m100m or 50m90m or 40m60mRatings for other products (PYRO etc.) available on request.Power Off250 O C250 O C250 O C250 O C200 O C200 O C200 O C260 O C260 O C260 O C260 O C260 O C260 O C260 O C17INDUSTRIAL TRACE HEATING GUIDELINES

DOMESTIC / COMMERCIAL TRACE HEATING GUIDELINES18ApplicationFrost protection for pipework at max. 65 O C operating temperature.FS-A-2X10 W/m at 5 O CFS-B-2X26 W/m at 5 O CFrost protection for pipework at max. 95 O C operating temperature and temperaturemaintenance for metal waste pipes with fatty waste water.FS-C-2X31 W/m at 5 O C22 W/m at 40 O CHeater SelectionFrost protection up to -20 O C.CableTypeFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XPipeDiameter10mm15mm20mm25mm30mm40mm50mmWINTERGARDInsulation Thickness151/2FS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2X223/4FS-B-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2X281FS-B-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2X351/4FS-B-2XFS-B-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2X421 1 /2FS-B-2XFS-B-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2XFrost 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.542FS-B-2XFS-B-2XFS-B-2XFS-A-2XFS-A-2XFS-A-2XFS-A-2X672 1 /2FS-B-2XFS-B-2XFS-B-2XFS-B-2XFS-A-2XFS-A-2XFS-A-2X763FS-B-2XFS-B-2XFS-B-2XFS-B-2XFS-A-2XFS-A-2X1084FS-B-2XFS-B-2XFS-B-2XFS-B-2XFS-B-2XFS-A-2X1255FS-B-2XFS-B-2XFS-B-2XFS-B-2XFS-B-2X1506FS-B-2XFS-B-2XFS-B-2XFS-B-2X2008FS-B-2XFS-B-2XFS-B-2X(mm)(inches)HWAT(Hot Water Temperature Maintenance)Design GuideApplicationOptimum water temperature maintenance for single family houses, flats, offices, hotels,hospitals, convalescent homes, sports centres, etc.Heating Cable Type HWAT-L HWAT-M HWAT-RMaintenance Temperature Typically 45 O C Typically 55 O C Variable 50-70 O CMax. Exposure Temperature 65 O C 65 O C 80 O COuter Jacket Colour Yellow Orange RedControl unit HWAT-ECO - Compatible EssentialTimer QWT-04 Recommended - -Legionella PreventionInsulation ThicknessPipe Size (mm) 15 22 28 35 42 54Insulation Thickness (mm) 20 20 25 30 40 50Ambient Temperature: 18 O CThermal conductivity λ = 0.035 W/(m.K)For other thermal conductivity insulation materials, contact Cable Services.Electrical ProtectionPossibility ofthermal legionellaprevention up tothe draw off points• The total length of heating cable determines the number and size of the circuitbreakers.• 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 +12 O C, 230 VAC.HWAT-L HWAT-M HWAT-R10 A 80m 50m 50m13 A 110m 65m 65m16 A 140m 80m 80m20 A 180m 100m 100m19DOMESTIC / COMMERCIAL TRACE HEATING GUIDELINES

TRACE HEATING TROUBLESHOOTINGTroubleshooting GuideSymptomsA Overcurrent protection trips or blowsProbable CauseCorrective Action1 Electrical fault at: 1 Investigate and remedy (see note 1):a damaged heaterb faulty splices or teesc end seald connection2 Circuit oversized. 2 Resize or design within Electrical ProtectionBulletin 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 towithin exposure temperature given inProduct Data Sheet.c Energise part of circuit followed byreminder (e.g. in sequence).4 Defective protection. 4 Replace.SymptomsSymptomsC No power outputProbable CauseCorrective Action1 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 terminalsNB. 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.Symptoms21BRCCB tripsDLow pipe temperature20Probable CauseCorrective Action1 Electrical fault at: 1 Investigate and remedy (see note 1):a damaged heaterb faulty splices or teesc end seald connection2 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 seal3 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.Probable CauseCorrective Action1 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 orhalf and testing (e.g. Insulation Resistance) both halves until general area of damage is found. Remove insulation and expose fault.TRACE HEATING TROUBLESHOOTING

TRACE HEATING THERMOSTATS22DigiTrace ThermostatsSurface Sensing - OrdinaryTemp.Setting ExposureDescription Controller Temp. Sensor VoltageElectronicAT-TS-13 -5 O C +15 O C -20 O C +160 O C 230VAT-TS-14 0 O C +120 O C -20 O C +160 O C 230VRAYSTAT-CONTROL-10 0 O C +150 O C -40 O C +150 O C 230VPanelmountTCONTROL-CONT-02 Configurable Dependingbetween -1999 on type ofand +9999 sensor used* 110 / 240VTCON-CSD/07/0-100C Ranges 0 O C +100 O C Depending on typeof sensor used* 230VTCON-CSD/07/0-200C Ranges 0 O C +200 O C Depending on typeof sensor used* 230VMechanicalSurface Sensing - HazardousT-M-10-S/0+50C 0 O C +50 O C -40 O C +60 O C Upto 230VT-M-10-S/0+200C 0 O C +200 O C -20 O C +230 O C Upto 230VT-M-10-S/0+50+300C +50 O C +300 O C -20 O C +345 O C Upto 230VMechanicalDual SensingT-M-20-S/0+50C 0 O C +50 O C -40 O C +60 O C Upto 230VT-M-20-S/0+200C 0 O C +200 O C -20 O C +230 O C Upto 230VT-M-20-S/0+50+300C +50 O C +300 O C -20 O C +345 O C Upto 230VTemp.Setting ExposureDescription Controller Temp. Sensor VoltageElectronicRAYSTAT-EX-03 0 O C +499 O C -50 O C +585 O C 110 / 240VMechanicalRAYSTAT-EX-02 -4 O C +163 O C -50 O C +215 O C 240VMechanicalDual SensingT-M-20-S/+5+215C/EX +5 O C +215 O C -30 O C +250 O C Upto 400VT-M-20-S/+70+350C/EX +70 O C +350 O C -30 O C +380 O C Upto 400V(*) 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).Ambient Sensing - OrdinaryRule of Thumb!Useful Design InformationCalculating Heat Losses On Uninsulated PipesIndoors9.4 watts X surface area in metres squared X O C of Delta T.Outdoors30 watts X surface area in metres squared X O C 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 AreasDigiTrace ThermostatsTemp.Setting ExposureDescription Controller Temp. Sensor VoltageElectronicAmbient Sensing - HazardousAT-TS-13 -5 O C +15 O C 230VRAYSTAT-ECO-10 0 O C +30 O C 230VMechanicalT-M-10-S/0+50C 0 O C +50 O C Upto 230VTemp.Setting ExposureDescription Controller Temp. Sensor VoltageElectronicRAYSTAT-EX-04 0 O C +49 O C 110 / 240VCylindrical = π x D x HCircle = π R 2Sphere = 4 π R 2Hemisphere = 2 π R 2Cone = π x (R + r) x (R - r) 2 + H 223TRACE HEATING THERMOSTATS / RULE OF THUMB

RS 21752RS 21753RS 22195RS 14517(Northwest) LtdRhosddu Industrial Estate,Rhosrobin, Wrexham LL11 4YZ.Tel: 01978 356948Fax: 01978 310438Email: nw@cableservices.co.ukRS 21753(UK) LtdRhosddu Industrial Estate,Rhosrobin, Wrexham LL11 4YZ.Tel: 01978 340450Fax: 01978 311315Email: uk@cableservices.co.ukRS 21752(Central) Ltd2 Windermere Street, Cobridge-Hanley,Stoke-on-Trent ST1 5EGTel: 01782 274714Fax: 01782 280547Email central@cableservices.co.ukRS 14517(Liverpool) Ltd43 St. Johns Road, Liverpool L20 8AZ.Tel: 0151 9339022Fax: 0151 9339765Email: lpool@cableservices.co.ukRS 22195