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Summary of Contents for nvent RAYCHEM BTV
- Page 1 Industrial Heat Tracing Installation and Maintenance Manual for Self-Regulating and Power-Limiting Heating Cable Systems...
- Page 2 • Approvals and performance of the heat-tracing systems are based on the use of nVent specified parts only. Do not substitute parts or use vinyl electrical tape. • Bus wires will short if they contact each other. Keep bus wires separated.
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Page 3: Table Of Contents
Heating Cable Selection Heating Cable Installation 3.1 Heating Cable Storage 3.2 Pre-Installation Checks 3.3 Installation Heating Cable Components 4.1 General Component Information Control and Monitoring Thermal Insulation 6.1 Pre-Insulation Checks 6.2 Insulation Installation Hints 6.3 Marking 6.4 Post-Insulation Testing nVent.com | iii... - Page 4 7.2 Electrical Loading 7.3 Ground-Fault Protection Commissioning and Preventive Maintenance 8.1 Tests 8.2 Preventive Maintenance Test Procedures 9.1 Visual Inspection 9.2 Insulation Resistance (Megger) Test 9.3 Power Check 9.4 Fault Location Tests Troubleshooting Guide Installation and Inspection Records iv | nVent.com...
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Page 5: General Information
This installation and maintenance manual is for nVent RAYCHEM Self-Regulating and Power-Limiting heat-tracing systems on thermally insulated pipes and vessels only. This includes nVent RAYCHEM BTV, HBTV, QTVR, HQTV, XTV, HXTV, KTV, VPL heating cables and the appropriate RAYCHEM components. -
Page 6: Warranty And Approvals
• Select the heating cable type and rating in accordance with the Industrial Product Selection and Design Guide (nVent literature #H56550), or TraceCalc Pro software, or the website design software. • Ensure all pipes, tanks, etc., have been released by the client for tracing prior to installation of the heating cables. -
Page 7: Heating Cable Selection
Check the design specification to make sure the proper heating cable is installed on each pipe or vessel. Refer to the Industrial Product Selection and Design Guide, TraceCalc Pro or the nVent web site, nVent.com, to select the proper heating cable for your application. nVent.com | 3... -
Page 8: Heating Cable Installation
• Walk the system and plan the routing of the heating cable on the pipe. • Inspect the piping for burrs, rough surfaces, or sharp edges. Remove if necessary. • Verify that any surface coatings are dry to the touch 4 | nVent.com... -
Page 9: Installation
I-beam, you will need to reinstall it or cut and splice it. Single cable Pipe Multiple cables from two reels Pipe Multiple cables from a single reel nVent.com | 5... - Page 10 One heating cable Two heating cables ATTACHMENT TAPES Use one of the following RAYCHEM attachment tapes to secure the heating cable on the the pipe: GT-66 or GS-54 fiberglass tape, or AT-180 aluminum tape. 6 | nVent.com...
- Page 11 Heating Cable Installation nVent RAYCHEM GT-66 fiberglass tape • General purpose tape for installation at 40°F (5°C) and above nVent RAYCHEM GS-54 fiberglass tape • Special application tape for stainless steel pipes • For installations at –40°F (–40°C) and above...
- Page 12 Refer to “Typical installation examples” on page 12 for attaching heating cable to heat sinks. Install heating cable components immediately after attaching the heating cable. If immediate installation is not possible, protect the heating cable ends from moisture. 8 | nVent.com...
- Page 13 10. For example, if the spiral factor of 1.3 is called for, leave a 13-foot loop of heating cable at every 10-foot section of pipe. Attach the loop to the pipe at each interval using the appropriate RAYCHEM attachment tape. nVent.com | 9...
- Page 14 BENDING THE CABLE 1/2" 3/4" Self-regulating Power-limiting minimum bend radius minimum bend radius When positioning the heating cable on the pipe, do not bend tighter than 1/2” for self-regulating cables and 3/4” for power-limiting cables. 10 | nVent.com...
- Page 15 FOR VPL HEATING CABLE ONLY: CUTTING THE CABLE Cut the heating cable to length after it is attached to the pipe. Heating cable can be cut to length without affecting the heat output per foot. nVent.com | 11...
- Page 16 Note: Cable loop length Pipe varies depending on heat loss Heating cable Single crossover only, allowed FLANGE for power-limiting cables Glass tape (typical) Loop length is twice Heating cable the diameter of the pipe 12 | nVent.com...
- Page 17 Support shoe Pipe Glass tape Heating cable secured to pipe ELBOW 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. nVent.com | 13...
- Page 18 Heating Cable Installation PRESSURE GAUGE Pipe Glass tape Heating cable SPLIT CASE CENTRIFUGAL PUMP To power connection Pump discharge Heating cable Glass tape Pump body Motor Pump suction Use AT-180 tape 14 | nVent.com...
- Page 19 Pipe hanger No additional heating cable is required for pipe hangers unless Heating cable called for in the design specification, then use loop length specified. Pipe hanger Heating cable Glass tape Do not clamp heating cable with support nVent.com | 15...
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Page 20: Heating Cable Components
• Heating cables must be installed over, not under, pipe straps used to secure components. • For VPL, cut cable 12” (30 cm) from last active node (indentation) to be sure an inactive zone is used to enter the component. Refer to component installation instructions. 16 | nVent.com... - Page 21 WARNING: The black heating cable core and fibers are electrically conductive and can short. They must be properly insulated and kept dry. Damaged bus wires can overheat or short. Do not break bus wire strands when stripping the heating cable. nVent.com | 17...
- Page 22 Heating Cable Components nVent RAYCHEM Components for Nonhazardous, CID2 and Zone 1 Hazardous Locations Power Connection Splice End Seal JBM-100-A PMKG-LS E-150 PKMG-LT E-100-L JS-100-A S-150 T-100 E-100 T-100 JBS-100-A PMKG-LE RAYCHEM Components for CID1 Hazardous Locations Splice HAK-JB3-100 junction box...
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Page 23: Control And Monitoring
Control and Monitoring nVent RAYCHEM control and monitoring products are designed for use with Self-Regulating and Power-Limiting heat-tracing systems. Thermostats, controllers and control and monitoring systems are available. Compare features of these products in the table below. For additional information on each product, refer to the Industrial Product Selection and Design Guide or contact your nVent representative. - Page 24 Control and Monitoring nVent Control and Monitoring Products THERMOSTATS CONTROLLERS AMC-F5 AMC-1B AMC-2B-2 AMC-F5 E507S-LS 1, 2 RAYCHEM Series AMC-1A E507S-2LS-2 AMC-1H Raystat-EX-03-A 910 920 200N T2000 NGC-30 Communications Local display ...
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Page 25: Thermal Insulation
After the insulation is complete, perform an insulation resistance test on each circuit to confirm that the cable has not been damaged (refer to Section 9). WARNING: Use only fire-resistant insulation, such as fiberglass, mineral wool, or calcium silicate. nVent.com | 21... -
Page 26: Power Supply And Electrical Protection
If arcing does occur, the fault current may be too low to trip conventional circuit breakers. nVent, the U.S. National Electrical Code, and the Canadian Electrical Code require both ground-fault protection of equipment and a grounded metallic covering on all heating cables. -
Page 27: Commissioning And Preventive Maintenance
Commissioning and Preventive Maintenance nVent requires a series of tests be performed on the heat-tracing system upon commissioning. These tests are also recommended at regular intervals for preventive maintenance. Results must be recorded and maintained for the life of the system, utilizing the “Installation and Inspection Record”... -
Page 28: Preventive Maintenance
Commissioning and Preventive Maintenance 8.2 Preventive Maintenance Recommended maintenance for nVent heat-tracing systems consists of performing the commissioning tests on a regular basis. Procedures for these tests are described in Section 9. Systems should be checked before each winter. If the heat-tracing system fails any of the tests, refer to Section 10 for troubleshooting assistance. -
Page 29: Test Procedures
First measure the resistance between the heating cable bus wires and the braid (Test A) then measure the insulation resistance between the braid and the metal pipe (Test B). Do not allow test leads to touch junction box, which can cause inaccurate readings. nVent.com | 25... - Page 30 WARNING: Fire hazard in hazardous locations. The insulation resistance test can produce sparks. Be sure there are no flammable vapors in the area before performing this test. 26 | nVent.com...
- Page 31 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 nVent for assistance. Test A Test B nVent.com | 27...
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Page 32: Power Check
Set the thermostat to the desired control temperature, or to a setting high enough to turn the circuit on if the pipe temperature is above the control temperature. • Turn on the main circuit breaker. • Turn on the branch circuit breakers. 28 | nVent.com... -
Page 33: Fault Location Tests
A shorted heating cable could result in a tripped circuit breaker or a cold section of pipe. Measure the bus-to-bus conductor resistance from the front end (measurement A) and the back end (measurement B) of the suspected section. nVent.com | 29... - Page 34 Example: A = 0.6 ohms B = 0.9 ohms Fault location: D = 0.6 / (0.6 + 0.9) x 100 = 40% The fault is located 40% along the circuit as measured from the front end (A). 30 | nVent.com...
- Page 35 (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 (A) of the circuit. nVent.com | 31...
- Page 36 (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 heating circuit length. 32 | nVent.com...
- Page 37 10XTV1-CT-T3 10.3 5BTV1-CR 10XTV2-CT-T3 10.7 5BTV2-CT 15XTV1-CT-T3 8BTV1-CR 15XTV2-CT-T3 8BTV2-CT 20XTV1-CT-T2 8BTV1-CR 20XTV2-CT-T2 10.1 8BTV2-CT 5KTV1-CT 10.8 10BTV1-CR 5KTV2-CT 11.1 10BTV2-CT 8KTV1-CT 10.3 10BTV1-CR 8KTV2-CT 10.5 10BTV2-CT 15KTV1-CT 10QTVR1-CT 15KTV2-CT 10QTVR2-CT 20KTV1-CT 15QTVR2-CT 20KTV2-CT 10.1 All VPL-CT nVent.com | 33...
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Page 38: Troubleshooting Guide
Bus wires are connected at the end. Nick or cut exists in heating cable or power feed wire with moisture present or moisture in connections. GFPD is undersized (5 mA used instead of 30 mA) or miswired. Reference tests: 34 | nVent.com... - Page 39 Replace the heating cable, as necessary. Dry out and reseal the connections and splices. Using a megohmmeter, retest insulation resistance. Replace undersized GFPD with 30 mA GFPD. Check the GFPD wiring instructions. Insulation Resistance Test, Fault Location Test, Visual Inspection nVent.com | 35...
- Page 40 Improper component connec- tion causing a high-resistance connection. Control thermostat is wired in normally open position. Pipe is at an elevated temperature. The heating cable has been exposed to excessive temperature, moisture or chemicals. Reference tests: 36 | nVent.com...
- Page 41 Splice in additional heating cable but do not exceed maximum circuit length. Reset the thermostat. Contact your nVent representative to confirm the design and modify as recommended. Reinstall the thermocouple on the pipe. Power Check, Visual Inspection Corrective Action Repair the electrical supply lines and equipment.
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Page 42: Installation And Inspection Records
Test B 500 Vdc (braid to pipe) 1000 Vdc 2500 Vdc Power check Circuit voltage Panel (Vac) Circuit end* (Vac) Circuit amps after 10 min (Amps) Pipe temperature (°F) Power = Volts x amps/ft (watts/ft) * Commissioning only 38 | nVent.com... - Page 43 Ohms Ohms Ohms Ohms nVent.com | 39...
- Page 44 Installation and Inspection Records nVent Heat-Tracing Installation and Inspection Record Facility Circuit number Heating cable type Circuit length Commission Inspection date: Visual Inspection Visual inspection inside connection boxes for signs of overheating, corrosion, moisture, loose connections and other problems. Proper electrical connection, ground, and bus wires insulated over full length.
- Page 45 Ohms Ohms Ohms Ohms nVent.com | 41...
- Page 46 FM Required Installation Record for Class I, Division 1, Hazardous Locations To complete the FM approval process, this complete form must be returned to the nVent Customer Service Center (fax number (800) 527-5703) Company name _____________________________________________ Circuit ID no. ________________________________________________ Area ________________________________________________________ Autoignition temp.
- Page 47 Circuit length: _______________________________________________ Temp ID (T-rating) ___________________________________________ Splice: ______________________________________________________ End seal: ____________________________________________________ Device trip level: ____________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Calibration date: Test value Date Initials ___________________________________________________________________ ___________________________________________________________________ Test value Date Initials ___________________________________________________________________ ___________________________________________________________________ Company Date Company Date nVent.com | 43...
- Page 48 Fax +1.713.868.2333 thermal.info@nvent.com nVent.com ©2018 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.
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