Table of Contents
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Introduction
H55838
2/12
Pipe Freeze Protection
and Flow Maintenance
XL-Trace System
This step-by-step design guide provides the tools necessary to design a Raychem XL-Trace
pipe freeze protection or flow maintenance system. For other applications or for design
assistance, contact your Tyco Thermal Controls representative or phone Tyco Thermal
Controls at (800) 545-6258. Also, visit our web site at www.tycothermal.com.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
XL-Trace Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Regulating Heating Cable Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe Freeze Protection Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Pipe Freeze Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fire Sprinkler Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flow Maintenance Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Flow Maintenance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Greasy Waste Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pipe Freeze Protection and Flow Maintenance Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Design Step by Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
esign conditions and pipe heat loss . . . . . . . . . . . . . . . . . . . . . 13
Select the heating cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2
3
Determine the heating cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Determine the electrical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4
Select the connection kits and accessories . . . . . . . . . . . . . . . . . . . . . . . . 26
5
Select the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6
Select the power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7
Complete the Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8
Raychem XL-Trace is designed for pipe freeze protection and flow maintenance in the
following applications:
• Freeze protection of general water piping (aboveground and buried)
• Freeze protection of fire sprinkler systems (aboveground and buried supply pipes)
• Flow waste lines (aboveground and buried)
• Flow maintenance of fuel lines (aboveground)
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Table of Contents
Related Manuals for Raychem XL-Trace
Summary of Contents for Raychem XL-Trace
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Page 1: Table Of Contents
Complete the Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet . . . . . . 37... -
Page 2: How To Use This Guide
(800) 545-6258 . How to Use this Guide This design guide presents Tyco Thermal Controls’ recommendations for designing an XL-Trace pipe freeze protection or flow maintenance system . It provides design and performance data, electrical sizing information, and application configuration suggestions . Following these recommendations will result in a reliable, energy-efficient system . -
Page 3: Warranty
. Tyco Thermal Controls offers the option of three self-regulating heating cables with the XL-Trace system: 5XL, 8XL, and 12XL (208–277 V only) for applications using 120 and 208–277 V power supplies . The cable’s output is reduced automatically as the pipe warms, so there is no possibility of failure due to overheating . -
Page 4: Self-Regulating Heating Cable Construction
PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Self-Regulating Heating Cable Construction Raychem XL-Trace self-regulating heating cables are comprised of two parallel nickel-coated bus wires in a cross-linked polymer core, a tinned copper braid, and a fluoropolymer or polyolefin outer jacket . These cables are cut to length, simplifying the application design and installation . -
Page 5: Pipe Freeze Protection Applications
A pipe freeze protection system is designed to maintain water temperature at a minimum of 40°F (4°C) to prevent freezing . Typical Pipe Freeze Protection System A typical pipe freeze protection system includes the XL-Trace self-regulating heating cables, connection kits, ambient temperature control, and power distribution . Power Distribution Panel... -
Page 6: General Water Piping
• A 30-mA ground-fault protection device (GFPD) is used . • The heating cable is installed per manufacturer’s instructions with approved Raychem connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . - Page 7 • Closed-cell, waterproof thermal insulation with fire-retardant, waterproof covering is used . • The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 15 on page 29 and the XL-Trace System Installation and Operation Manual (H58033) .
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Page 8: Fire Sprinkler Systems
. XL-Trace is c-CSA-us Certified for use on fire suppression systms under CSA C22 .2 no . 130-03 for Canada and Ieee 515 .1-2005 for the US . -
Page 9: Flow Maintenance Applications
. Typical Flow Maintenance System A typical flow maintenance system includes the XL-Trace self-regulating heating cables with a fluoropolymer outer jacket, connection kits, line-sensing temperature control and power distribution . -
Page 10: Greasy Waste Lines
• Tees and splices are installed using pipe mounting brackets, not in direct contact with piping . • The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Pipe Heat Loss Calculations,”... - Page 11 • Closed-cell, waterproof thermal insulation with fire-retardant, waterproof covering is used . • The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 15 on page 29 and the XL-Trace System Installation and Operation Manual (H58033) .
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Page 12: Fuel Lines
• A 30-mA ground-fault protection device (GFPD) is used . • The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . -
Page 13: Pipe Freeze Protection And Flow Maintenance Design
. As you go through each step, use the “XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet,” page 37, to document your project parameters, so that by the end of this section you will have the information you need for your Bill of Materials . - Page 14 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Example: Pipe Freeze Protection – Greasy Waste Line Location Buried Maintain temperature (T 110°F (43°C) Maximum system temperature (T 125°F (52°C) Minimum ambient temperature (T 50°F (10°C) (soil temperature) Pipe diameter and material 4-inch metal Pipe length 200 ft (61 m) Thermal insulation type and thickness...
- Page 15 Pipe Freeze Protection and Flow Maintenance Design Insulation thickness 1 inch 60°F (33°C) Heat loss (Q ) for 60°F must be calculated through interpolation between DT at 50°F and DT at 100°F from Table 2 . For difference between the DT of 50°F and the DT of 100°F: 3 .2 W/ft (from Table 2) 6 .8 W/ft (from Table 2) -100...
- Page 16 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Table 2 Pipe Heat Loss (q ) for Outdoor or buried Pipe (W/ft) for 1/2 to 3-1/2 inches Insulation thickness (DT) Pipe diameter (IPS) in inches (in) °F °C 1-1/4 1-1/2 2-1/2 3-1/2 0 .5 1 .0 1 .2 1 .4...
- Page 17 Pipe Freeze Protection and Flow Maintenance Design Table 1.2 continued Pipe Heat Loss (q ) for Outdoor or buried Pipe (W/ft) for 4 to 20 inches Insulation thickness (DT) Pipe diameter (IPS) in inches (in) °F °C 0 .5 3 .8 5 .3 6 .8 8 .4...
- Page 18 Pipe Freeze Protection and Flow Maintenance To select the appropriate XL-Trace heating cable for your application, you must determine 1. Determine design your cable supply voltage, power output, and outer jacket . Once you select these, you will be...
- Page 19 Pipe Freeze Protection and Flow Maintenance Design Table 5 Power Output Correction Factors voltage correction factors 5XL1 8XL1 5XL2 8XL2 12XL2 120 V 1 .00 1 .00 – – – 208 V – – 1 .00 1 .00 1 .00 240 V –...
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Page 20: Step 3 Determine The Heating Cable Length
Select the appropriate heating cable outer jacket for the application . Jacket options are: -CR Compatible with most XL-Trace applications -CT Required for grease and fuel line flow maintenance; may be used in other XL-Trace applications for improved mechanical strength and chemical resistance . - Page 21 Pipe Freeze Protection and Flow Maintenance Design Table 7 Additional Heating Cable for valves Pipe diameter (IPS) (inches) Heating cable (feet (meters)) 0 .8 (0 .24) 1 .3 (0 .4) 2 .0 (0 .6) 1-1/4 3 .3 (1 .1) 1-1/2 4 .3 (1 .3) 4 .3...
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Page 22: Step 4 Determine The Electrical Parameters
PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Example: Flow Maintenance – Greasy Waste Line Pipe length 200 ft (61 m) (from Step 1) Pipe diameter 4-inch metal (from Step 1) number of heating cable runs 1 (from Step 2) Valves 2 gate valves [4 .3 ft x 2 gate valves] x 1 run = 8 .6 ft (2 .6 m) Pipe supports 2 non-insulated hangers... - Page 23 Pipe Freeze Protection and Flow Maintenance Design Table 9 Maximum Circuit Length in Feet 40°F / 110°F Maintain* 5XL1 8XL1 5XL2 8XL2 12XL2 Start-up Cb size temperature ( ° 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v...
- Page 24 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Table 10 Maximum Circuit Length in Meters 4°C / 43°C Maintain* 5XL1 8XL1 5XL2 8XL2 12XL2 Start-up Cb size temperature (°C) 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v...
- Page 25 Pipe Freeze Protection and Flow Maintenance Design DETERMInE TRAnSFORMER LOAD Transformers must be sized to handle the load of the heating cable . Use the following tables to calculate the total transformer load . Table 11 Transformer Sizing (Amperes/foot) 5XL1 8XL1 5XL2 8XL2...
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Page 26: Step 5 Select The Connection Kits And Accessories
Pipe Freeze Protection and Flow Maintenance All XL-Trace systems require a power connection and end seal kit . Splice and tee kits are 1. Determine design used as required . Use Table 13 on page 27 (for aboveground applications) and conditions and heat Table 15 on page 29 (for buried applications) to select the appropriate connection kits . - Page 27 Pipe Freeze Protection and Flow Maintenance Design Table 13 Connection kits and Accessories for Aboveground Piping Standard Heating cable Catalog number Description packaging usage allowance Connection kits RayClic-PC Power connection and end seal (RayClic-SB-04 1 per circuit 2 ft (0 .6 m) pipe mounting bracket included) RayClic-PS Powered splice and end seal (RayClic-SB-04...
- Page 28 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Table 13 Connection kits and Accessories for Aboveground Piping (Continued) Standard Heating cable Catalog number Description packaging usage allowance Accessories RayClic-SB-04 Pipe mounting bracket As required – RayClic-SB-02 Wall mounting bracket As required – “electric-Traced”...
- Page 29 The FTC-XC power connection and end 1 per circuit 2 ft (0 .6 m) seal kit is for use with XL-Trace heating cable that is run through conduit to a junc- tion box . Materials for one power connec- tion and end seal is included in the kit .
- Page 30 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Table 15 Connection kits and Accessories for buried Piping (Continued) Standard Heating cable Catalog number Description packaging usage allowance Accessories RayClic-SB-04 Pipe mounting bracket As required – RayClic-SB-02 Wall mounting bracket As required – “electric-Traced”...
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Page 31: Step 6 Select The Control System
Pipe Freeze Protection and Flow Maintenance Design Step Select the control system Pipe Freeze Protection Pipe Freeze Protection and Flow Maintenance and Flow Maintenance Temperature controls save energy by ensuring that the system is energized only when 1. Determine design necessary . - Page 32 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Table 18 Control Systems Catalog number Description Electronic Thermostats and Accessories eC-TS electronic thermostat housed in a neMA 4X enclosure with 2 x 1/2-in conduit entries for power and one gland entry for the sensor . The temperature set point and LeD indicators for alarm, power, and heating cable status can be visually checked through the clear lid .
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Page 33: Step 7 Select The Power Distribution
Once the heating cable circuits have been defined, you must select how to provide power to conditions and heat them . Power to the XL-Trace heating cables can be provided in several ways: directly through loss the temperature control, through external contactors, or through HTPG power distribution 2. - Page 34 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Alarm horn (optional) Door disconnect Main circuit (optional) breaker Distribution Push button for panelboard light testing Alarm relay (optional) COMMON ALARM Selector switch TB 1 PUSH TO ACKNOWLEDGE Main contactor Fuse holder POWER ON Terminals HAND/OFF/AUTO Ground...
- Page 35 Pipe Freeze Protection and Flow Maintenance Design Table 19 Power Distribution Catalog number Description Power Distribution HTPG Heat-tracing power distribution panel with ground-fault and monitoring for group control . COMMON ALARM PUSH TO ACKNOWLEDGE POWER ON HAND/OFF/AUTO Contactors e104 Three-pole, 100 Amp per pole, 600 V maximum contactor housed in UL Listed, CSA Certified, neMA 4X enclosure with two 1-inch conduit entries .
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Page 36: Step Complete The Bill Of Materials
PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Pipe Freeze Protection Pipe Freeze Protection Step Complete the bill of Materials and Flow Maintenance and Flow Maintenance 1. Determine design If you used the Design Worksheet to document all your design parameters, you should have conditions and heat all the details necessary complete your Bill of Materials . -
Page 37: Xl-Trace System Pipe Freeze Protection And Flow Maintenance Design Worksheet
XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step Determine design conditions and pipe heat loss Design conditions Max. Min. Maintain system ambient XL-Trace temp. temp. temp. - Page 38 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Determine the pipe heat loss: See Table 2 for the base heat loss of the pipe (Q ) . If the T for your system is not listed, interpolate between the two closest values . ∆T1 B-50 W/ft (W/m)
- Page 39 XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Compensate for insulation type and pipe location See Table 2 for the pipe heat loss (Q ) . If the T for your system is not listed, interpolate between the two closest values .
- Page 40 Supply voltage (from Step 1) Pipe material (metal or plastic) (from Step 1) XL-Trace application (water, fuel oil, or greasy waste) (from Step 1) Pipe freeze protection: general water piping, sprinkler piping Flow maintenance: greasy waste lines, fuel lines Maximum system use temperature (T...
- Page 41 XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step Determine the heating cable length For additional heating cable allowance for valves: See Table 7 . See Table 8 . For additional heating cable allowance for pipe supports and flanges:...
- Page 42 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Step Determine the electrical parameters Determine maximum circuit length and number of circuits See Table 9 and Table 10 . Total heating cable length required T 120 V T 208 V Supply voltage: T 240 V T 277 V T 15 A...
- Page 43 XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step Select the connection kits and accessories See Table 13 . Connection kits – Aboveground Description quantity Heating cable allowance Power connection and end seal ____________ __________________ RayClic-PC...
- Page 44 PIPe FReeze PROTeCTIOn AnD FLOW MAInTenAnCe Step Select the control system See Table 18 . Thermostats, controllers and accessories Description quantity electronic thermostat with 25-ft sensor _____________ eC-TS SB-110 Pipe mounting bracket for eC-TS _____________ DigiTrace C910 Microprocessor-based single-point heat-tracing controller _____________ ...
- Page 45 TraceMaster, Tracer, Tracer logo, TRACERLYNX, TRACERLYNX logo, TraceStat, TraceTek, TraceTek logo, TruckPak, VLBTV, VLKTV, VPL, We manage the heat you need, WinterGard, WinterGard logo, WinterGard Plus, WinterGard Wet, XL-ERATE, XL-ERATE logo, XL-Trace, XTV and Zero EMI are registered and/or unregistered trademarks of Tyco Thermal Controls LLC or its affiliates.