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Summary of Contents for nvent RAYCHEM HWAT-SYSTEM
- Page 1 HWAT-SYSTEM Installation and Maintenance Manual for Pipes with Thermal Insulation...
- Page 2 Safety warnings The following instructions must be followed to avoid fires or electric shock as well as to satisfy the nVent warranty conditions and the requirements of the product approvals. nVent RAYCHEM HWAT Systems must be installed correctly to ensure proper operation and to prevent shock and fire.
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Page 3: Table Of Contents
General information Heat-tracing cable selection Heat-tracing cable installation HWAT components Controlling and monitoring Thermal insulation Power supply and electrical protection 19 Commissioning Troubleshooting List of possible faults Installation and test sheet nVent.com | 3... -
Page 4: General Information
The guidelines and instructions contained in this guide are important. Follow them carefully to minimise these risks and to ensure that the HWAT System performs reliably. 4 | nVent.com... - Page 5 Connection Warning label Tee connection Power connection Control unit Note: Partial pipe insulation shown here for clarity. All pipes must be insulated at least according to the specified regulations. Figure 1: Typical HWAT heat-tracing cable system nVent.com | 5...
- Page 6 Ensuring that the installation of the HWAT System is included in the overall construction schedule will help ensure a successful and trouble-free installation. 6 | nVent.com...
- Page 7 • Heat gun or propane gas burner (when using shrink kits) For testing the heat-tracing cable: • Insulation tester 500 VDC to 2500 VDC • Multimeter (voltage, resistance and capacitance) • Temperature measuring device • Infrared thermometer, e.g. the CDE-IR-Temp from RAYCHEM nVent.com | 7...
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Page 8: Heat-Tracing Cable Selection
Figure 2 shows the structure of the heat-tracing cables. Protective jacket of modified polyolefin Protective tinned copper braid Aluminium laminated foil (For protection against chemical ingress) Modified polyolefin insulation Self-regulating heating element Copper conductor (1.2 mm²) Figure 2: Heat-tracing cables HWAT-M and HWAT-R 8 | nVent.com... -
Page 9: Heat-Tracing Cable Installation
• Install the cable in straight runs along the pipe. Spiralling the heat-tracing cable is not necessary. • When installing the heat-tracing cable, the cable must not be compressed or pinched between two objects. Wall and floor penetrations and pipe straps are particular areas of concern. nVent.com | 9... - Page 10 • Metre marks on the HWAT cable make it easier to determine the length of the heat-tracing cable. • Protect all heat-tracing cable ends from moisture, contamination and mechanical damage. 10 | nVent.com...
- Page 11 When positioning the heat-tracing cable on the pipe, do not bend tighter than 10 mm radius. The heat- tracing cable does not bend in the flat plane. Do not force such a bend, as the heat-tracing cable will be damaged. nVent.com | 11...
- Page 12 Figure 7: Fastening the heat-tracing cable CAUTION: Do not use metal attachments such as pipe straps or tie wire. Do not use untested adhesive tapes. Use only fastening materials approved by nVent and listed in the Technical Manual. 12 | nVent.com...
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Page 13: Hwat Components
4 HWAT COMPONENTS 4.1 General connection kit information nVent RAYCHEM RayClic connection kits must be used with HWAT heat-tracing cables. A complete circuit requires a power connection and an end seal. Splices and tees and other connection kits are used as needed. - Page 14 CAUTION: The black heat-tracing cable core is electrically conductive and can short. It must be properly insulated and kept dry. Damaged bus wires can overheat or short. CAUTION: RAYCHEM specified components must be used. Do not replace RAYCHEM components with untested components. 14 | nVent.com...
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Page 15: Controlling And Monitoring
5 CONTROL AND MONITORING 5.1 HWAT-ECO Control Unit The nVent RAYCHEM HWAT-ECO control unit is designed exclusively for using with the HWAT-M and HWAT-R heat-tracing cables. It is used to optimise the HWAT temperature maintenance system. Refer to the HWAT-ECO Installation and Operation Manual for the installation and operation instructions of the control unit (INST-189). -
Page 16: Thermal Insulation
50 mm 60 mm Heat losses in W/m, pipe 55°C in 5°C environment Insulation Type DN 15 DN 20 DN 32 DN 40 DN 50 15 mm 20 mm 30 mm 40 mm 50 mm 60 mm 16 | nVent.com... - Page 17 (mm) Ambient temperature: 18°C Thermal conductivity l = 0.035 W/(m.K) For other thermal conductivity insulation materials, contact your nVent representative. 6.2 Insulation installation • Before insulating the pipe, visually inspect the heat-tracing cable and connection kits to ensure they are properly installed and there are no signs of damage.
- Page 18 • After installing insulation, electrical codes require that you install “Electric Traced” labels along the piping at suitable intervals (5 m intervals recommended) on alternate sides. CAUTION: Only use thermal insulation approved for hot water pipes according to local insulation regulations. 18 | nVent.com...
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Page 19: Power Supply And Electrical Protection
This must be checked and approved by the installation technician. CAUTION: In order to reduce risk, nVent recommendations for fault current circuit breakers (max. 30 A) must be installed as protection against ground faults. -
Page 20: Commissioning
8 COMMISSIONING nVent requires a series of commissioning tests be performed on the HWAT System. Individual 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” (refer to Section 11). - Page 21 500 and 1000 volts. Measure the resistance between the bus wires of the heat-tracing cable and the protective braid (figure 10). Note: System tests and regular maintenance procedures require that insulation resistance testing be performed. Testing Figure 10: Insulation resistance test nVent.com | 21...
- Page 22 Make sure that the cold water and hot water is not in the same hydraulic pressure zone. Different flow pressures lead to strong temperature fluctuations at the outlet valve. 22 | nVent.com...
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Page 23: Troubleshooting
The fault is at 40% of the circuit length measured from end “A”. 9.2 Determining interruptions on self-regulating heat-tracing cables Interruptions in the heat-tracing cables can be localised with this method. A damaged heat-tracing cable can lead to a cold pipe section. nVent.com | 23... - Page 24 2. The capacitance must be measured between both bus wires twisted together (positive lead) and the braid (negative lead). Note down the value. Figure 11: Capacitance test 3. Select the capacitance factor for the installed heat-tracing cable from table 4. 24 | nVent.com...
- Page 25 100 yields the distance from the end “A”, expressed as a percentage of the total heat-tracing cable circuit length. See Table 4 for capacitance factors. Fault location: C = x 100 (A + B) nVent.com | 25...
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Page 26: List Of Possible Faults
Connection kit or RayClic not connected properly HWAT-ECO setting or connection incorrect. The heating cable has been exposed to excessive temperature, moisture or chemicals Heating cable with too low a power installed 26 | nVent.com... - Page 27 Check the pipe or boiler temperature. Compare the heating power of the HWAT cable according to the layout with the actual heating power. Reduce the pipe temperature if possible or consult your nVent representative to have the layout confirmed. Replace damaged heat-tracing cable. Check the pipe temperature.
- Page 28 (5 mA instead of 30 mA) or incorrectly wired Symptom Probable causes Low or Mechanical damage to protective jacket inconsistent of heat-tracing cable or damaged insulation insulation of the heating element resistance Moisture is present in the connection kits. 28 | nVent.com...
- Page 29 Check seal in lid of RayClic and then re-close (the catch must close audibly and visibly). If water has penetrated the Rayclic system, the heat-tracing cable may have been damaged. The heat-tracing cable must then be replaced. nVent.com | 29...
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Page 30: Installation And Test Sheet
1000 VDC (test A) 2500 VDC Power test Operating voltage Heating circuit current after 2 hours Pipe temperature (°C) Power = (volts x amps after 2 hrs) / circuit length (watts/m) 30 | nVent.com... - Page 31 | 31...
- Page 32 0800 0224993 salesnl@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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