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Raychem XL-Trace Installation And Operation Manual

Other manuals for XL-Trace: Manual
Manual is about: pipe freeze protectIon and flow maIntenance

Summary of XL-Trace

  • Page 1

    Xl-trace system installation and operation manual for pipe freeze protection and flow maintenance thermal management www.Pentairthermal.Com.

  • Page 2

    Ii raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 important safeguards and warning s 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 ...

  • Page 3: Table of Contents

    Iii raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 table of contents 1 general information 1 1.1 use of the manual 1 1.2 xl-trace applications 2 1.3 safety guidelines 2 1.4 approvals 3 2 installation guidelines 4 2.1 heating cable storage 4 2.2 pre-installation checks 4 2.3 heating cable ...

  • Page 4

    Iv raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01.

  • Page 5: General Information

    1 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 1 general information 1.1 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- ...

  • Page 6: General Information

    2 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 1 general information 1.2 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 metal...

  • Page 7: General Information

    3 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 1 general information 1.4 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 t...

  • Page 8: Installation Guidelines

    4 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines 2.1 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. 2.2 pre-installation checks check ma...

  • Page 9: Installation Guidelines

    5 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 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 o...

  • Page 10: Installation Guidelines

    6 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 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 equipmen...

  • Page 11: Installation Guidelines

    7 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines figure 3: attaching the heating cable.

  • Page 12: Installation Guidelines

    8 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 1: additional heating cable for valves pipe diameter (ips) heating cable in feet (meters) 1/2 0.8 (0.24) 3/4 1.3 (0.4) 1 2.0 (0.6) 1-1/4 3.3 (1.1) 1-1/2 4.3 (1.3) 2 4.3 (1.3) 3 4.3 (1.3) 4 4.3 (1.3) 6 5.0 (1....

  • Page 13: Installation Guidelines

    9 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines • run insulation through the pipe hanger ensuring that the pipe is not resting on the heater. Heating cable heating cable beneath insulation and pipe hanger heating cable over pipe hanger pipe hanger under insulati...

  • Page 14: Installation Guidelines

    10 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 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...

  • Page 15: Installation Guidelines

    11 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines one heating cable 45° two heating cables 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 attach...

  • Page 16: Installation Guidelines

    12 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 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 drawin...

  • Page 17: Installation Guidelines

    13 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 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 ...

  • Page 18: Installation Guidelines

    14 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines valve body multiple crossovers allowed for self-regulating cables single crossover only, allowed for power-limiting cables glass tape pipe heating cable pipe heating cable note: cable loop length varies depending ...

  • Page 19: Installation Guidelines

    15 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines heating cable glass tape pipe figure 12: pressure gauge glass tape pump discharge pump body heating cable pump suction use at-180 tape motor to power connection pump body pump body figure 13: split case centrifuga...

  • Page 20: Installation Guidelines

    16 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines heating cable secured to pipe glass tape heating cable loop support shoe pipe figure 14: pipe support shoe heating cable glass tape (typical) for pipe diameters of 2" and larger, the heating cable should be instal...

  • Page 21: Installation Guidelines

    17 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines heating cable heating cable beneath insulation and pipe hanger heating cable over pipe hanger pipe hanger under insulation pipe hanger over insulation insulation over pipe hanger heating cable figure 16: pipe hang...

  • Page 22: Installation Guidelines

    18 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines rayclic-pc power connection junction box ec-ts electronic thermostat rayclic-s splice rayclic-t tee insulation rayclic-le lighted end seal (optional) rayclic-e end seal figure 17: aboveground xl-trace system use t...

  • Page 23: Installation Guidelines

    19 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 3: connection kits for general aboveground piping catalog number description heating cable allowance 1 rayclic-pc 2,3 power connection and end seal kit; use 1 per circuit standard pkg: 1 2 ft (0.6 m) ftc-p 4...

  • Page 24: Installation Guidelines

    20 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 3: connection kits for general aboveground piping catalog number description heating cable allowance 1 continued ftc-hst 4 low-profile splice/tee; use as needed for pipe branches standard pkg: 2 3 ft (0.9 m)...

  • Page 25: Installation Guidelines

    21 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 4: accessories for general aboveground piping catalog numberdescription heating cable allowance etl “electric traced” label (use 1 label per 10 feet of pipe) 10 labels gt-66 glass cloth adhesive tape for att...

  • Page 26: Installation Guidelines

    22 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines 110 f 43c 90f 32c 70f 21c 50f 10c 30f –1c temperature sensor insulation ec-ts electronic thermostat conduit xl-trace heating cable ground alternate power connection alternate end seal ground wall rayclic-le* raycl...

  • Page 27: Installation Guidelines

    23 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 5: connection kits for general buried piping catalog number description heating cable allowance* ftc-xc • power connection and end seal • junction box supplied by customer • use 1 per circuit standard pkg: 1...

  • Page 28: Installation Guidelines

    24 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 2 installation guidelines table 6: accessories for general buried piping catalog number description standard pkg etl “electric traced” label (use 1 label per 10 feet of pipe) 10 labels gt-66 glass cloth adhesive tape for attaching heating ...

  • Page 29: Thermal Insulation

    25 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 3 thermal insulation 3.1 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. 3.2 insulation ins...

  • Page 30: Thermal Insulation

    26 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 3 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 ...

  • Page 31: Thermal Insulation

    27 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 3 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 ...

  • Page 32: Power Supply and Electrical

    28 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 4 power supply and electrical protection 4.1 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. 4.2 circuit breaker sizing...

  • Page 33: Power Supply and Electrical

    29 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 4 power supply and electrical protection 4.5 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 cabl...

  • Page 34: Distribution

    30 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution 5.1 control systems electronic thermostats provide higher accuracy of the heating cable circuit with thermistor sensors and built-in ground-fault protection. Electronic controllers provide super...

  • Page 35: Distribution

    31 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution table 8: control systems description electronic thermostats ec-ts 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 ent...

  • Page 36: Distribution

    32 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution table 8: control systems description acs-uit2 acs-pcm2-5 the raychem acs-30 advanced commercial control system is a multipoint electronic control and monitoring system for heat- tracing used in ...

  • Page 37: Distribution

    33 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution 5.2 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: di...

  • Page 38: Distribution

    34 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution a common alarm push to acknowledge hand/off/auto 1 2 3 4 5 6 7 8 9 10 11 12 main circuit breaker main contactor distribution panelboard fuse holder c power on tb 1 tb 2 ar r ground bus bar selec...

  • Page 39: Distribution

    35 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 5 control, monitoring and power distribution three-pole main circuit breaker three-pole main contactor one-pole with 30-ma ground-fault trip (120/277 vac) two-pole with 30-ma ground-fault trip (208/240 vac) power connection heating cable a...

  • Page 40: Commissioning and Preventive

    36 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 6 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 ...

  • Page 41: Commissioning and Preventive

    37 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 6 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. F...

  • Page 42: Test Procedures

    38 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 test procedures 7.1 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 insula...

  • Page 43: Test Procedures

    39 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 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 m...

  • Page 44: Test Procedures

    40 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 test procedures test a test b attach to pipe l2 l1 figure 26: insulation resistance test.

  • Page 45: Test Procedures

    41 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 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 th...

  • Page 46: Test Procedures

    42 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 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 ...

  • Page 47: Test Procedures

    43 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 test procedures pipe temperature p ow er w/ft 50 (10) 30 (–1) 40 (5) 60 (15) 70 (21) 80 (27) 90 (32) 100 (38) 110 (43) 120 (49) 130 (54) °f (°c) 10 8 14 12 6 4 2 0 5xl1-cr and 5xl1-ct (120 v) 5xl2-cr and 5xl2-ct (208 v) 8xl1-cr and 8xl1-...

  • Page 48: Test Procedures

    44 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 test procedures a b a b a b braid 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 = a x 100 _____...

  • Page 49: Test Procedures

    45 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 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 se...

  • Page 50: Test Procedures

    46 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 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 fa...

  • Page 51: Test Procedures

    47 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 7 test procedures.

  • Page 52: Troubleshooting Guide

    48 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 8 troubleshooting guide symptom probable causes corrective action circuit breaker trips circuit breaker is undersized recheck the design for startup temperature and current loads. Do not exceed the maximum circuit length for heat- ing cabl...

  • Page 53: Troubleshooting Guide

    49 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 8 troubleshooting guide symptom probable causes corrective action circuit breaker trips circuit breaker is undersized recheck the design for startup temperature and current loads. Do not exceed the maximum circuit length for heat- ing cabl...

  • Page 54: Appendix

    50 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a1 maximum circuit length in feet start-up temperature (°f) cb size (a) application 40°f/ 110°f maintain* circuit breaker sizing (ft) 5xl1 8xl1 5xl2 8xl2 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 27...

  • Page 55: Appendix

    51 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a1 maximum circuit length in feet start-up temperature (°f) cb size (a) application 40°f/ 110°f maintain* circuit breaker sizing (ft) 5xl1 8xl1 5xl2 8xl2 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 27...

  • Page 56: Appendix

    52 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a2 maximum circuit length in feet start-up temperature (°c) cb size (a) application 4°c/ 43°c maintain* circuit breaker sizing (fm) 5xl1 8xl1 5xl2 8xl2 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 ...

  • Page 57: Appendix

    53 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a2 maximum circuit length in feet start-up temperature (°c) cb size (a) application 4°c/ 43°c maintain* circuit breaker sizing (fm) 5xl1 8xl1 5xl2 8xl2 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 ...

  • Page 58: Appendix

    54 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a3 transformer sizing (amperes/foot) minimum start-up temperature (°f) 5xl1 8xl1 5xl2 8xl1 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 v –20 0.119 0.159 0.069 0.067 0.065 0.092 0.087 0.082 0.108 0...

  • Page 59: Appendix

    55 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 9 appendix table a3 transformer sizing (amperes/foot) minimum start-up temperature (°f) 5xl1 8xl1 5xl2 8xl1 12xl2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 v –20 0.119 0.159 0.069 0.067 0.065 0.092 0.087 0.082 0.108 0...

  • Page 60: Installation and Inspection

    56 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 10 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 ...

  • Page 61: Installation and Inspection

    57 raychem-im-h58033-xltracepipefreezeprotectioncom-en 18/01 10 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 ...

  • Page 62

    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 ...