Pentair Raychem XL-Trace Installation And Operation Manual
  1. Manuals
  2. Brands
  3. Pentair Manuals
  4. Heater
  5. Raychem XL-Trace
  6. Installation and operation manual
Pentair Raychem XL-Trace Installation And Operation Manual

Pentair Raychem XL-Trace Installation And Operation Manual

Pipe freeze protection and flow maintenance
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
All manuals and user guides at all-guides.com
XL-Trace System
InstallatIon and operatIon manual for
pIpe freeze protectIon and flow
maIntenance
Thermal managemenT
WWW.PenTaIrThermal.COm

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Raychem XL-Trace and is the answer not in the manual?

Questions and answers

Related Manuals for Pentair Raychem XL-Trace

Summary of Contents for Pentair Raychem XL-Trace

  • Page 1 All manuals and user guides at all-guides.com XL-Trace System InstallatIon and operatIon manual for pIpe freeze protectIon and flow maIntenance Thermal managemenT WWW.PenTaIrThermal.COm...
  • Page 2 All manuals and user guides at all-guides.com Important Safeguards and Warnings WarnIng: FIre anD ShOCK haZarD. raychem heat-tracing systems must be installed cor- rectly to ensure proper operation and to prevent shock and fire. read these important warnings and carefully follow all the installation instructions.

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com Table of Contents general Information 1.1 Use of the Manual 1.2 XL-Trace Applications 1.3 Safety Guidelines 1.4 Approvals Installation guidelines 2.1 Heating Cable Storage 2.2 Pre-Installation Checks 2.3 Heating Cable Installation 2.4 Heating Cable Connections Thermal Insulation 3.1 Insulating the System 3.2 Insulation Installation Power Supply and electrical Protection 4.1 Voltage Rating 4.2 Circuit Breaker Sizing 4.3 Electrical Loading...
  • Page 4 All manuals and user guides at all-guides.com Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 5: General Information

    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 thermal.info@pentair.com www.pentairthermal.com Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 6: Xl-Trace Applications

    All manuals and user guides at all-guides.com General Information Xl-Trace applications XL-Trace heat-tracing systems are approved and qualified for the applications listed below. Freeze protection • general water piping. Freeze protection (40°F (4°C) maintain) of insulated metallic or plastic water piping. • Sprinkler piping systems. Freeze protection (40°F (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.

  • Page 7: Approvals

    All manuals and user guides at all-guides.com 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: Installation Guidelines

    All manuals and user guides at all-guides.com Installation Guidelines heating Cable Storage • Store the heating cable in a clean, dry location. Temperature range: 0°F (–18°C) to 140°F (60°C). • Protect the heating cable from mechanical damage. Pre-Installation Checks Check materials received Catalog number: 5, 8 or 12 XL — 1 or 2 -CR -CT Power output (W/ft) Product family Voltage 1 = 120 Vac (only available for 5 or 8) 2 = 208–277 Vac (available for 5, 8, or 12) Jacket type: Polyolefin or...

  • Page 9: Heating Cable Installation

    All manuals and user guides at all-guides.com Installation Guidelines 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...
  • Page 10 All manuals and user guides at all-guides.com Installation Guidelines Figure 2: Paying out the heating cable When paying out the heating cable, aVOID: • Sharp edges • Excessive pulling force or jerking • Kinking or crushing • Walking on or running over the heating cable with equipment WarnIng: Fire and shock hazard. Do not install damaged heating cable.
  • Page 11 All manuals and user guides at all-guides.com Installation Guidelines Figure 3: attaching the heating cable Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 12 All manuals and user guides at all-guides.com Installation Guidelines TaBle 1: aDDITIOnal heaTIng CaBle FOr ValVeS Pipe diameter (IPS) heating cable in 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 (1.3) 4.3 (1.3) 4.3 (1.3) 5.0...
  • Page 13 All manuals and user guides at all-guides.com Installation guidelines • Run insulation through the pipe hanger ensuring that the pipe is not resting on the heater. Pipe hanger Pipe hanger under insulation over insulation Insulation over pipe hanger 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...
  • Page 14 All manuals and user guides at all-guides.com Installation Guidelines • 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.
  • Page 15 All manuals and user guides at all-guides.com Installation guidelines One heating cable Two heating cables 45° 45° 45° Figure 7: Positioning the heating cable Securing the heating cable WarnIng: Damage to the heating cable can cause electrical arcing or fire. Do not use metal attachments such as pipe straps or tie wire.
  • Page 16 All manuals and user guides at all-guides.com Installation guidelines • Tape lengthwise over the heating cable as required by the design drawing or specification (see Figure 8). • Recommended for heat-tracing pump bodies or odd-shaped equipment, or as called out in the design drawing as a heat-transfer aid. • Install at temperatures above 32°F (0°C). AT-180 Pipe Heating aluminum tape cable Glass cloth tape Weather proofing Thermal insulation Pipe AT-180 aluminum tape Heating cable over heating cable (Required for proper output for plastic pipe applications)
  • Page 17 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Installation guidelines Valve body Pipe Glass tape Heating cable Multiple crossovers allowed for self-regulating cables 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)
  • Page 19 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Installation guidelines Heating cable loop Support shoe Pipe Glass tape 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.

  • Page 21: Heating Cable Connections

    All manuals and user guides at all-guides.com Installation guidelines Pipe hanger Pipe hanger under insulation over insulation Insulation over pipe hanger Heating cable Heating cable over pipe hanger beneath insulation Heating cable Heating cable and pipe hanger Figure 16: Pipe hanger heating Cable Connections general requirements All XL-Trace systems require a power connection...
  • Page 22 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Installation Guidelines TaBle 3: COnneCTIOn KITS FOr general aBOVegrOUnD PIPIng heating cable 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:...
  • Page 24 All manuals and user guides at all-guides.com 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.
  • Page 25 All manuals and user guides at all-guides.com Installation Guidelines 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...
  • Page 26 All manuals and user guides at all-guides.com Installation guidelines EC-TS electronic thermostat –1C Alternate end seal RayClic-LE* FTC-XC with wall power mounting connection Wall bracket Conduit Ground Temperature sensor Junction box Insulation RayClic-E end seal RayClic-PC* Conduit Ground with wall mountiung bracket XL-Trace...
  • Page 27 All manuals and user guides at all-guides.com Installation Guidelines 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.
  • Page 28 All manuals and user guides at all-guides.com Installation Guidelines TaBle 6: aCCeSSOrIeS FOr general BUrIeD PIPIng Catalog Standard number Description “Electric Traced” label (use 1 10 labels label per 10 feet of pipe) GT-66 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)

  • Page 29: Thermal Insulation

    All manuals and user guides at all-guides.com Thermal Insulation Insulating the System Pipes must be insulated with the correct thermal insulation to maintain the desired pipe tempera- tures. Confirm that the insulation thickness agrees with the system design. 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...
  • Page 30 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Power Supply and Electrical Protection Voltage rating Verify that the supply voltage is either 120 or 208–277 volts as specified by the XL-Trace system design and printed on the jacket of the heating cable. Circuit Breaker Sizing Circuit breakers must be sized using the heating cable lengths shown in the Appendix. Do not exceed the maximum circuit length shown for each breaker size. Use circuit breakers that incorporate 30-mA ground-fault circuit protection, or provide equivalent levels of ground-fault protection. electrical loading The maximum current draw for XL-Trace heating cables is shown in the Appendix. To size the trans- former, multiply the total heating cable length (ft) by the appropriate current draw. ground-Fault Protection If the heating cable is improperly installed or physi- cally damaged to the point that water contacts the bus wires, sustained arcing or fire could result. If arcing does occur, the fault current may be too low to trip conventional circuit breakers. Thermal Management and national electrical codes require both ground-fault protection of equipment and a grounded metallic covering on all heating cables.

  • Page 33: Important Power Supply Safeguards

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Control, Monitoring and Power Distribution Control Systems Electronic thermostats provide higher accuracy of the heating cable circuit with thermistor sensors and built-in ground-fault protection. Electronic controllers provide superior accuracy with RTD temperature sensors, built-in ground-fault pro- tection, monitoring and alarm output. ambient-Sensing Control 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.
  • Page 35 All manuals and user guides at all-guides.com 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.
  • Page 36 All manuals and user guides at all-guides.com 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...

  • Page 37: Power Distribution

    All manuals and user guides at all-guides.com Control, Monitoring and Power Distribution Power Distribution Once the heating cable circuits have been defined, you must select how to provide power to them. Power to the XL-Trace heating cables can be pro- vided in several ways: directly through the tempera- ture control, through external contactors, or through HTPG power distribution panels Typical Wiring Schematics Single circuit control ø Heating ø cable supply Temperature controller 1-pole GFEP breaker Heating cable sheath, braid or ground Figure 22: Single circuit control Group control Temperature...
  • Page 38 All manuals and user guides at all-guides.com Control, Monitoring and Power Distribution Alarm horn (optional) Door disconnect (optional) Push button for light testing COMMON ALARM Selector switch PUSH TO ACKNOWLEDGE POWER ON HAND/OFF/AUTO Alarm option shown above Main circuit breaker Distribution panelboard Alarm relay...
  • Page 39 All manuals and user guides at all-guides.com Control, Monitoring and Power Distribution Alarm remote annunciation (with alarm option) Power connection Three-pole main Ø 1 Ø 2 Ø 3 Contactor Hand Auto circuit breaker coil Heating cable Three-pole main End seal contactor External controller/ Panel...

  • Page 40: Commissioning And Preventive Maintenance

    All manuals and user guides at all-guides.com 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...
  • Page 41 All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Test Procedures System Tests The following tests must be done after installing the connection kits, but before the thermal insulation is applied to the pipe: 1. Visual inspection 2. Insulation resistance test After the thermal insulation has been installed on the pipe, the following tests must be performed: 1. Visual inspection 2. Insulation resistance test 3. Circuit length verification (Capacitance test) 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.
  • Page 43 All manuals and user guides at all-guides.com Test Procedures • Before installing connection kits • Before installing the thermal insulation • After installing the thermal insulation • Prior to initial start-up (commissioning) • As part of the regular system inspection • After any maintenance or repair work procedure Insulation resistance testing (using a megohm- meter) should be conducted at three voltages: 500, 1000, and . Potential problems may not be 2500 Vdc detected if testing is done only at 500 and 1000 volts. 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. Important: System tests and regular maintenance procedures require that insulation resistance testing be performed.
  • Page 44 All manuals and user guides at all-guides.com Test Procedures Test A Test B Attach to pipe Figure 26: Insulation resistance test Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 45 All manuals and user guides at all-guides.com Test Procedures insulation resistance test procedure 1. De-energize the circuit. 2. Disconnect the controller if installed. 3. Disconnect bus wires from terminal block. 4. Set test voltage at 0 Vdc. 5. Connect the negative (–) lead to the heating cable metallic braid or RayClic green wire. 6. Connect the positive (+) lead to both heating cable bus wires or RayClic black wires. 7. Turn on the megohmmeter and set the voltage to 500 Vdc; apply the voltage for one minute. Meter needle should stop moving. Rapid deflection indicates a short. Record the insulation resis- tance value in the Inspection Record. 8. Repeat Steps 4–7 at 1000 and 2500 Vdc. 9. Turn off the megohmmeter. 10. If the megohmmeter does not self-discharge, discharge phase connection to ground with a suitable grounding rod. Disconnect the megohmmeter.
  • Page 46 All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com Test Procedures    °F (–1) (10) (15) (21) (27) (32) (38) (43) (49) (54) (°C) Pipe temperature 5XL1-CR and 5XL1-CT (120 V)  12XL2-CR and 12XL2-CT (208 V)  5XL2-CR and 5XL2-CT (208 V) 8XL1-CR and 8XL1-CT (120 V) ...
  • Page 48 All manuals and user guides at all-guides.com Braid Test Procedures Figure 29: heating cable resistance measurement 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% 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:...
  • Page 49 All manuals and user guides at all-guides.com Test Procedures Conductance method The conductance method uses the core resistance of the heating cable to approximate the location of a fault when the heating cable has been severed and the bus wires have not been shorted together. A severed heating cable may result in a cold section of pipe and may not trip the circuit breaker. Measure the bus-to-bus heating cable resistance at each end (measurement A and measurement B) of the suspect section. Since self-regulating heating cables are a parallel resistance, the ratio calculations must be made using the conductance of the heating cable. 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%...
  • Page 50 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com Test Procedures Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...

  • Page 52: Troubleshooting Guide

    All manuals and user guides at all-guides.com Troubleshooting Guide Symptom Probable Causes Corrective action Circuit breaker trips Circuit breaker is undersized Recheck the desi loads. Do not exc ing cable used. R improperly sized. Connections and/or splices are Visually inspect th shorting out. Physical damage to heating cable is Check for damag causing a direct short. there may have b sections of heatin Bus wires are shorted at the end. Check the end se If a dead short is permanently dam be replaced. Circuit lengths too long. Separate the circ maximum circuit Nick or cut exists in heating cable or Replace the heati power feed wire with moisture pres- the connection an ent or moisture in connections.
  • Page 53 All manuals and user guides at all-guides.com Troubleshooting Guide Corrective action ndersized 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. splices are Visually inspect the connection kits. Replace if necessary. heating cable is Check for damage around the valves and any area where ort. there may have been maintenance work. Replace damaged sections of heating cable. ed at the end. 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. ong. Separate the circuit into multiple circuits that do not exceed maximum circuit lengths. heating cable or Replace the heating cable, as necessary. Dry out and reseal h moisture pres- the connection and splices. Using a megohmmeter, retest onnections. insulation resistance. (5 mA used Replace undersized GFPD with 30-mA GFPD. Check the r miswired. GFPD wiring instructions heating cable.

  • Page 54: Appendix

    All manuals and user guides at all-guides.com Appendix TaBle a1 maXImUm CIrCUIT lengTh In FeeT Start-up 5Xl1 8Xl1 5Xl2 8Xl2 temperature CB size (°F) 120 V 120 V 208 V 240 V 277 V 208 V 240 V 131 138 175 184 –20°F...
  • Page 55 All manuals and user guides at all-guides.com Appendix application 40°F/110°F maintain* Circuit breaker sizing (ft) 5Xl2 8Xl2 12Xl2 240 V 277 V 208 V 240 V 277 V 208 V 240 V 277 V 131 138 146 111 114 117 175 184 194...
  • Page 56 All manuals and user guides at all-guides.com Appendix TaBle a2 maXImUm CIrCUIT lengTh In FeeT Start-up 5Xl1 8Xl1 5Xl2 8Xl2 temperature CB size (°C) 120 V 120 V 208 V 240 V 277 V 208 V 240 V 23 53 54 56 40...
  • Page 57 All manuals and user guides at all-guides.com Appendix application 4°C/43°C maintain* Circuit breaker sizing (fm) 5Xl2 8Xl2 12Xl2 240 V 277 V 208 V 240 V 277 V 208 V 240 V 277 V 54 56 40 42 44 34 35 36 72...
  • Page 58 All manuals and user guides at all-guides.com Appendix TaBle a3 TranSFOrmer SIZIng (amPereS/FOOT) 5Xl1 8Xl1 5Xl2 8Xl1 minimum start-up temperature 120 V 120 V 208 V 240 V 277 V 208 V 240 V (°F) –20 0.119 0.159 0.069 0.067 0.065 0.092 0.087...
  • Page 59 All manuals and user guides at all-guides.com Appendix S/FOOT) 5Xl2 8Xl1 12Xl2 240 V 277 V 208 V 240 V 277 V 208 V 240 V 277 V 0.067 0.065 0.092 0.087 0.082 0.108 0.106 0.102 0.059 0.057 0.080 0.076 0.072 0.100 0.098...

  • Page 60: Installation And Inspection Records

    All manuals and user guides at all-guides.com Installation and Inspection Record Installation and Inspection record Facility Test Date: Circuit number: Heating cable type: Controllers: Temperature setting: Circuit length: Commission Inspection date: 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...
  • Page 61 All manuals and user guides at all-guides.com Installation and Inspection Record ating/function) overheating, corrosion, wires insulated over aged, missing, cracked labeled on insulation. point, switch operation. m-Ohms ce (nF) x (Vac) (Amps) (°F) (°C) th (watts/ft) (watts/m) Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01...
  • Page 62 All manuals and user guides at all-guides.com www.pentairthermal.com north america 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...

Table of Contents