Raychem XL-Trace System Installation And Operation Manual
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Raychem XL-Trace System Installation And Operation Manual

Raychem XL-Trace System Installation And Operation Manual

Pipe freeze protection and flow maintenance
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  • Page 1 XL-Trace System InstallatIon and operatIon manual for pIpe freeze protectIon and flow maIntenance Thermal managemenT WWW.PenTaIrThermal.COm...
  • Page 2 • Do not attempt to repair or energize damaged heating cable. remove damaged sections at once and replace them with a new length using the appropriate raychem splice kit. replace damaged connection kits. • Use only fire-resistant insulation materials such as fiberglass wrap or flame-retardant foams.

  • Page 3: Table Of Contents

    4.1 Voltage Rating 4.2 Circuit Breaker Sizing 4.3 Electrical Loading 4.4 Ground-Fault Protection 4.5 Important Power Supply Safeguards Control, monitoring and Power Distribution 5.1 Control Systems 5.2 Power Distribution Commissioning and Preventive maintenance 6.1 Tests Test Procedures 7.1 System Tests 7.2 Fault Location Tests Troubleshooting guide appendix Installation and Inspection records Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 4 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 5: Use Of The Manual

    General Information Use of the manual This manual covers the installation of Raychem XL-Trace self-regulating heating cables and con- nections for commercial construction pipe systems in ordinary (nonhazardous) areas. The manual cov- ers general heating cable installation procedures and specific installation details and shows available connection kits for the different applications. The manual also discusses controls, testing, and periodic maintenance. This manual assumes that the proper heat-tracing design has been completed according to the Pipe Freeze Protection and Flow Maintenance Design Guide (H55838). Only the applications described in Section 1.2 are approved by Thermal Management for XL-Trace systems when used with approved Raychem connection kits. The instructions in this manual and the installation instructions included with the connection kits, control systems, power dis- tribution systems, and accessories must be followed for the Thermal Management warranty to apply. Contact your Thermal Management representative for other applications and products. For additional information, contact: Thermal management 7433 Harwin Drive Houston, TX 77036 USA Tel: +1.800.545.6258 Tel: +1.650.216.1526 Fax: +1.800.527.5703 Fax: +1.650.474.7711...

  • Page 6: Xl-Trace Applications

    (4°C) maintain) of insulated metallic standpipes and supply piping up to 20". Flow maintenance • greasy waste lines. Flow maintenance (110°F (43°C) maintain) of insulated-grease disposal lines. • Fuel lines. Flow maintenance (40°F (4°C) main- tain) for insulated metallic piping containing #2 fuel oil. For heating cable applications other than those listed above, please see your Thermal Management repre- sentative or call us at (800) 545-6258. Safety guidelines As with any electrical equipment, the safety and reli- ability of any system depends on the quality of the products selected and the manner in which they are installed and maintained. Incorrect design, handling, installation, or maintenance of any of the system connection kits could damage the system and may result in inadequate performance, overheating, electric shock, or fire. To minimize these risks and to ensure that the system performs reliably, read and carefully follow the information, warnings, and instructions in this guide. Pay special attention to the following: • Important instructions are marked Important • Warnings are marked WarnIng Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 7: Approvals

    General Information approvals XL-Trace heat-tracing systems carry agency approvals for the different applications shown in Section 1.2. For detailed information on which approvals are carried for the specific applica- tion, refer to the Pipe Freeze Protection and Flow Maintenance design guide (H55838). Warranty Thermal Management standard limited warranty applies to all products. An extension of the limited warranty period to ten (10) years from the date of installation is available if a properly completed online warranty form is submit- ted within thirty (30) days from the date of installa- tion. You can access the complete warranty on our web site at www.pentairthermal.com. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 8: Heating Cable Storage

    Jacket type: Polyolefin or Fluoropolymer (Required for grease and fuel lines) Figure 1: Xl-Trace catalog number • Review the heating cable design and compare the list of materials to the catalog numbers of the heating cables and connection kits received to confirm that the proper materials are on site. The heating cable type is printed on its jacket. • Ensure that the service voltage available is correct for the XL-Trace heating cable selection. • Inspect the heating cable and connection kits to ensure there is no in-transit damage. • Verify the system design does not exceed the max- imum exposure temperature of the heating cable 5XL/8XL: 150°F (65°C) 12XL: 185°F (85°C) • Verify that the heating cable jackets are not dam- aged by conducting the insulation resistance test (refer to Section 7) on each reel of heating cable. Do not power the heating cable when it’s on the reel. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 9: Heating Cable Installation

    Check piping to be traced • Make sure all mechanical pipe testing (i.e. hydro- static testing/purging) is complete and the system has been cleared by the client for tracing. • Walk the system and plan the routing of the heat- ing cable on the pipe. • Inspect the piping and remove any burrs, rough surfaces, or sharp edges. heating Cable Installation Minimum installation temperature of: 0°F (–18°C). Heating cable installation involves three basic steps: 1. Paying out the heating cable 2. Attaching the heating cable to the pipe 3. Wrapping heat sinks Paying out the heating cable Mount the reel on a holder and place it near either end of the pipe run to be traced. Use a reel holder that pays out smoothly with little tension as shown in Figure 2. Avoid jerking the heating cable while pulling. Pay out the heating cable and loosely string it along the pipe, making sure the heating cable is always next to the pipe when crossing obstacles. If the heat- ing cable is on the wrong side of a crossing pipe or I-beam, you will have to reinstall it or cut and splice it. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 10 WarnIng: Fire and shock hazard. Do not install damaged heating cable. Connection kits and heat- ing cable ends must be kept dry before and during installation. attaching the heating cable Once the heating cable has been run for the entire section, begin fastening it to the pipe. Start at the end and work toward the reel. The additional heat- ing cable required for valves and other heat sinks is shown in Table 1 and Table 2. Refer to Table 3 for the additional heating cable required for connection kits. The heating cable may be installed in single or in multiple runs as required by the design. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 11 Installation Guidelines Figure 3: attaching the heating cable Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 12 5.0 (1.5) 5.6 (1.7) 5.9 (1.9) 7.3 (2.2) 9.4 (2.9) 10.5 (3.2) TaBle 2: aDDITIOnal heaTIng CaBle FOr PIPe SUPPOrTS anD FlangeS Support additional heating cable Pipe hangers (insulated) No additional heating cable Pipe hangers noninsulated and Add 2x pipe diameter U-bolt supports: Welded support shoes Add 3x the length of the shoe Flanges Add 2x pipe diameter note: For applications where more than one heating cable is required per foot of pipe, this correction factor applies for each heating cable run. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 13 Heating cable Heating cable over pipe hanger beneath insulation Heating cable Heating cable and pipe hanger Figure 4: Pipe hanger with heating cable Figure 5: Single pipe floor penetration • When making floor or wall penetrations, make sure the hole is large enough to accommodate the pipe and the thermal insulation. When sealing around pipes at floor penetrations, avoid damag- ing or cutting the heating cable, or pinching it between the pipe and the concrete. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 14 • The heating cable must not be embedded directly in the sealing material; the pipe should have ther- mal insulation over it (if allowed by local codes) or the heating cable should be run through the pene- tration in a tube or conduit. If the conduit must be sealed, use a pliable fire-resistant material (Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame- Safe) that can be removed if necessary. Figure 6: multiple pipe floor penetration • On vertical piping groups, run the heating cable along the inside of the pipe close to other pipes so it will not be damaged if the pipe hits the side of the floor penetration. Run the heating cable over the outside of the pipe support. Do not clamp the heating cable to the pipe with the pipe support. • In high-rise construction it may be necessary to install the XL-Trace system 10 or 12 floors at a time to fit into the construction schedule. If so, the end of the heating cable should be sealed with a RayClic-E end seal and placed in an accessible location. This allows testing of one part of the heating cable at a time, and allows splicing it to another section when the system is complete. • When XL-Trace is installed behind walls, the power connection kit must be accessible. Whenever possible, position the heating cable on the lower section of the pipe as shown in Figure 7 to protect it from damage. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 15 Use one of the following attachment methods to secure the heating cable onto the pipe: GT-66 or GS-54 glass cloth tape, AT-180 aluminum tape, or plastic cable ties. Glass clotH adHesiVe tape • GT-66 (66-foot roll) general-purpose tape for installation at 40°F (4°C) and above. Apply at 1-foot intervals. • GS-54 (54-foot roll) general-purpose tape for installation below 40°F (4°C). Apply at 1-foot intervals. at-180 aluMinuM tape • Required for plastic pipe applications to ensure proper power output of heating cable. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 16 (Required for proper output for plastic pipe applications) Figure 8: attaching the heating cable caBle ties • Recommended in applications where the pipe sur- face prevents proper tape adhesion. • Use plastic cable ties only. • Cable ties must be hand-tightened only to prevent damage to heating cable! Bending/Crossing/Cutting the heating Cable BendinG tHe HeatinG caBle When positioning the heating cable on the pipe, do not bend tighter than 1/2" radius. The heating cable does not bend easily in the flat plane. Do not force such a bend, as the heating cable will be damaged. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 17 Installation guidelines 1/2" Figure 9: Bending technique crossinG tHe HeatinG caBle XL-Trace heating cables are self-regulating and may be overlapped whenever necessary without over- heating or burning out. cuttinG tHe HeatinG caBle Cut the heating cable to the desired length after it is attached to the pipe. XL-Trace can be cut to length without affecting the heat output per foot. Wrapping the heat Sinks Once the straight sections are secured the heating cable can be secured to the heat sinks. Attach the heating cable to the heat sinks according to Figure 10 below. The length of heating cable installed is determined in the design. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 18 Note: Cable loop length Pipe varies depending on heat loss. Heating cable Single crossover only, allowed for power-limiting cables Figure 10: Valve Glass tape (typical) Loop length is twice Heating cable the diameter of the pipe Figure 11: Flange Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 19 Installation guidelines Pipe Glass tape Heating cable Figure 12: Pressure gauge To power connection Pump discharge Heating cable Glass tape Pump body Pump body Pump body Motor Pump suction Use AT-180 tape Figure 13: Split case centrifugal pump Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 20 Heating cable secured to pipe Figure 14: Pipe support shoe Heating cable Glass tape (typical) For pipe diameters of 2" and larger, the heating cable should be installed on the outside (long) radius of the elbow. Figure 15: elbow Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 21: Heating Cable Connections

    If your design has an exposure temperature >150°F (65°C) but < 185°F (85°C), install all connections kits off the pipe. WarnIng: Connection kit approvals and perfor- mance are based on the use of specified parts only. Do not use substitute parts or vinyl electrical tape. Follow installation instructions provided with each kit. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 22 Installation guidelines EC-TS electronic thermostat Junction RayClic-PC power connection RayClic-LE RayClic-S lighted end seal splice (optional) Insulation RayClic-T RayClic-E end seal Figure 17: aboveground Xl-Trace System Use Table 3 for general aboveground piping, sprin- kler piping, and grease and fuel lines. Allow extra heating cable for ease of connection kit installation. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 23 Catalog number Description allowance Power connection and end 2 ft (0.6 m) seal kit; use 1 per circuit Standard pkg: RayClic-PC Power connection and end 2 ft (0.6 m) seal kit; use 1 per circuit Standard pkg: Junction box not included FTC-P Splice used to join two 2 ft (0.6 m) sections of heating cable Standard pkg: 2,3,6 RayClic-S Tee kit with end seal; 2 ft (0.6 m) use as needed for pipe branches Standard pkg: RayClic-T Alternate lighted end seal 2 ft (0.6 m) Standard pkg: RayClic-LE Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 24 Installation Guidelines TaBle 3: COnneCTIOn KITS FOr general aBOVegrOUnD PIPIng heating cable Catalog number Description allowance Continued Low-profile splice/tee; use as 3 ft (0.9 m) needed for pipe branches Standard pkg: FTC-HST Replacement end seal 0.3 ft (0.1 m) Standard pkg: RayClic-E For ease of component installation, allow extra heating cable. Powered splice, powered tee, and cross (tee with three legs) connections are also available. For grease and fuel lines, install RayClic-LE or end seal off the pipe in junction box. Not permitted with grease or fuel lines. Use for circuits supplied with 40 A circuit breaker. For grease and fuel lines, install tees and splices on pipe mounting bracket (RayClic-SB-04). Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 25 TaBle 4: aCCeSSOrIeS FOr general aBOVegrOUnD PIPIng heating cable Catalog numberDescription allowance “Electric Traced” label (use 1 label 10 labels per 10 feet of pipe) Glass cloth adhesive tape for 66 ft attaching heating cable to pipe at 40°F (4°C) or above. See Table 7. GT-66 Glass cloth adhesive tape for 54 ft attaching heating cable to pipe above –40°F (–40°C). See Table 7. GS-54 Aluminum tape. Required for 180 ft attaching heating cable to plastic pipe (use 1 foot of tape per foot of heating cable). AT-180 Pipe mounting bracket. Required 1 ea for mounting the kits off the pipe for exposure temperatures greater than 150°F (65°C) and for grease and fuel line splices and tees. RayClic-SB-04 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 26 Convolex tubing between the conduit and the RayClic connection kits. Figure 18: Buried pipe Xl-Trace System WarnIng: all heating cable connections (power, splice, tee, and end termination) are made above-ground. no buried or in-conduit splices or tees are allowed.
  • Page 27 TaBle 5: COnneCTIOn KITS FOr general BUrIeD PIPIng heating cable Catalog number Description allowance* • Power connection and 2 ft (0.6 m) end seal • Junction box supplied by customer • Use 1 per circuit Standard pkg: FTC-XC Power connection and end seal kit Standard pkg: RayClic-PC Replacement end seal. 0.3 ft (0.1 m) Standard pkg: RayClic-E Alternate lighted end seal 2 ft (0.6 m) Standard pkg: RayClic-LE * For ease of connection kit installation, allow extra heating cable. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 28 Glass cloth adhesive tape for 66 ft attaching heating cable to pipe at 40°F (4°C) or above. See Table 7. GS-54 Glass cloth adhesive tape for 54 ft attaching heating cable to pipe above –40°F (–40°C). See Table 7. AT-180 Aluminum tape. Required for 180 ft attaching heating cable to plastic pipe (use 1 foot of tape per foot of heating cable). RayClic-SB-02 Wall mounting bracket TaBle 7: QUanTITy OF glaSS ClOTh aDheSIVe TaPe reQUIreD (aTTaCh aT 1-FOOT InTerValS) Pipe size (in) <2 Feet of pipe per GT-66 roll Feet of pipe per GS-54 roll Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 29: Insulating The System

    Insulation Installation • Before insulating the pipe, visually inspect the heating cable and connection kits to ensure they are properly installed and there are no signs of damage. Damaged heating cable or connection kits must be replaced. • Check that the insulation type and thickness is correct. • Insulate the pipes immediately after the heating cable is installed and has passed all tests to mini- mize damage to the heating cable. • Insulate the pipe at floor and wall penetrations. Failure to do so will cause cold spots in the water system and could lead to damage to the heating cable. If local codes do not allow this, the heating cable should be run through a conduit or channel before the firestop is installed. Use a fire-resistant sealing compound such as Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame-Safe. • Do not use staples to seal insulation. Use tape or the adhesive-lined edge of the insulation to ensure that the seam remains sealed. Staples can damage the heating cable. Figure 19: Sealing the insulation seam Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 30 Thermal Insulation • All systems for outdoor, buried, or wet areas must use waterproof fire-resistant thermal insulation. • Mark the location of splices, tees, and end seals on the outside of the insulation with labels pro- vided in the kits, while installing the insulation. Use large diameter insulation or sheets to cover splices, tees, or service loops. Figure 20: Installing connection kits below insulation Figure 21: Installing connection kits above insulation Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 31 Thermal Insulation • Make sure that all heat-traced piping, fittings, wall penetrations, and branch piping are insu- lated. Correctly designed systems require properly installed and dry thermal insulation. Uninsulated or wet sections of pipe can result in cold spots or frozen sections. • After installing insulation, electrical codes require that you install “Electric Traced” labels along the piping at suitable intervals (10-foot intervals rec- ommended) on alternate sides. WarnIng: Use only fire-resistant insulation materials such as fiberglass wrap or flame-retardant foams. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 32: Power Supply And Electrical Protection

    Thermal management requirements, agency certifi- cations, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. arcing may not be stopped by conventional circuit breakers. WarnIng: Disconnect all power before making connections to the heating cable. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 33: Important Power Supply Safeguards

    Power Supply and Electrical Protection Important Power Supply Safeguards • Make sure that the heating cable load you are connecting is within the rating of the control sys- tem selected. Check the design drawings for the heating cable load. • The electrical conduit that feeds wiring to the control device must have a low-point drain so condensation will not enter the thermostat enclosure. • Make sure that the line voltage you are con- necting to the control system is correct. For proper wiring, follow the installation instructions enclosed with the control device. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 34: Control, Monitoring And Power Distribution

    Ambient-sensing systems energize the circuit when the ambient temperature drops below the set point. • Mount the device above grade level and out of sunlight. • Mount the device where it will be exposed to the coldest temperature and the highest wind. line-Sensing Control Line-sensing systems sense the pipe temperature by means of a sensor attached to the pipe and con- nected to the device. • Install the sensor on the pipe at 90 degrees from the heating cable so that the heating cable does not thermally interfere with the sensor. Be sure the sensor is firmly attached with aluminum tape to the pipe in order to get good thermal contact between the bulb and the pipe. • Locate the sensor at least 3 feet (1 meter) from any heat sinks, such as valves, pipe supports, and pumps. Ideally, the sensor should be located at the end of the heating cable circuit. • Be sure that you set the control to the proper temperature. • Mount the device on a nearby wall or support, or install a mounting stanchion. Thermostats must be mounted above grade level. In all cases, pro- tect the sensor from physical damage. To prevent damage, mount the device where it will be away from foot and equipment traffic. • To prevent water entry, seal the insulation where the capillary tube exits the insulation. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 35 Control, monitoring and Power Distribution TaBle 8: COnTrOl SySTemS Description electronic thermostats The Raychem EC-TS is an ambient or line- sensing electronic thermostat housed in a NEMA 4X enclosure with 2 x 1/2 in conduit entries for power and 1 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. Electrical rating is 30 A at 100– 277 V, 50–60 Hz, SPST switch. The EC-TS EC-TS includes a 25 ft (7.6 m) sensor. The Raychem ECW-GF is an ambient or line- sensing electronic controller with 30-mA ground-fault protection. The controller can be programmed to maintain temperatures up to 200°F (93°C) at voltages from 100 to 277 V and can switch current up to 30 Amperes. The ECW-GF is complete with a 25-ft (7.6- m) temperature sensor and is housed in a NEMA 4X rated enclosure. The controller ECW-GF features an AC/DC dry alarm contact relay. An optional ground-fault display panel (ECW- GF-DP) can be added to provide ground-fault or alarm indication in applications where the controller is mounted in inaccessible locations. ECW-GF-DP...
  • Page 36 Control, monitoring and Power Distribution TaBle 8: COnTrOl SySTemS Description The Raychem ACS-30 Advanced Commercial Control System is a multipoint electronic control and monitoring system for heat- tracing used in commercial freeze protection and flow maintenance applications. The Raychem ACS-30 system can control up to 260 circuits with multiple networked ACS- PCM2-5 panels, with a single ACS-UIT2 user interface terminal. The ACS-PCM2-5 panel ACS-UIT2 can directly control up to 5 individual heat- tracing circuits using electromechanical ACS-PCM2-5 relays rated at 30 A up to 277 V. Stainless steel jacketed three-wire RTD (Resistance Temperature Detector) used with Raychem C910-485 and ACS-30 controllers. RTD-200: 3-in (76 mm) temperature sensor with a 6-ft (1.8 m) lead wire and 1/2-in NPT RTDs bushing RTD3CS: temperature sensor with a 3-ft (0.9 m) flexible armor, 18-in (457mm) lead wire and 1/2-in NPT bushing RTD10CS: temperature sensor with a 10-ft (3 m) flexible armor, 18-in (457 mm) lead wire and 1/2-inch NPT bushing RTD50CS: temperature sensor with a 50-ft (3 m) flexible armor, 18-in (457 mm) lead wire and 1/2-in NPT bushing...

  • Page 37: Power Distribution

    Figure 22: Single circuit control Group control Temperature controller ø 1-pole GFEP breaker ø supply ø 3-phase ø 4-wire supply ø (WYE) 3-pole main breaker Contactor G (Typ 3) Heating cable sheath, braid or ground Figure 23: group circuit control Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 38 Selector switch PUSH TO ACKNOWLEDGE POWER ON HAND/OFF/AUTO Alarm option shown above Main circuit breaker Distribution panelboard Alarm relay (optional) Main TB 1 Fuse holder contactor Terminals Ground (optional) bus bar TB 2 Figure 24: hTPg power distribution panel Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 39 End seal Panel contactor External controller/ energized thermostat* One-pole Heating with 30-mA cable circuit ground-fault trip (120/277 Vac) Heating cable shealth, braid or ground Heating Two-pole cable circuit with 30-mA ground-fault trip (208/240 Vac) Figure 25: hTPg schematic Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 40: Commissioning And Preventive Maintenance

    Thermal Management requires a series of commis- sioning tests be performed on the XL-Trace system. These tests are also recommended at regular inter- vals for preventive maintenance. Results must be recorded and maintained for the life of the system, utilizing the “Installation and Inspection Record” (refer to Section 9). Submit this manual with initial commissioning test results to the owner. Tests A brief description of each test is found below. Detailed test procedures are found in Section 7. Visual Inspection Visually inspect the pipe, insulation, and connections to the heating cable for physical damage. Check that no moisture is present, electrical connections are tight and grounded, insulation is dry and sealed, and control and monitoring systems are operational and properly set. Damaged heating cable must be replaced. Insulation resistance Insulation Resistance (IR) testing is used to verify the integrity of the heating cable inner and outer jackets. IR testing is analogous to pressure testing a pipe and detects if a hole exists in the jacket. Circuit length Verification (Capacitance Test) The installed circuit length is verified through a capacitance measurement of the XL-Trace heat- ing cable. Compare the calculated installed length against the system design. If the calculated length is shorter than the system design, confirm all con- nections are secure and the grounding braid is continuous. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 41 Commissioning and Preventive Maintenance Power Check The power check is used to verify that the system is generating the correct power output. This test can be used in commissioning to confirm that the circuit is functioning correctly. For ongoing maintenance, compare the power output to previous readings. The heating cable power output per foot is calculated by dividing the total wattage by the total length of a circuit. The current, voltage, operation temperature, and length must be known. Circuit length can be determined from “as built” drawings, meter marks on the heating cable, or with the capacitance test. The watts per foot can be compared to the heating cable output in Figure 28 on page 43 for an indica- tion of heating cable performance. ground-Fault Test Test all ground-fault breakers per manufacturer’s instructions. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 42: Test Procedures

    4. Power test 5. Temperature test All test procedures are described in this manual. It is the installer’s responsibility to perform these tests or have an electrician perform them. Record the results in the Installation and Inspection Record in Section 10. Visual Inspection Test • Check inside all power, splice, and tee kits for proper installation, overheating, corrosion, mois- ture, or loose connections. • Check the electrical connections to ensure that ground and bus wires are insulated over their full length. • Check for damaged, missing, or wet thermal insulation. • Check that end seals, splices, and tees are prop- erly labeled on insulation cladding. • Check the controller for proper setpoint and operation. Refer to its installation and operation manual for details. Insulation resistance Test frequency Insulation resistance testing is required during the installation process and as part of regularly sched- uled maintenance, as follows: • Before installing the heating cable Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 43 B for any particular circuit should not vary more than 25 percent as a function of measuring voltage. greater variances may indicate a problem with your heat-tracing system; confirm proper installation and/ or contact Thermal management for assistance. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 44 Test Procedures Test A Test B Attach to pipe Figure 26: Insulation resistance test Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 45 11. Repeat this test between braid and pipe. 12. Reconnect bus wires to terminal block. 13. Reconnect the temperature controller. Circuit length verification (capacitance test) Connect the capacitance meter negative lead to both bus wires and the positive lead to the braid wire. Set the meter to the 200 nF range. Multiply this read- ing by the capacitance factor for the correct heating cable shown below to determine the total circuit length. Length (ft or m) = Capacitance (nF) x Capacitance factor (ft/nF or m/nF) TaBle 9: CaPaCITanCe FaCTOrS Capacitance factor heating cable ft/nF (m/nF) 5XL and 8XL (1.6) 12XL (1.8) Compare the calculated circuit length to the design drawings and circuit breaker sizing tables. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 46 Test Procedures Figure 27: Capacitance test Power Check The power output of self-regulating heating cable is temperature-sensitive and requires the following special procedure to determine its value: 1. Power the heating cable and allow it to stabilize for 2 hours, then measure current and voltage at the junction box. If a controller is used, refer to details below. 2. Check the pipe temperature under the thermal insulation at several locations. 3. Calculate the power of the heating cable by multiplying the current by the input voltage and dividing by the actual circuit length. Power (w/ft or m) = Volts (Vac) x Current (Amps) ________________________ Length (ft or m) The power calculated should be similar to the value generated by: Rated Power (w/ft or m) = Volts (Vac) x Rated Current Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 47: Fault Location Tests

    8XL1-CR and 8XL1-CT (120 V)  8XL2-CR and 8XL2-CT (208 V) Figure 28: Power output Fault location Tests There are three methods used for finding a fault within a section of heating cable. 1. Ratio method 2. Conductance method 3. Capacitance method ratio method The ratio method uses resistance measurements taken at each end of the heating cable to approxi- mate the location of a bus wire short. A shorted heating cable could result in a tripped circuit break- er. If the resistance can be read on a standard ohm meter this method can also be used to find a fault from a bus wire to the ground braid. This type of short would trip a GFPD and show a failed insulation resistance reading. Measure the bus-to-bus heating cable resistance at each end (measurement A and measurement B) of the suspected section. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 48 ________ (A + B) example: A = 1.2 ohms B = 1.8 ohms Fault location: D = 1.2 / (1.2 + 1.8) x 100 = 40% To locate a low resistance ground fault, measure between bus and braid. Braid Figure 30: low resistance ground-fault test The approximate location of the fault, expressed as a percentage of the heating cable length from the front end, is: Fault location: D = x 100 ________ (A + B) example: A = 1.2 ohms B = 1.8 ohms Fault location: D = 1.2 / (1.2 + 1.8) x 100 = 40% The fault is located 40% into the circuit as measured from the front end. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 49 Figure 31: heating cable resistance measurement The approximate location of the fault, expressed as a percentage of the heating cable length from the front Braid end, is: Fault location: D = 1/A x 100 ________ (1/A + 1/B) example: A = 100 ohms B = 25 ohms Fault location: D = (1/100) / (1/100 + 1/25) x 100 = 20% The fault is located 20% from the front end of the circuit. Capacitance method This method uses capacitance measurement (nF) as described on Figure 26, to approximate the location of a fault where the heating cable has been severed or a connection kit has not been connected. Record the capacitance reading from one end of the heating cable. The capacitance reading should be measured between both bus wires twisted together Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 50 Test Procedures (positive lead) and the braid (negative lead). Multiply the measured capacitance with the heating cable’s capacitance factor as listed in the following example: example: 5XL2-CR = 16.2 nF Capacitance factor = 5.0 ft/nF Fault location = 42.2 nF x 5.0 ft/nF = 211 ft (64 m) The ratio of one capacitance value taken from one end (A) divided by the sum of both A and B (A + B) and then multiplied by 100 yields the distance from the first end, expressed as a percentage of the total heating cable circuit length. See Table 9 on page 41 for capacitance factors. Fault location: C = x 100 ________ (A + B) Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 51 Test Procedures Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 52 Troubleshooting Guide Symptom Probable Causes Circuit breaker trips Circuit breaker is undersized Connections and/or splices are shorting out. Physical damage to heating cable is causing a direct short. Bus wires are shorted at the end. Circuit lengths too long. Nick or cut exists in heating cable or power feed wire with moisture pres- ent or moisture in connections. GFPD is undersized (5 mA used instead of 30 mA) or miswired. Low or inconsistent Nicks or cuts in the heating cable. insulation resistance Short between the braid and heating cable core or the braid and pipe. Arcing due to damaged heating- cable insulation. Moisture present in the connection kits. Test leads touching the junction box. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 53 Troubleshooting Guide Corrective action Recheck the design for startup temperature and current loads. Do not exceed the maximum circuit length for heat- ing cable used. Replace the circuit breaker if defective or improperly sized. Visually inspect the connection kits. Replace if necessary. Check for damage around the valves and any area where there may have been maintenance work. Replace damaged sections of heating cable. Check the end seal to ensure that bus wires are not shorted. If a dead short is found, the heating cable may have been permanently damaged by excessive current and may need to be replaced. Separate the circuit into multiple circuits that do not exceed maximum circuit lengths. Replace the heating cable, as necessary. Dry out and reseal the connection and splices. Using a megohmmeter, retest insulation resistance. Replace undersized GFPD with 30-mA GFPD. Check the GFPD wiring instructions If heating cable is not yet insulated, visually inspect the entire length for damage, especially at elbows in flanges and around valves. If the system is insulated, remove the connec- tion kits one-by-one to isolate the damaged section. Replace damaged heating-cable sections. If moisture is present, dry out the connections and retest. Be sure all conduit entries are sealed, and that condensate in conduit cannot enter power connection boxes. If heating- cable core or bus wires are exposed to large quantities of water, replace the heating cable. (Drying the heating cable is not sufficient, as the power output of the heating cable can be significantly reduced.) Clear the test leads from junction box and restart. Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 54 – – – – – – – – – – – – – – – 65°F – – – – – (indoors – – – – – grease) – – – – – * When circuit breaker sizing is listed in: • black type, the value is for applications with a 40°F maintain • type, the value is for applications with a 110°F maintain Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 55 172 177 346 365 385 253 258 266 370/462 390/486 420/513 340/349 344 355 206 217 229 142 145 150 275 290 306 190 194 200 370/416 390/438 420/462 285 291 300 370/554 390/584 420/616 349/398 360/406 380/419 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 56 – – – – – – – – – – – – – – – 18°C – – – – – (indoors – – – – – grease) – – – – – * When circuit breaker sizing is listed in: • black type, the value is for applications with a 4°C maintain • type, the value is for applications with a 43°C maintain Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 57 52 54 106 111 117 77 79 81 113/141 119/148 128/156 104/106 105 108 63 66 70 43 44 46 84 88 93 58 59 61 113/127 119/134 128/141 87 89 91 113/169 119/178 128/188 104/121 110/124 116/128 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 58 240 V 277 V (°C) –20 0.391 0.521 0.226 0.221 0.215 –18 0.343 0.457 0.198 0.194 0.188 –7 0.294 0.394 0.170 0.166 0.161 0.246 0.331 0.142 0.139 0.135 – – – – – – – – – – Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 59 277 V 0.301 0.286 0.270 0.354 0.347 0.336 0.264 0.251 0.238 0.329 0.322 0.312 0.227 0.216 0.205 0.311 0.305 0.296 0.191 0.181 0.172 0.276 0.271 0.263 0.172 0.164 0.155 0.259 0.254 0.246 0.145 0.138 0.130 0.233 0.228 0.221 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 60 Visual inspection Confirm 30-mA ground-fault device (proper rating/function) Visual inspection inside connection boxes for overheating, corrosion, moisture, and other problems. Proper electrical connection, ground, and bus wires insulated over full length Damaged or missing thermal insulation; damaged, missing, cracked lagging or weatherproofing. Covered end seals, splices, and tees properly labeled on insulation. Check controllers for moisture, corrosion, setpoint, switch operation. Insulation resistance test m-Ohms Bus to braid (Test A) 500 Vdc 1000 Vdc 2500 Vdc Braid to pipe (Test B) 500 Vdc 1000 Vdc 2500 Vdc Circuit length verification Capacitance test: Circuit length (ft) = Capacitance (nF) x Capacitance factor (x 3.28 = m) Power check Circuit voltage Panel (Vac) Circuit amps after 2 hours (Amps) Pipe temperature (°F) (°C) Power = (volts x amps after 2 hrs) / circuit length (watts/ft) (watts/m) Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 61 Installation and Inspection Record Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 62 Tel: +1.800.545.6258 Fax: +1.800.527.5703 Tel: +1.650.216.1526 Fax: +1.650.474.7711 thermal.info@pentair.com Pentair, RayClic, and XL-Trace are owned by Pentair or its global affili- ates. All other trademarks are the property of their respective owners. Pentair reserves the right to change specifications without prior notice. © 2008–2018 Pentair. Thermal managemenT Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

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