Self-regulating and power limiting heating cable systems Installation and maintenance manual
| nVent.
1 General information 9 2 Heating cable selection 10 3 Heating cable installation 10 4 Components installation 19 5 Thermostats 25 6 Thermal insulation and marking 26 7 Power supply and electrical protection 28 8 Heating cable testing 28 9 Operation, maintenance and pipe repairs 31 10 Heating cable damage 32 11 Troubleshooting guide 32 Register for your extended warranty on nVent.com/RAYCHEM. nVent.
ATEX/UKEX Certificate No Code II 2 G Ex 60079-30-1 eb IIC T6 Gb II 2 D Ex 60079-30-1 tb IIIC T80°C Db BTV SGS20ATEX0048X (BAS21UKEX0497X) or II 2 G Ex 60079-30-1 eb mb IIC T6 Gb II 2 D Ex 60079-30-1 mb tb IIIC T80°C Db Tmin –60°C II 2 G Ex 60079-30-1 eb IIC T4 Gb II 2 D Ex 60079-30-1 tb IIIC T130°C Db QTVR SGS20ATEX0050X (BAS21UKEX0498X) XTV SGS20ATEX0049X (BAS21UKEX0499X) KTV SGS20ATEX0051X (BAS21UKEX0500X) HTV PTB21ATEX1003X (BAS21UKEX0649X) VPL SGS20ATEX0045X (BAS21UKEX0503X) or II 2 G Ex
HTV IECxPTB21.0007X Ex 60079-30-1 eb IIC T* Gb Ex 60079-30-1 tb IIIC T**°C Db or Ex 60079-30-1 eb mb IIC T* Gb Ex 60079-30-1 mb tb IIIC T**°C Db Tmin -60°C (* ** see schedule) VPL IECEx BAS 20.0008X “Ex 60079-30-1 eb IIC T* Gb Ex 60079-30-1 tb IIIC T**°C Db or Ex 60079-30-1 eb mb IIC T* Gb Ex 60079-30-1 mb tb IIIC T**°C Db Tmin –60°C (* ** see schedule)” Product name in SAP Certificate No Code BTV CABLE ТС RU C-BE. МЮ62.В.
Specific Conditions of Use The following limiting temperatures for the end seals, splices and power connections shall not be exceeded: +110°C for the S-20 and E-20 +260°C for the E-40 and S-40 +150°C for the C-150-E, S-150 and E-150 +151°C for the E-100, E-100-L and JBS-100 +155°C for the JBM-100 and T-100 +110°C for the C25-21 and C25-100 +180°C for the C25-100-METAL/C3/4-100-METAL The E-100, E-100-L, JBM-100, JBM-100-L, JBS-100, JBS-100-L and T-100 have limiting temperatures based on an internal component
Rated Voltage BTV1, QTVR1, KTV1, XTV1, HTV1, VPL1: 110V, 120V BTV2, QTVR2, KTV2, XTV2, HTV2, VPL2: 230V, 277V, VPL4: 400V, 480V BSA BTV QTVR XTV KTV HTV VPL –60°C ≤ T < –20°C 35 35 35 51 26 25 19 –20°C ≤ T < –10°C 30 30 30 35 20 20 15 –10°C ≤ T < 0°C 25 25 25 25 15 15 15 0°C ≤ T < +10°C 20 20 20 20 15 15 15 T ≥ +10°C 10 12 12 12 12 13 12 Minimum Installation Temperature –60°C –60°C –60°C –60°C –60°C –60°C –60°C Min.
Cable 110 V 230 V 254 V 277 V 400 V 480 V 20VPL1-CT 150°C - - - - - 5VPL2-CT - 230°C 225°C 225°C - - 10VPL2-CT - 210°C 200°C 195°C - - 15VPL2-CT - 180°C 145°C 105°C - - 20VPL2-CT - 150°C - - - - 5VPL4-CT - - - - 230°C 230°C 10VPL4-CT - - - - 215°C 205°C 15VPL4-CT - - - - 195°C 160°C 20VPL4-CT - - - - 150°C 150°C 8 | nVent.
1 GENERAL INFORMATION Use of the manual The Installation and Maintenance manual is for nVent RAYCHEM self-regulating and power limiting heating cable systems on thermally insulated pipes and vessels only. For information regarding other applications contact your nVent representative. BSA, BTV, QTVR, XTV, KTV, HTV Self Regulating Heating Cables L N • Power output varies with temperature. As pipe temperature increases, power output decreases.
2 HEATING CABLE SELECTION The design of electrical resistance heat tracing systems shall be overseen by persons knowledgeable of heat tracing following the design methodology for explosive atmospheres as specified by the manufacturer. Check the design specification to make sure the proper heating cable is installed on each pipe or vessel. Refer to nVent product literature and the TraceCalc software to select the proper heating cable for each thermal, chemical, electrical and mechanical environment.
Check piping to be traced: • Ensure all pressure testing is complete and pipework has final paint coating. • Walk the system and plan the routing of the heating cable on the pipe. • Check pipework against specification drawing. If different consult design authority. • Inspect piping for burrs, rough surfaces, sharp edges etc. which could damage the heating cable. Smooth off or cover with layers of glass cloth tape or aluminium foil. 3.
• Power Limiting technology dictates that the heating cable can be overlapped only once on to itself. If VPL cables are installed parallel to each other, please allow for minimum 15 mm clearance. For VPL heating cable only: • Fix in place with a minimum of two wraps the appropriate self-adhesive glass cloth tape (see figure 1) or plastic cable ties at 300 mm intervals and additionally where necessary. • Plastic cable ties must have a temperature rating that matches the system exposure temperature.
Figure 1 30 0m m Top Pipe Glass cloth tape (typical) Tight on pipe Thermal insulation (typical) 45° (nominal) nVent attachment tapes: GT66 Self-adhesive glass cloth tape General purpose tape. Not for stainless-steel surfaces or for installation temperatures <4°C. GS54 Self-adhesive glass cloth tape Recommended for use on stainless-steel and cupronickel surfaces or for installation temperatures <4°C. Figure 2 ATE-180 Aluminium tape Use only if the design requires it.
Spiral Pitch Table (mm). NB NPS (mm) (inches) Spiral Ratio Metres of cable per metre of pipe 1.1 1.2 1.3 1.4 1.
Refer to design specification for spiral pitch Mark the pipe at the spiral pitch or use a simple length gauge Fix the heating cable as installation progresses Thermally insulate and weatherproof to specification 3.5 Cutting the heating cable • Cut the heating cable to length after it is attached to the pipe. Before cutting it, confirm the tracing allowance as per Sections 3.3 and 3.6. • nVent RAYCHEM heating cable can be cut to length without affecting the heat output per metre. 3.
3.6.1 Valve Figure 3 Pipe Valve body Heating cable Glass tape The heating cable configuration will vary for different valve shapes and heating cable lengths. • • • Refer to design specification for additional heating cable length. Fix with self-adhesive glass cloth tape. Thermally insulate and weatherproof to specification (including valve stem). 3.6.
3.6.3 Flange Figure 5 Pipe Glass cloth tape (typical) Heating cable • Additional heating cable is 2-3 times diameter of pipe (typical) • Fix with self-adhesive glass cloth pipe • Thermally insulate and weatherproof to specification 3.6.4 Pipe bar hanger Figure 6 Bar hanger Sealer Weatherproofing Thermal insulation Pipe Heating cable Bar hanger Sealer Glass cloth tape (typical) Heating cable – Do not clamp heating cable with support.
3.6.5 Pipe support shoe Figure 7 Side view Glass cloth tape (typical) Support shoe Pipe Bottom view Heating cable Pipe • Refer to design specification for additional heating cable length • Fix with self-adhesive glass cloth tape • Thermally insulate and weatherproof to specification 18 | nVent.
4 COMPONENTS INSTALLATION General notes: Select the required components from nVent product literature or use the TraceCalc software. nVent RAYCHEM component kits (including power connections, splices and end seals) must be used to satisfy Standards and Approval Body requirements. Installation instructions included in the kit must be followed, including those for preparation of the heating cable conductors for connections.
4.2 Typical systems installation Below components are not suitable for BSA. You can find the solutions for BSA in DOC2210 or contact your local nVent representative. Figure 8a Valve SB-100 JBU-100 Heating cable End seal 20 | nVent.
Wallmounted IEK-25-04 Insulation entry kit JBU-100 Junction box for modular system C25-100 Connection kit Heating cable Splice (as required) Thermal insulation Glass cloth tape (typical) Insulation Entry kit SB-101 Thermostat nVent.
Figure 8b JBM-100 Integrated power/ tee connection T-100 Tee or splice connection JBS-100 Integrated power connection (shown with light) C-150 Low profile power connection IEK-25-04 Insulation entry kit 22 | nVent.
E-100-L Lighted end seal E-100 End seal S-150 Low profile splice E-150 Low profile end seal nVent.
4.3 Component installation hints • On horizontal pipes locate junction boxes below pipe wherever possible. Pinch out drainhole in the stand when installing upside down. • Locate junction boxes for easy access but not exposed to mechanical abuse. • Position junction boxes so that power cable and heating cable entries do not point upwards. Figure 9a JBS-100-L-EP Integrated power connection (with earth plate and light) • Fix lids in place where access not required.
5 THERMOSTATS • In temperature-sensitive applications, thermostatic control may be necessary. If maximum temperature is a concern, consult your nVent representative for design assistance. • 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.
6 THERMAL INSULATION AND MARKING 6.1 Pre-insulation checks • Visually inspect the heating cable and components for correct installation and damage. (See Section 10 if damaged.) • Insulation resistance (Megger) testing (as per Section 8) is recommended prior to covering the pipe with thermal insulation. 6.2 Insulation installation hints • Correct temperature maintenance requires properly installed and dry thermal insulation. • Thermally insulate and weatherproof to design specification.
6.3 Marking • For power limiting heating cable install label: LAB-I-35 as shown (typical) in figures 10a & 10b Figure 10a 0 60 d se 0 0 II ergifnen öf S -1 x e U ile en ng ion J B 2 G EE 1058 en whannutens X II ATEX t op r Spsous 02 no te ir 10 .D. 199X B 97 Do t unouvr -95 PT s Ex 96D3 X Nich pa 03 B Nr. . Ex 10 Ne PTS No .D. 8X 19 -95 Ex 96D3 X 04 B Nr. . Ex 10 PTS No .D. 200X BA -95 Ex 96D3 X 05 B Nr. . Ex 10 PTS No .D. 435X BA -95 Ex 96D3 X 05 B Nr. . Ex 10 PTS No .D.
7 POWER SUPPLY AND ELECTRICAL PROTECTION In the event of an earth fault or over current interruption, the device shall not be reset until the cause of the trip has been investigated by qualified personnel 7.1 Electrical loading Size overcurrent protective devices according to the design specification or applicable nVent product literature. If devices other than those specifically identified are used, consult the nVent representative for the appropriate sizing information. 7.
Figure 11 Test between heating cable and braid Capacitance Test Method This method uses capacitance measurement (nF) to approximate the location of a fault where the heating cable has been severed. It also gives an estimate of total heating cable length in a non-severed circuit. This reading must be taken at the power connection and will only work when the heating cable has passed IR testing.
Heating cable capacitance factors (m/nF) Cable catalog number Capacitance factor Cable catalog number Capacitance factor 3BTV1-CR 2.29 5KTV1-CT 3.29 3BTV2-CT 2.29 5KTV2-CT 3.38 5BTV1-CR 2.29 8KTV1-CT 3.14 5BTV2-CT 2.29 8KTV2-CT 3.2 8BTV1-CR 1.68 15KTV1-CT 2.96 8BTV2-CT 1.68 15KTV2-CT 3.02 10BTV1-CR 1.68 20KTV1-CT 2.83 10BTV2-CT 1.68 20KTV2-CT 3.08 10QTVR1-CT 1.43 3HTV1-CT 3.2 10QTVR2-CT 1.43 3HTV2-CT 3.51 15QTVR2-CT 1.01 5HTV1-CT 3.2 15QTVR1-CT 1.
9 OPERATION, MAINTENANCE AND PIPE REPAIRS Caution: consult the heat tracing system documentation prior to maintenance/repair/modification. 9.1 Heating cable operation • Temperature exposure must not exceed that specified in nVent product literature. Exceeding those limitations will shorten the service life and may permanently damage the heating cable. • Pipe insulation must be complete and dry to maintain the correct temperature. 9.
10 HEATING CABLE DAMAGE • Do not repair damaged heating cable. Remove entire damaged section and splice in a new length using the appropriate nVent RAYCHEM splice kits. • Replace damaged heating cable at once. Damage allowing moisture and contamination to enter the heating cable may result in arcing earth faults and potential fire hazards. • Heating cable exposed to fire or flame may cause further fire damage if powered. Remove from service at once and replace before re-use.
CIR CU IT N O. INSTALLATION RECORD SHEET INSTALLATION RECORDS FOR: Circuit breaker number Drawing reference number Megger test on pipe before insulating (bypass thermostat if applicable) Reading Initial Date nVent.
O. IT N CU CIR 34 | nVent.com/RAYCHEM INSPECTION AND MAINTENANCE RECORD SHEET MAINTENANCE CHECKS FOR: No signs of overheating, moisture, or corrosion, etc. MONTH: Initial Date In connection systems Heating cable and cable glands tight Connection terminals tight Earth connection tight Insulation in good condition Initial Thermostats set properly and capillaries are protected Initial Date Date YR.
Megger test (bypass thermostat if applicable) Reading Initial Date Circuit voltage Panel Connection terminals All boxes and thermostats have been firmly closed Initial Date nVent.
Troubleshooting guide A Symptom: Overcurrent protection trips or blows Probable Causes 1 Electrical fault at a damaged heating cable b faulty splices or tees c end seal d connection 2 Circuit oversized 3 Start-up below design temperature 4 Defective electrical protection B Symptom: RCD trips Probable Causes 1 Earth fault at: a damaged heating cable b faulty splices or tees c end seal d connection 2 Excessive moisture in: a junction boxes b splices and tees c end seals 3 High leakage current
Corrective Actions 1 Investigate and remedy (see note 1): 2 Resize or redesign within Technical Databook Guidelines. (If larger protection is required, ensure supply cables are compatible). 3 a b c 4 redesign for lower start-up temperatures preheat pipe from alternative heat source to within exposure temperatures given in Product Data Sheets Energize part of circuit followed by remainder (e.g.
C Symptom: No power output. Probable Causes 1 Loss of supply voltage due to: a overcurrent or residual current protection operating b loose terminals in junction box c loss of supply cable continuity (e.g., open circuited from damage 2 Control thermostat is connected in the normally open position 3 High resistance connection at: a junction box terminals b splices and tees D Symptom: Low pipe temperature.
Corrective Actions 1 Restore supply voltage a following A and B (page 31) b re-tighten terminals NB: If excessive heating has occurred due to high resistance, replace terminals or crimps c locate damage and repair 2 Reconnect to normally closed position 3 Locate and remedy by: a re-tighten b repair NB: If excessive heating has occurred due to high resistance, replace terminals or crimps Corrective Actions 1 Remove and replace with dry insulation of correct specification and ensure complete weatherp
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