Selection guide for self-regulating heat-tracing systems

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Selection guide for self-regulating heat-tracing systems

Selection guide for self-regulatingheat-tracing systems


We manage the heat you need...... with easy project design1>>2>>Follow this design guideto get to the right solution for your application. This paper guide offersthe benefit that it is fast and easy to use at any location where you mayneed it. First select the correct heating cable, then take care of theelectrical design and select the components and accessories tocomplete your heat-tracing system.Or use our software design toolsTraceCalc Net or TraceCalc Pro to generate a complete bill of materials,design summary and line list for your heat-tracing system. Both offer the possibilityto do designs for use in hazardous or non-hazardous areas and for frost protection ortemperature maintenance. With TraceCalc Net selecting the appropriate industrialpipe heat-tracing products is easy.The simple 3-step design process consists of:1. Select your heat-tracing design2. Enter the design data3. Get a bill of materials and request a quotationRegister for this online design tool at:www.tycothermal.com/TraceCalc/For heat-tracing in industrial applications, TraceCalc Pro providesdesign calculations such as pipe heat loss, number of circuits, electricalloads and maximum temperatures, automated heating cable andcomponent selection, recommendations for control and monitoring selection,and much more.It provides easy-to-use standard reports and last but not least, its powerful featureshelp you obtain the best heat-tracing solution for your particular project.With TraceCalc Pro, Tyco Thermal Controls provides you with an unprecedenteddesign tool giving you an optimal heat-tracing solution.Please contact your Tyco Thermal Controls representative for moreinformation.3>>Or let us do the design for youSimply complete the project information sheet provided at theend of this guide and email or fax it back to your Tyco Thermal Controlsrepresentative who will quickly provide you with a most appropriate design,a bill of materials and pricing.DOC-565 Rev.2 03/11


We manage the heat you need...... with a‘high performance’heat-tracing systemOur Raychem self-regulatingheat-tracing system is …… Super Safe… Cost Saving• Raychem self-regulating heat-tracingcables are certified for unconditionalT-rating in accordance with EuropeanStandard EN 60079-30-1. The surfacetemperature of the heating cable willnever exceed its T-class temperature.• The self-regulating principle ensuresthat the cable senses overlaps. It regulatesits heat accordingly and preventsany heat build-up or burn out.Furthermore, complex shapes likevalves, flanges or pipe supports areeasily traced with this system.• The cable is easy to tee, splice, installand repair. No special skills are required,resulting in reduced installationtime.• Due to its self-regulating principle, thissystem saves energy and thus operationalcosts.• The system requires a minimum ofmaintenance and is fully resistant to allpipe maintenance procedures.• To easily accommodate designchanges on site, the cable can becut-to-length when being installed.km cab500.00DOC-565 Rev.2 03/11


RSpacerCopper conductorSelf-regulatingconductive fibreFluoropolymer electricalinsulationTinned copper braidFluoropolymerouter jacketFiber construction… ReliableCopper conductorSelf-regulatingconductive coreElectrical insulationTinned copper braidFluoropolymerouter jacket(for -CT version)• Toughness is a major attribute of selfregulatingheat-tracing cables. An outerjacket of fluoropolymer offers mechanicalstrength as well as chemicalresistance. Both XTV and KTV typeheating cables have a unique fiberconstruction and are manufacturedusing high performance polymers.• The cable compensates for variationsin heat loss and voltage. It can be finetunedto control your pipe temperatureto a tolerance of 3°C by installing apipe sensor and feeding the input to acontrol unit.Monolithic construction• Even variations in ambient temperatureare automatically compensated for bythe self-regulating heating cable.• Our company can build on more than30 years of experience in theheat-tracing business.• With Tyco Thermal Controls, customerscan rely on a company that has shippedover a billion feet (> 300.000 km) ofself-regulating heat-tracing cables.le sold0Cold Pipe: In response to cold,the core or fiber contractsmicroscopically opening upelectrical paths.Warm Pipe: In response towarmth, the core or fiber beginsto expand microscopicallydisrupting the electrical paths.Hot Pipe: The core or fiberexpands enough to disruptalmost all of the electrical paths.DOC-565 Rev.2 03/11


Heat-Tracing Design GuideHow to select and designthe heat-tracing system for pipesThis Design Guide outlines a simple procedure for designing and selecting a completeheat-tracing system using BTV, QTVR, XTV or KTV heating cables.By following the design steps in the 3 sections, a bill of materials can be easily producedwhich includes the heating cable type, length, components and accessoriesneeded to install the heat-tracing system correctly.1.0 Heating cable selection 62.0 Electrical design 113.0 Components and accessories selection 13InstallationTyco Thermal Controls heat-tracing systems must be installed following Tyco ThermalControls guidelines. Contact your Tyco Thermal Controls representative for a copy ofthe installation manual. All components are supplied with easy-to-follow instructions.Additional informationFull technical information on components and heating cables can be found in ourTechnical Databook. Combined with the installation instructions this supplements theinformation in this guide. These documents are available from your local Tyco ThermalControls representative and from the Tyco Thermal Controls website(www.tycothermal.com).1.0 Heating cable selectionHeating Cable Selection1. Determine heat lossTo select the correct heating cable determine• Pipe or tubing diameter• Thermal insulation thickness• T m: Maintain Temperature (desired fluid temperature)2. Select heating cablefamily3. Select heating cable4. Determine heatingcable lengthThermal insulation thicknessPipe or tubingdiameter+20+100-10-20Minimum ambienttemperature1007550250MaintaintemperatureT mExample:Fluid: Process liquid, steam-cleanedLine size: NB 50 mmInsulation thickness: 50 mmT m: 50°C6 DOC-565 Rev.2 03/11


Heating Cable Selection1. Determine heat lossStep 1.1Table 1Determine heat lossHeat Loss Table2. Select heating cablefamily3. Select heating cable4. Determine heatingcable lengthThe table is based on the following parameters:• Mineral wool insulation• Minimum expected ambient temperature: –20°C• Pipes located outdoors• Steel pipes• • Safety factor 10%For other configurations (dimensions, temperatures, etc.), please use TraceCalc Proor TraceCalc Net software or consult your Tyco Thermal Controls representative.1. Select the pipe diameter and insulation thickness Example: NB 50 mm,2. Select the desired maintain temperature 50 mm insulation3. Note the heat loss result thicknessT m: 50°C18.8 W/mDN= ∅ pipe (NB)Insulationthickness (mm)Maintain temperature (°C)5 10 20 30 40 50 608 25 3.9 4.7 6.4 8.1 9.9 11.8 13.730 3.5 4.3 5.8 7.5 9.1 10.8 12.640 3.1 3.8 5.1 6.5 8.0 9.5 11.015 25 4.9 6.0 8.2 10.4 12.7 15.1 17.630 4.5 5.4 7.4 9.4 11.5 13.7 15.940 3.9 4.7 6.4 8.1 9.9 11.8 13.720 25 5.7 6.9 9.4 11.9 14.6 17.4 20.230 5.1 6.2 8.4 10.7 13.1 15.6 18.140 4.4 5.3 7.2 9.2 11.2 13.3 15.525 25 6.6 7.9 10.8 13.8 16.9 20.0 23.330 5.9 7.1 9.6 12.3 15.0 17.9 20.840 4.9 6.0 8.1 10.4 12.7 15.1 17.532 25 7.6 9.3 12.6 16.1 19.7 23.3 27.130 6.8 8.2 11.2 14.2 17.4 20.7 24.140 5.7 6.9 9.3 11.9 14.6 17.3 20.140 25 8.4 10.2 13.8 17.6 21.5 25.6 29.730 7.4 9.0 12.2 15.5 19.0 22.6 26.240 6.1 7.4 10.1 12.9 15.8 18.7 21.850 30 8.6 10.5 14.2 18.2 22.2 26.4 30.640 7.1 8.6 11.7 14.9 18.2 21.7 25.250 6.1 7.5 10.1 12.9 15.8 18.821.865 30 10.2 12.4 16.9 21.5 26.4 31.3 36.440 8.3 10.1 13.7 17.5 21.4 25.4 29.650 7.2 8.7 11.8 15.0 18.4 21.8 25.480 40 9.3 11.3 15.4 19.6 24.0 28.5 33.150 8.0 9.7 13.1 16.7 20.5 24.3 28.380 5.9 7.1 9.7 12.3 15.1 17.9 20.8100 50 9.5 11.6 15.7 20.1 24.5 29.1 33.980 6.9 8.3 11.3 14.5 17.7 21.0 24.4100 6.0 7.2 9.8 12.5 15.3 18.2 21.2150 50 12.8 15.6 21.2 27.0 33.0 39.2 45.680 9.0 10.9 14.9 18.9 23.2 27.5 32.0100 7.7 9.3 12.7 16.2 19.8 23.5 27.3DOC-565 Rev.2 03/117


Heating Cable Selection1. Determine heat loss2. Select heating cablefamily3. Select heating cable4. Determine heatingcable lengthStep 1.2Example:Select heating cable family• Verify that maximum exposure temperatures of heating cable are sufficient• Select correct heating cable according to temperature classificationSteam-cleaned: System is cleaned for 6 hours per year using 20 bar saturated steam (215°C)Normal operating temperature is 50°CTemperature classification is T3Correct family is XTV2-CT-T3Cable typeTemperatureclassificationMax. exposure temperaturescontinuousintermittent(1000 hourscumulated)BTV2-CT T6 65°C 85°CQTVR2-CT T4 110°C 110°CXTV2-CT-T3 T3 120°C 215°C20XTV2-CT-T2 T2 120°C 215°CKTV2-CT T2 150°C 215°CHeating Cable Selection1. Determine heat loss2. Select heating cablefamily3. Select heating cable4. Determine heatingcable lengthStep 1.3Select heating cable• Select graph below based on the heating cable family• Draw a vertical line at the maintain temperature• Draw a horizontal line for the heat loss• Select nearest cable above crossover BTV2-CT of these two linesBTV2-CTABCD10BTV2-CT8BTV2-CT5BTV2-CT3BTV2-CT40W/m30AB20C10DQTVR2-CTA 20QTVR2-CTB 15QTVR2-CTC 10QTVR2-CT80W/m7060504030200 10 20 30 40 50 60 70QTVR2-CTPipe temperature (°C)ABC1 00 20 40 60 80 100 120Pipe temperature (°C)8 DOC-565 Rev.2 03/11


XTV2-CT-T80XTV2-CT-T* (*=3 or 2)A 20XTV2-CT-T270B 15XTV2-CT-T3 W/mC 12XTV2-CT-T360D 8XTV2-CT-T3E 4XTV2-CT-T35040302010ABCDE0 20 40 60 80 100 120Pipe temperature (°C)KTV2-CTA 20KTV2-CTB 15KTV2-CTC 8KTV2-CTD 5KTV2-CT80W/m70605040KTV2-CTAB302010CD0 20 40 60 80 100 120 140 160Pipe temperature (°C)Example:XTV graphMaintain temperature = 50°CHeat loss = 18.8 W/mNearest cable above crossoveris D = 8XTV2-CT-T380706050ABA 20XTV2-CT-T2B 15XTV2-CT-T3C 12XTV2-CT-T3D 8XTV2-CT-T3E 4XTV2-CT-T340C18.8 W/m heat loss302010DE0 20 40 60 80 100 12050°C maintainDOC-565 Rev.2 03/119


Step 1.4Determine heating cable lengthHeating Cable Selection1. Determine heat loss2. Select heating cablefamily3. Select heating cable4. Determine heatingcable lengthDetermine the total length of the heating cable by combining lengths from each componentin the piping system.For the pipingCalculate the amount of heating cable required for the pipe length. In the case of astraight heating cable run, this quantity is equal to the total length of the piping.Add at least one metre to allow for the entry into a junction box and the end seal.Add a heating cable length of 5-10% for bends, flanges, elbows etc.For each valveAdd the following heating cable lengths:Valve typeHeating cable length (m) per valveGate 1.0Butterfly 0.4Ball 0.5Globe 0.9Pipe supportsAdd the following heating cable lengths:Pipe size (mm) Support Type Heating cable length (m) per support8 - 25 Pipe hangers 032 - 50 Small shoe (100 mm x 5 mm) 1.065 - 150 Medium shoe (150 mm x 8 mm) 2.0Other fittings and fixturesConsult your local Tyco Thermal Controls representative.Example: Heating cable length =Pipe: 30 m =Junction Box entry + end seal =Flanges: 5% =Valves: 3 ball valves x 0.5 =Supports: 5 small shoes x 1 =Total length of 8XTV2-CT-T3 =30.0 m1.0 m1.5 m1.5 m5.0 m39.0 m10 DOC-565 Rev.2 03/11


2.0 Electrical DesignElectrical design1. Determine minimumpipe start-uptemperature °C2. Select protectionratingAll Raychem heating cables must be installed with electrical protection in accordancewith local codes and practices.Circuit definitionFor ease of system design and use, only one type of heating cable should be connectedin each circuit.Each heat-tracing circuit should have its own electrical protection.A circuit may be composed of several branches (see figure below) but the sum of allheating cable lengths should not exceed the maximum circuit length determined insection 2.2.Power Line 1Line 3Line 2Example:Line 1 + Line 2 + Line 3 ≤ Maximum Circuit lengthElectrical protection sizingRaychem heating cables are self-regulating: power output and current draw decreaseas temperature increases. This current draw must be co-ordinated with the electricalprotection. Table 2 on page 12 shows maximum circuit lengths for use with commonlyavailable protection devices (Type C to EN 60898 circuit breaker) and applies forRaychem heating cables installed on thermally insulated surfaces without the use ofheat transfer aids. The table was generated in accordance with European practices forheating cables powered at 230 Vac.For other supply voltages, applications, protection devices, start-up temperatures orproducts, consult your Tyco Thermal Controls representative.Earth leakage protectionTyco Thermal Controls requires the use of a 30 mA residual current device toprovide maximum safety and protection from fire.To select the circuit breaker sizing, determine:• minimum start-up temperature• total length of heating cableElectrical design1. Determine minimumpipe start-uptemperature °C2. Select protectionratingStep 2.1Example:Determine minimum pipe start-up temperature (°C)The power output and current draw of a Raychem heating cable depend on its temperature.Electrical protection sizing must be based on the minimum pipe start-uptemperature.0°CElectrical design1. Determine minimumpipe start-uptemperature °C2. Select protectionratingStep 2.2Select protection ratingFrom table 2 on page 12, match the heating cable catalogue number (seestep 1-3) at the expected minimum start-up temperature with the total heating cablelength (see step 1.4).Select protection rating (A) for which the length of the heating cable is less or equalthan the maximum recommended heating cable length (L ≤ L max.).Power cable sizingPower supply cables from the electrical protection to the Raychem connection systemshould be sized to meet appropriate codes of practice, protection rating and voltagedrop considerations.DOC-565 Rev.2 03/1111


3.0 Components and accessoriesselectionComponents andaccessories1. Power connections2. Splices and Tees3. End sealsA complete range of cold applied components and accessories is available for allBTV, QTVR, XTV and KTV heating cable types. All of the components work togetherto provide a safe and reliable heat-tracing system that is easy to install and maintain.Raychem components must be used to ensure proper functioning of the product andcompliance with relevant standards and regulations. A heat-tracing system consistsof at least one power connection and one end seal. Additional components such assplices and tees are used as required.4. Thermostats5. AccessoriesE-100-LLightedend sealJBM-100Integrated powerconnectionE-100End sealT-100Tee or splice connectionS-150Low profile spliceJBS-100-LIntegrated powerconnection(shown with light)E-150Low profileend sealIEK-25-04Insulation entry kitJBU-100Junction box formodular systemC-150Low profile powerconnectionC25-100Connection kitDOC-565 Rev.2 03/1113


Power connectionsComponents andaccessories1. Power connections2. Splices and Tees3. End seals4. Thermostats5. AccessoriesPower connections may be mounted on or off the pipe. For pipe mounted applications,select one of the integrated components below. For mounting off the pipe, select aseparate junction box and the necessary connection kits and insulation entry kits fromthe modular components table on the next page.The kits can be used with Raychemindustrial heating cables: BTV, QTVR, XTV and KTV.The power connections JBS, JBM and JBU can also be ordered with a green light forsimple indication if power is on.Integrated componentsIntegrated components combine the functions of the junction box, connection, insulationentry, and support bracket. These components provide full protection of theheating cable for safe operation. The cold-applied core sealing and innovative WAGOcage clamp terminals ensure reliable connections and significantly reduce installationtime. The integrated components are designed for industrial applications and are approvedfor use in hazardous areas.Threads are metric (M25).Above the insulationJBS-100-EJBS-100-EPJBM-100-EJBM-100-EPIntegrated power connection for 1 heating cable.Cold applied.One power cable gland included.Requires 1 pipe strap, to be ordered separately.Part number P/N: 829939-000With green light, order reference: JBS-100-L-E(P/N 054363-000)Integrated power connection for 1 heating cable.Includes earth plate and earth stud for use with armouredcables.Cold applied. Requires 1 pipe strap and 1 metal power cablegland to be ordered separately.Part number P/N: 158251-000With green light, order reference: JBS-100-L-EP(P/N 075249-000)Integrated power connection for up to 3 heating cables.May also be used for tee and splice connections.Cold applied.One power cable gland included.Requires 2 pipe straps, to be ordered separately.Part number P/N: 831519-000With green light, order reference: JBM-100-L-E(P/N 395855-000)Integrated power connection for up to 3 heating cables.Includes earth plate and earth stud for use with armouredcables.May also be used for tee and splice connections.Cold applied. Requires 2 pipe straps and 1 metal powercable gland to be ordered separately.Part number P/N: 986415-000With green light, order reference: JBM-100-L-EP(P/N 300273-000)Under the insulation14 DOC-565 Rev.2 03/11C-150-ELow profile power connection for 1 heating cable.Maximum load of 25ACold appliedSuitable for non-armoured power cables up to 2.5 mm 2with stranded copper conductorsC-150-E is used as a connector:• where connection to a junction box is difficult e.g.because of space limitations• on instrument lines or loading arms• where installation of under insulation components ispreferred• as a cost effective alternative for JBS-100-E on short linesPart number P/N: 073704-000


CModular componentsBAModular components are used for making power connections for up to 3 heating cables.The junction boxes are designed for surface mounting, and versions for both hazardousand non-hazardous areas are available. The JBU-100 includes the innovativecage clamp terminals from WAGO. The connection kits and insulation entry kits arecold applied and have to be ordered separately. Select one junction box for each circuit.Select one connection kit and one insulation entry kit for each heating cable terminatedin the junction box. Optionally a conduit system for mechanical protection of theheating cable where it transitions from the junction box to the pipe can be selected.ACRJunction box B Connection kitIEK-25-PIPEIEK-25-04Insulation entry kitMetric system (M25)HazardousNon-HazardousA Junction boxesFor non-armoured JBU-100-E (1)JB-82power cableFor armouredJBU-100-EP (1)(2) –power cableB Connection kits C25-100 C25-100C Insulation entry kitFor pipes, vessels, pumps IEK-25-04IEK-25-04and instrumentsFor pipes IEK-25-PIPE (3) IEK-25-PIPE (3)D Conduit systemFor medium temperature CCON25-100 + CCON-CMT-2M CCON25-100 + CCON-CMT-2MapplicationsFor high temperatureapplicationsCCON25-100 + CCON-CHT-2M CCON25-100 + CCON-CHT-2M(1)with green light, order reference: JBU-100-L-E orJBU-100-L-EP(2)includes internal earth plate and earth stud; requiresmetal power cable gland, to be ordered separately.(3)requires 2 pipe straps, to be ordered separatelySplices and TeesComponents andaccessories1. Power connectionsFor in-line joining or making T-connections of the heating cables. Approved for use inhazardous areas (Ex e).2. Splices and Tees3. End seals4. Thermostats5. AccessoriesAbove the insulationJBM-100-EFor making splice or tee connections with terminals abovethe insulation.Cold applied.Requires 2 pipe straps, to be ordered separately.Part number P/N: 831519-000With internal earth plate and earth stud, order reference:JBM-100-EP (P/N 986415-000)DOC-565 Rev.2 03/1115


T-100 For making tee or splice connections with crimps above theinsulation.Cold applied.Requires 2 pipe straps, to be ordered separately.Part number P/N: 447379-000Required crimp tool, reference: T-100-CT(P/N 954799-000)(Panduit: CT-1570)Under the insulationS-150 For making splice connections with terminals under the insulation.Cold applied.Part number: 497537-000End sealsComponents andaccessories1. Power connectionsEnd seals are used for terminating the heating cable. Approved for use in hazardousareas. Select 1 end seal for each remote heating cable end.2. Splices and Tees3. End seals4. Thermostats5. AccessoriesAbove the insulationE-100-EMechanical end seal (Ex e).Cold applied.Requires 1 pipe strap, to be ordered separately.Part number: 101255-000E-100-L2-EMechanical end seal with green LED light module(Ex em).Cold applied.Requires 1 pipe strap, to be ordered separately.Part number: 726985-000Under the insulationE-150-ELow profile end seal (Ex e).Cold applied.Part number: 979099-00016 DOC-565 Rev.2 03/11


CCON25-100Conduit connection kit for parallel heating cables.Part number: 1244-003272CCON25-CMT-2MMedium temperature conduit for parallel heating cables,2m precut length.Part number: 1244-003281CCON25-CHT-2MHigh temperature conduit for parallel heating cables,2m pre-cut length.part number: 1244-003284CCON25-CMT-25MMedium temperature conduit for parallel heating cables,25m spool .Part number: 1244-003280CCON25-CHT-25MHigh temperature conduit for parallel heating cables,25m spool.part number: 1244-003284CCON25-CMT/HT-1.67/0.33MMixed medium temperature conduit (1.67m) with hightemperature conduit (0.33m) joined with a heat shrinksleevePart number: 1244-003474ThermostatsComponents andaccessories1. Power connections2. Splices and Tees3. End seals4. Thermostats5. AccessoriesThermostats may be required for process temperature maintenance (surface sensing)or freeze protection (ambient sensing) applications. Use the table below to select theappropriate thermostat. For surface sensing, select one thermostat per circuit.For ambient sensing, select one thermostat per site.For significant reductions in energy consumption in freeze protection applications, selectthe RAYSTAT-ECO-10. This electronic thermostat continuously matches the heattracingoutput to the pipe heat loss based on the ambient temperature.Area Type Catalogue numberNon-hazardousHazardousAmbient sensingProportional Ambient sensingSurface sensingAmbient sensingSurface sensingAT-TS-13RAYSTAT-ECO-10AT-TS-14RAYSTAT-CONTROL-10RAYSTAT-EX-04 (electronic)RAYSTAT-EX-02 (mechanical)RAYSTAT-EX-03 (electronic)DOC-565 Rev.2 03/1117


RAYSTAT-ECO-10Proportional ambient sensing controller for use innon-hazardous areasSensor type: 3-wire RTD (Pt 100)Mounting: surface mountedSetpoint range: 0°C to +30°CSwitching capacity: 25AIncludes an alarm relay to allow remote indication ofsystem statusPart number: 145232-000R AY S TAT-C O N T R O L -1 0RAYSTAT-CONTROL-10Electronic surface sensing thermostat for use innon-hazardous areasSensor type: 3-wire RTD (Pt 100)Mounting: surface mounted, or pipe mounted usingSB-100 or SB-101(option)Setpoint range: 0°C to +150°CSwitching capacity: 25AIncludes an alarm relay to allow remote indication ofsystem statusPart number: 828810-00018 DOC-565 Rev.2 03/11AT-TS-13AT-TS-14RAYSTAT-EX-02RAYSTAT-EX-03RAYSTAT-EX-04Electronic ambient sensing thermostat for use innon-hazardous areasSensor type: PTC KTY 83-110Mounting: wall mounted, or pipe mounted usingSB-110 or SB-111(option)Setpoint range: -5°C to +15°CSwitching capacity: 16APart number: 728129-000Electronic surface sensing thermostat for use innon-hazardous areasSensor type: PTC KTY 83-110Mounting: surface mounted, or pipe mounted usingSB-110 or SB-111 (option)Setpoint range: 0°C to +120°CSwitching capacity: 16APart number: 648945-000Mechanical surface sensing thermostat for use inhazardous areasSensor type: bulb and capillarySensor length: 3 mApproval: II 2GD Ex d IIC T6 (Ta –40°C to +60°C)Ex tD A21 IP6X T80°C (-40°C ≤ Tamb ≤ +60°C)Mounting: on pipe with SB-100 or SB-101 (option) orsurface mountedSetpoint range: –4 to +163°CSwitching capacity: 22 ACable gland (3/4" NPT) to be ordered separately: for armouredcable use GL-33; for non-armoured cable use GL-34Part number: 404385-000Electronic surface sensing thermostat for use in hazardousareasSensor type: 2 wire RTD (Pt 100)Sensor length: 2 mApproval: II 2 GD T=85°C Ex emia IIC T6(–50°C ≤ Ta ≤ 55°C)Mounting: on pipe with SB-100 or SB-101 (option) orsurface mountedSetpoint range: 0 to +499°CSwitching capacity: 16 APart number: 333472-000Electronic ambient sensing thermostat for use in hazardousareasApproval: II 2 GD T=85°C Ex emia IIC T6(–50°C ≤ Ta ≤ 55°C)Mounting: on pipe with SB-100 or SB-101 (option) orsurface mountedSetpoint range: 0 to +49°CSwitching capacity: 16 APart number: 462834-000


Control and Monitoring productsMoniTrace 200NIn addition to products in this document, Tyco Thermal Controls also offers control &monitoring units ranging from single up to hundreds of circuits.For further information, refer to the Product Catalogue for Industrial Heat-TracingSystems, visit our website (www.tycothermal.com) or contact your Tyco ThermalControls representative.AccessoriesComponents andaccessories1. Power connections2. Splices and Tees3. End seals4. Thermostats5. AccessoriesStainless steel support bracketsSupport brackets are used to fix equipment such as thermostats or junction boxes onpipes. Support brackets require additional pipe straps which are to be ordered separately.They include a set of M6 and/or M4 fixing screws, nuts, washers and springlock washers for the fixation of one junction box or thermostat. The table below outlinesthe typical compatibility of each bracket with relevant equipment, for other equipmentplease contact your Tyco Thermal Controls representative.SB-100 SB-101 SB-110 SB-111AT-TS-13 x x x xAT-TS-14 x x x xJBU-100-E x xJBU-100-EP x xRAYSTAT-CONTROL-10 x xRAYSTAT-ECO-10 x xRAYSTAT-EX-02 x x x xRAYSTAT-EX-03 x xRAYSTAT-EX-04 x xTechnical dataplate size (mm) X x Y 160 x 230 160 x 160 130 x 130 130 x 130distance pipe-plate (mm) 100 160 100 100number of pipe straps2 2 1 2requiredPart number 192932-000 990944-000 707366-0000 579796-000DOC-565 Rev.2 03/1119


Warning labelsWarning labels indicate the presence of electrical heat-tracing under the insulation ofthe pipe or other equipment. (min. of 1 label per 5 m of heat-tracing line).Language Label reference PNCroatian LAB-ETL-HR 938764-000Czech LAB-ETL-CZ 731605-000Danish LAB-ETL-DK C97690-000Dutch LAB-I-23 749153-000English LAB-I-01 938-947-000Finnish LAB-ETL-SF 756479-000French LAB-ETL-F 883061-000German / French / Italian LAB-ETL-CH 148648-000German LAB-ETL-G 597779-000Hungarian LAB-ETL-H 623725-000Italian LAB-ETL-I C97688-000Latvian LAB-I-32 841822-000Lithuanian LAB-ETL-LIT 105300-000Norwegian LAB-ETL-N C97689-000Norwegian / English LAB-ETL-NE 165899-000Polish LAB-ETL-PL 258203-000Portugese LAB-ETL-POR 945960-000Romanian LAB-ETL-RO 902104-000Russian LAB-ETL-R 574738-000Slovenian LAB-ETL-SLO 538156-000Spanish LAB-ETL-SPANISH C97686-000Swedish LAB-ETL-S 691703-000Pipe strapsAre used for fixing components. Select the appropriate pipe strap (stainless steel)according to the pipe diameter. For JBS-100, JBM-100, E-100, E-100-L, T-100 andIEK-25-PIPE, add 25 mm to the pipe diameter.Pipe outer diameter in mm (inches) Pipe strap Part number20-47 (1/2" - 1 1 /4") PSE-047 700333-00040-90 (1 1 /4" - 3") PSE-090 976935-00060-288 (2" - 10") PSE-280 664775-00060-540 (2" - 20") PSE-540 364489-000Thermostat kitHWA-WAGO-TSTAT-KITKit with supplementary terminals to connect thermostattype RAYSTAT-EX-02 to the junction boxes JBS, JBM andJBU.The kit includes 2 terminals WAGO 284 series(1 x L,1 x PE) and 1 power cable gland GL-36-M25.Part number: 966659-00020 DOC-565 Rev.2 03/11


Fixing tapeSelect the tape according to the pipe material.Applied in 3 turns every 300 mm across heating cable.Determine the quantity from the table below.Number of rolls =Total pipe lengthm of pipe per rollAdd another 20% to allow for fixing the heating cable on valves, flanges, etc.if appropriate.GT-66GS-54Standard glass cloth tape.For carbon steel pipes.20 m per roll.Part number: C77220-000Glass cloth tape with low halogen content.For carbon and stainless steel pipes.16 m per roll.Part number: C77221-000For the use of aluminium tape as heat transfer aid, use TraceCalc Pro orTraceCalc Net or consult your Tyco Thermal Controls representative.Pipe sizemminchesGT-66m of pipe per rollGS-54m of pipe per roll8 1/4" 46.5 37.215 1/2" 29.9 23.920 3/4" 23.8 19.125 1" 19.1 15.232 1 1 /4" 15.1 12.140 1 1 /2" 13.2 10.550 2" 10.6 8.465 2 1 /2" 8.7 7.080 3" 7.2 5.7100 4" 5.6 4.5150 6" 3.8 3.0Protective grommetG-02 Protective grommet to protect the heating cable frommechanical damage (e.g. at a sharp edge).Supplied in 1 m sections, to be cut to length.Part number: 412549-000DOC-565 Rev.2 03/1121


GlandsGL-333/4" NPT cable gland (Ex d II C) for RAYSTAT-EX-02.Nickel plated brass.For use with armoured power cables.Part number: 493217-000GL-343/4" NPT cable gland (Ex d II C) for RAYSTAT-EX-02.Nickel plated brass.For use with non-armoured power cables.Part number: 931945-000GL-36-M25M25 power cable gland (Ex e).Polyamide.For use with non-armoured power cables with outer diameterrange 8–17 mm.Spare part for JBS-100, JBM-100 and JBU-100.Part number: 774424-000GL-38-M25-METALM25 cable gland (Ex e II and Exd II C) for boxes with earthplate (-EP).Nickel plated brass.For use with armoured power cables.Part number: 056622-000ExampleExample:Power connectionT-connectionEnd sealArea classification: HazardousPower cables, non-armouredPipe Ø: 50 mmHeating cable type: 8XTV2-CT-T3Heating cable length: 39 mBill of materials1 x JBS-100-E integrated power connection1 x T-100 T-connection2 x E-100 end seal kit8 x LAB-I-01 warning label5 x PSE-090 pipe strap4 x GT-66 fixing tape22 DOC-565 Rev.2 03/11


Distributor:Fax/email to: ..............................................................................................................Fax fromName ...............................................................................................................................................................................................Company ........................................................................................................................................................................................Fax n° ........................................................................................................... Date ..................................................................ProjectparametersProject name and location ........................................................................................................................................................Done for ..........................................................................................................................................................................................Done by ...........................................................................................................................................................................................Tel ................................................................................................................... Fax .....................................................................DesignparametersApplication Frost protection Temperature maintenanceCondensation preventionTemperatures Maintain temperature ............................°CAmbient temperature min. ...........................°C max. ............................°CProcess temperatureMax. pipe temperatureMax. allowed pipe temperatureStart-up temperaturecontinuous: .............................°Cintermittent (upset) max.: ............................°C............................°C............................°C............................°CPipes are steam-cleaned yes no max. temp. ............................°CVoltage 230 Vac Other ....................VacLocation Indoors OutdoorsInsulation typeMineral wool (Rockwool)Other ............................ Insulation k-factor @ 10°C .............. W/(m · K)Area Classification Zone 1 Zone 2 Zone 11 Zone 21 Non-HazardousTemperature Classification T1 T2 T3 T4 T5 T6 Non-HazardousPipe material Steel Stainless steel PE PVC Other .......................................LinesRef. NoDiameter(mm)Insulationthickness(mm)Pipelength(m)PipesupportsValves /Pumps etc...FlangesType N° Type N° N°12345678DOC-565 Rev.2 03/11


Raychem Heat-Tracing Systems• Safe and reliable• Easy project design• Self-regulatingtechnology• Steam-cleanablesystems• Unique and safeconstruction• Cold appliedcomponents• Support by a qualityorganisationOur products satisfythe requirements of therelevant European Directives.www.tycothermal.comRaychem, Pyrotenax, DigiTrace, Tracer,Isopad, TraceTek and Trac-Loc are trademarksof Tyco Thermal Controls, LLC or itsaffiliates. HEW-THERM is a trademark ofHEW-KABEL/CDT GmbH & Co.KG.We manage the heat you needAmericasWorldwide HeadquartersTyco Thermal Controls7433 Harwin DriveHouston, TX 77036,USATel: 800-545-6258Tel: 650-216-1526Fax: 800-527-5703Fax: 650-474-7711info@tycothermal.comwww.tycothermal.comUSATracer IndustriesService Headquarters7433 Harwin DriveHouston, TX 77036, USATel: 800-545-6258Fax: 800-527-5703Tel: 713-868-4800Fax: 713-868-2333Tyco Thermal Controls307 Constitution DriveMenlo Park, CA 94025-1164,USATel: 800-545-6258Tel: 650-216-1526Fax: 800-527-5703Fax: 650-474-7711Tyco Thermal Controls6735 Exchequer Drive, Suite 100Baton Rouge, LA 70809, USATel: 225-755-8800Fax: 225-752-5251Tyco Thermal Controls18 Spring Mill DriveMalvern, PA 19355, USATel: 610-296-5500Fax: 610-993-1226Tyco Thermal Controls2505 W. Walter Zimny DrivePosen, IL 60469, USATel: 708-824-3000Fax: 708-824-3030Tyco Thermal Controls830 80th Street SWSuite 400Everett, WA 98203, USATel: 888-778-7485Fax: 650-474-7761CanadaTyco Thermal Controls250 West St.Trenton, Ontario K8V 5S2CanadaTel: 800-545-6258Fax: 800-527-5703Tel: 613-392-6571Fax: 613-392-3999Tyco Thermal ControlsTracer Industries Canada Limited11004 - 174 StreetEdmonton, Alberta T5S 2P3CanadaTel: 780-455-8111Fax: 780-455-8115Tyco Thermal ControlsTyco Service Center985 Memorial DriveP.O. Box 4950Fort McMurray, Alberta T9H 3G2CanadaTel: 780-743-4229Fax: 780-743-6128Europe, Middle east, Africa (EMEA)Tyco Thermal ControlsRomeinse Straat 143001 LeuvenBelgië / BelgiqueTel: +32 16 213 511Fax: +32 16 213 603Tyco Thermal ControlsWestern Commerce Court3003 - 16 Street N.E.Calgary, Alberta T2E 7K8CanadaTel: 403-291-5659Fax: 780-455-8115Tyco Thermal Controls101 Webster RoadKitchener, Ontario N2G 3Y4CanadaTel: 519-894-1222Fax: 519-894-11011Latin AmericaTyco Thermal Controls7433 Harwin DriveHouston, TX 77036, USATel: 713-868-4800Tel: 713-735-8645Fax: 713-868-2333Tyco Flow ControlHamburgo #231 A 3er PisoColonia JuarezMexico DF CP 06600Tel: +52 55 52089068 xt. 13Tyco Flow ControlAvda Antonio Bardella 3000Sorocaba, Sao Paulo – Brasil18085-270Tel: +55 11 50773658Tyco Flow ControlCamino Santa Marta 650 MaipuSantiago, ChileTel: +56 2 4109009Tyco Thermal Control Czech, s.r.o.Pražská 636252 41 Dolní BřežanyČeská RepublikaTel: +420 241 911 911Fax: +420 241 911 100Tyco Thermal Controls GmbHEnglerstrasse 1169126 HeidelbergGermanyTel: +49 6221 30430Fax: +49 6221 3043956Tyco Thermal Controls GmbHBirlenbacher Strasse 19-2157078 Siegen-GeisweidGermanyTel: +49 271 356000Fax: +49 271 3560028Tyco Thermal Controls SAB.P. 9073895004 Cergy-Pontoise CedexFranceTel: +33 1 34407330Fax: +33 1 34407333Tyco Thermal Controls BalticSmolensko str. 6LT-03201 VilniusLithuaniaTel: +370 5 2136634Fax: +370 5 2330084Tyco Thermal Controls b.v.Van Heuven Goedhartlaan 1211181 KK AmstelveenNederlandTel: +31 20 6400411Fax: +31 20 6400469Tyco Thermal Controls PolskaSp. z o.o.ul. Cybernetyki 1902-677 WarszawaPolskaTel: +48 22 3312950Fax: +48 22 3312951Tyco Thermal Controls4 “a”, Smagulova St.Atyrau, 060005Republic of KazakhstanTel: +7 7122 325554Fax: +7 7122 586017Tyco Thermal Controls3 Sinaii Street, 3rd Floor,100357 Ploiesti PH,RomaniaTel: +40 34 4802144Fax: +40 34 4802141Tyco Thermal Controls Russia19, Panfilova Street, 11th floorCountry Park Business Center141407, Moscow Region, KhimkiRussiaTel: +7 495 9261885Fax: +7 495 9261886Tyco Thermal ControlsCtra. De la Coruña, km. 23,500Edificio ECU I28290 Las Rozas, MadridSpainTel. +34 902 125307Fax +34 91 6402990Tyco Thermal Controls Nordic ABFlöjelbergsgatan 20B431 37 MölndalSwedenTel: +46 31 3355800Fax: +46 31 3355899Tyco Thermal Controls (UK) Ltd3 Rutherford RoadStephenson Industrial EstateWashington, Tyne & WearNE37 3HX, United KingdomTel: +44 191 4198200Fax: +44 191 4198201Tyco Thermal Controls IndiaPvt. Ltd.A-26, Sector-63Noida 201 307Uttar Pradesh, IndiaTel: +91 120 4649500Fax: +91 120 4649548Tyco Thermal Controls IndiaPvt Ltd.1st Floor, Ujagar Compound,Sub Plot 2A, CTS No. 653/6,Opp. Deonar Bus Depot,Deonar, Mumbai400 088 IndiaTel: +91 22 6775 8800/01Fax: +91 22 2556 1491Tyco Thermal ControlsPO Box 44Dubai, U.A.ETel: +971 50 5629434Fax: +971 4 3538739ASIA PACIFICAsia PacificTyco Thermal Controls20F, Innovation Building,1009 Yi Shan Rd,Shanghai 200233, P.R.ChinaTel: +86 21 2412 1688Fax: +86 21 5426 29375426 3167Tyco Thermal ControlsTyco Service CentreShanghai Chemical IndustrialPark (SCIP)188 Chang Wei Road, JingshanDistrict,Shanghai, P.R.ChinaTel: +86 21 5727 70665727 6131Fax: +86 21 5727 6132Tyco Thermal Controls7 Floor, Office Tower 3,Sun Dong An Plaza,138 Wang Fu Jing Avenue,Dong Cheng District,Beijing 100006, P.R. ChinaTel: +86 10 5817 7118Fax: +86 10 5817 7116Tyco Thermal ControlsShuanglin Industry ZoneNanxun District, Huzhou ZhejiangProvince 313012ChinaTel: +86 572 736 2101Fax: +86 572 736 2126Tyco Thermal Controls16F-1, No. 59, Sec. 2 Tun HuaSouth Rd.Taipei 10691Taiwan R.O.CTel: +886 2 2754 6969Fax: +886 2 2754-6363Tyco Thermal Controls4F KC Bldg. 3-16-1Shin-Yokohama, Kohoku-kuYokohama, Kanagawa, 222-0033JapanTel: +81 45 471 7630Fax: +81 45 471 7631Tyco Thermal Controls4th Floor, Bibong Bldg, 840-10,Yeoksam-dong,Gangnam-gu, 135-936Seoul, KoreaTel: +82 2 2129 7700Fax: +82 2 2129 7777Tyco Thermal ControlsNo. 45 Tuas Avenue 9Singapore 639189Tel: +65 6869 9020Fax: +65 6861 1337Tyco Thermal Controls268 Milperra RoadMilperra NSW 2214AustraliaTel: +61 2 9792 0279Fax: +61 2 9774 5931This document was supplied to you by:Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evaluatethe suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracyor completeness of the information, and disclaims any liability regarding its use. Tyco Thermal Controls’ only obligations arethose in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco ThermalControls or its distributors be liable for any incidental, indirect or consequential damages arising from the sale, resale, useor misuse of the product. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reservesthe right to make changes, without notification to the Buyer, to processing or materials that do not affect compliance withany applicable specification.© 2004 Tyco Thermal Controls DOC-565 Rev.2 03/11

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