ELSR Self Regulating and Parallel Heating Cables
INSTALLATION MANUAL
ELSR & ELP
Installation and operation
self-regulating & parallel heating cables
eltherm GmbH
Ernst-Heinkel-Strasse 6 -10
57299 Burbach, Germany
P.: +49 2736 4413-0
F.: +49 2736 4413-50 info@eltherm.com
QAA 023 Rev.10
www.eltherm.com
IMPORTANT INFORMATION
– RETAIN FOR LATER
Please follow these instructions for proper and safe use of the
ELSR- and ELP heating cables.
Please retain these instructions for later reference purposes (for
example in the system documentation).
USE – FOR DISPOSAL
The WEEE logo indicates that this product must not be disposed
of with residential waste.
Further information about disposal and recycling of old electrical
and electronic devices and where to find collection points is available
from your local disposal company or from the manufacturer
from which you bought the product.
ATTENTION
Refers to a potentially dangerous situation.
If it is not prevented, there is a risk of damage or malfunction.
DANGER
Refers to an extremely dangerous situation. If it is not prevented
there is risk of death or at least a high risk of serious injuries.
Refers to an extremely dangerous situation. If it is not prevented there is risk of death or at least a high risk of serious injuries.
NOTE
Important information and instructions for safe, effective and environmentally
compatible usage.
WARNING
Refers to a dangerous situation. If it is not prevented there is risk of
injury or at least a high risk of material damage.
Proviso
We reserve the right to make technical changes. Changes, errors or misprints shall not form the basis for any claim to compensation for damages. Comply with the applicable and currently valid standards and regulations for safety-related components and systems.
eltherm GmbH
Ernst-Heinkel-Str. 6-10
57299 Burbach
T.: +49 2736 4413-0
F.: +49 2736 4413-50
info@eltherm.com
Document:
86430402001XX
Installation manual
ELSR & ELP heating cables
Author: J. Shilling Date: 01.12.2003
Revision: 10 Jonas Schmidt Date: 03.04.2024
Contact us: +49 2736 4413-0 • info@eltherm.com
INTRODUCTION
GENERAL INFORMATION
The trace heating systems ELSR-… and ELP-… are suitable for industrial use on pipelines, containers and associated equipment in non-classified (common) areas, outdoor areas, wet areas and areas where flammable gases, dust or fibres may be present.
WARRANTY
ATTENTION
In order tu fulfil the warranty conditions, the instructions of the respective product manuals must be followed. Please note that these instructions provide information on gene ral installation methods. Alway follow the project planning specifications and contact our project office if you have any queries.
INCOMING GOODS
- Compare the delivered goods with purchase order and the delivery slip.
- Inspect the heating cable and components for transport damage.
- Carry out all measurements required for the respective materials (insulation measurement on the heating cables, etc.)
ATTENTION
Ensure that the data sheet for the supplied heating cable is available in addition to these instructions. The information in the data sheet is required for safe installation. Installation must therefore not be carried out without the data sheet.
MOUNTING
SAFETY INSTRUCITONS
ATTENTION
• Mounting, testing and maintenance of electrical trace heating systems may only be carried out by qualified employees who have been trained in handling electrical equipment.
• Strict compliance with the relevant standards and safety regulations is a prerequisite for the safety of persons, systems and devices.
• The persons tasked with planning, installation and maintenance have a special responsibility and must be familiar with the exact details of the applicable regulations.
• The instructions must be kept with the system documentation for later use (maintenance, servicing).
STORAGE
• The goods have to be stored in a dry environment at an ambient temperature of -20…+60 °C.
• If measured lengths of the heating cable have to be re moved from storage, the end of the remaining heating cable must be protected effectively against penetration of moisture (for example by attaching an original end connection of the heating cable manufacturer).
• Make certain the goods are stored so they will be protected against mechanical damage.
• While the goods are in storage, avoid contact with chemicals (solvents, petrochemical products, etc.
LENGTH OF HEATING CIRCUIT
The max. allowable length of a heating circuit (according to the corresponding data sheet) for unilateral feed depends on the admissible voltage drop (we recommend not to exceed a voltage drop of 10%) and the utilization of the circuit Breaker (recommended: 16 A CB with „C“ characterization, utilization 80 %).
DANGER
• Prior to installation and maintenance work the relevant heating circuits and plant sections need to be de-energized!
• Prior to accessing plant sections (pipelines, vessels etc.) ensure sufficient cooling down to avoid burns.
• The metallic screen ( protective braid or aluminums foil with embedded earth wires), this has to be connected to the potential earth.
• Improver mounting or damage to the electrical trace heating can lead to a danger of short circuit and fire whi le the system is in operation.
• To ensure safe and error-free operation of eltherm electrical trace heating, only the original initial and medial connecting sets and termination sets specially develo ped and tested for this purpose may be used.
ELSR- & ELP heating cables QAA 023
Installation manual
Revision 10
• Design and installation of heating circuits is to be made compliant to the standards IEC EN 60519-10 and IEC EN 62395-2 as well as to any other locally applicable codes and standards.
• Trace heaters ELP should only be operated with a con troller. A controlled or stabilised mode of operation as per EN 62395-2 is to be implemented.
• Heaters and sensors need to be placed on the designated pipes / tanks in the planned positions in order to avoid overheating of equipment as well as insufficient tempe rature maintenance. Make sure the sensors are properly attached.
• For use as trace heating in accordance with IEC EN 62395-1 and IEC EN 60159-10 and for Ex applications, an RCD (30 mA) is mandatory.
• When using the heating tapes and metal surfaces, they also have to be protected against indirect contact acc. to DIN VDE 100, part 410 (or equivalent standards) before operation of the system.
PREPARATION OF MOUNTING
• Make certain that all mounting work is complete on the pipe system that will be heated.
• All pressure and material tests as well as coating and pain ting work on the pipelines must be completed. The coat of paint on the pipes must feel dry to the touch.
• Check the nature of the pipe surface. It must not have any sharp edges or burrs that could cause damage during installation. If necessary remove any or cover them with suitable material.
• Compare the design of the pipeline (dimensions, structure, nature and number of inserts) with the design data.
• Check all materials required for heating to ensure they are complete and for any transport damage.
• Compare the material list of the delivered components with the design documents.
• Check whether there are any special mounting instructions and wheather all the necessary material and tools are on hand.
• Measure the electrical and the insulation resistance of the heating cable and write them down in the mounting pro tocols provided for this purpose. Compare the value with the data in the design documents and technical specifications of the heating cables.
Contact us: +49 2736 4413-0 • info@eltherm.com
MOUNTING THE HEATING CABLE
WARNING
• Do not use adhesive tape with emollients (i.e. PVC)!
• Install according to the min. bending radius and installa tion temperature stated on the data sheet.
• ELP types: Make sure the tapes will not have contat to each other or cross after installation, this may lead to overheating and damage of the heating tapes and ne arby placed objects!
• ELSR types: An overlapping or contacting installation of the heating tape does not cause overheating due to the self-regulating heating characteristic.
• A heating circuit should be installed as shown in the fol lowing diagrams using the original Eltherm accessories.
• Do not crush the heating cable or pull it over sharp edges.
• Avoid stepping on or driving over the heating cable at all costs.
• Never use the heating cable as a step loop.
• Keep to the lengths specified in the project planning for the fixtures.
• The installation must be carried out on the intended system components at the positions specified by the planner in order to prevent system components from overheating and the desired holding temperatures from not being reached.
• The specified minimum bending radius must be observed and adhered to.
Preparation of the system
• Remove all unevenness, such as sharp burrs or similar, from the surface to be heated and clean the surface of grease and oil.
• Mark the installation distances required according to the projection on the surface to be heated.
Unrolling the heating cable
• Use a stable holder to unwind the heating cable.
• Ensure that the unwinding device runs smoothly to pre vent damage to the heating cable due to excessive tensile force.
• Unroll the heating cable straight over the edge of the drum, not off to the side.
Fastening the heating cable to the pipe
• Normally the heating cable is laid starched out along the pipe. Lay heating cables in a spiral pattern only if the pro jects planning explicity calls for it.
temperature sensor heating cable
• Do not lay the heating cable on the lowest point of the horizontal pipeline.
• Laying the heating cable on the top half of a horizontal pipeline is unfavorable for reasons of heat distribution and should only be done if the project planning calls for it.
ATTENTION
• The electrical connection and termination of the heating cables must only be carried out using eltherm accesso ries in accordance with the relevant assembly instruc tions. Failure to do so will invalidate any warranty claims.
• When making the electrical connection, it must be ensu red that no tensile, shear or torsional forces can act on the connection. This is achieved by providing suitable support for the heating cable in the immediate vicinity of the connection.
• Fasten the heating cable at intervals of 300 mm.
• Use only fastening materials that have been defined as suitable accessories by the manufacturer and that were selected in the design documents.
ELSR- & ELP heating cables QAA 023
Installation manual
Revision 10
• Make certain that the selected materials meet the requirements (for temperature, mechanical and chemical resistance).
• Check whether the use of other elements (such as aluminium adhesive tape for better heat transfer) is required in the design documents.
• When installing several heating cables on one pipe please refer to the following sketch.
1 heating cable
2 heating cables temperature sensor
3 heating cables
4 heating cables
WARNING
• Never use metal clips or binding wire for fastening as doing so could cause the heating cable to be damaged.
• Heating cables must be able to move slightly in the fastenings (for expansion and contraction).
• When using a pre-stamped stainless steel band, note that a burr is produced inside the tab due to punching. Follow the installation instructions in the drawing be low. This is the only way to ensure that the burr cannot damage the heating cable.
Contact us: +49 2736 4413-0
• info@eltherm.com
• We recommend covering the entire surface of the hea ting cable on plastic containers or pipes (PE/PP/PVC/ GRP/GRP or similar) with aluminium foil.
• To save energy and to keep process temperatures cons tant, the application of superior control units are re commended. Please ask our project engineers when in doubt.
ATTENTION
• To avoid short circuit, do not connect the two bus wires of the heating tape to each other. Under all circumstances observe the termination and maintenance instructions for the connection and termination of the heating tapes.
• Make sure that the trace heaters are never used at or ex posed temperatures above the nominal exposure temperature ratings.
• In areas of pipe supports, heating cables must be laid in a looped manner in order to be able to provide sufficient power at this point.
ATTENTION
• Observe the specified length allowances in project pla ning or design (for example in eltherm Designer).
• When laying a heating cable around a pipe bend, the heating cable must be laid on the outside of the pipe bend. If it is laid on the inside, the flow medium may be deposited in the pipe due to the lower heat input to the pipe.
Fastening the heating cable on flanges heating cable
Fastening the heating cable on level indicators
Fastening the heating cable on flanges
• When laying a heating cable around a flange connection, it must be ensured that the heating cable is laid once around the pipe directly in front of the flange connection. More power must be applied to the pipe at this point due to higher thermal expansion.
Fastening the heating cable on fittings
ATTENTION
Fittings and level indicators must be installed all round to ensure uniform thermal expansion.
ELSR- & ELP heating cables QAA 023
Installation manual
Revision 10
Fastening the heating cable on Plug-in disc
ATTENTION
• Make certain the metal braiding has the best possible contact with the surface of the fitting.
• Only fasten the heating cable with the fastening mate rial provided by the manufacturer and follow the recomendations for fastenings.
Fastening the heating cable on valves
• In areas with large pipe diameters, heating cables must be laid in a loop.
Fastening the heating cable onto metal braiding
• Cut the braid to size so that it fits exactly
• A Special mounting variant consists of fastening the heating cable onto metal braidings.
This variant is used mainly for heating geometrically complex shapes. This variant is also used if fittings (such as valves and pumps) have to be heated and easy access to the fittings is especially important (for maintenance purpose, etc.) This ensures that the metal braiding will be easy to open and close again without having to remove the heating cable first.
Contact us: +49 2736 4413-0 • info@eltherm.com
• Fasten the braiding onto the fitting
www.eltherm.com
ELECTRIC HEAT TRACING
eltherm GmbH
Ernst-Heinkel-Str. 6-10 • 57299 Burbach, Germany
Tel.: +49 (0) 27 36 – 44 13-0 • Fax: +49 (0) 27 36 – 44 13-50
info@eltherm.com • www.eltherm.com
INSPECTION OF THE HEATING CIRCUIT
• Fasten the heating cable onto the braiding
DANGER
• The max. operating temperature of the heated device as defined by the plant owner as well as the maximum heating cable temperatures as given on the label must not be exceeded. This may be achieved by use of an appropriate temperature control.
• Make sure the heater has a good contact to the surface to be heated. In case of gaps, fill those with thermally conductive and temperature resistant materials.
Cover the heating cable with metal foil
• To prevent the penetration of thermal insulation material between the heating cable and the surface to be heated and to keep the surface temperature of the heating cable as low as possible, the heating cable must be covered over its entire length with self-adhesive metal foil.
• If thermal insulation with a sheet metal jacket is used, an insulation bushing must be used to protect the heating cable from mechanical damage when it is led out of the panelling.
Attach type plate
• After completion of the heating circuit, a weather-resi stant, permanently legible identification plate with all relevant system details must be attached to the junction box or the connection pipe immediately at the entry to the junction box.
DANGER
• Electrically heated parts have to be identified in reasona ble distances with warning labels „Electrical heating“ on the thermal insulation.
• Approx. 5 m distance between each label on pipelines or at least 1 warning label per pipe-branch respectively.
• Carry out a visual inspection for any mechanical damage and check compliance with the installation guidelines. • Check whether a heating circuit type plate is attached. The information it contains must be legible.
• Check the insulation resistance.
• The insulation resistance of each circuit is to be measured between each single bus wire and the protective braid or screen. The measured values are to be noted.
• Check the heating circuit function.
• The heating cable temperature must be specifically monitored to prevent the heating cable from over heating.
ATTENTION
• Test voltage minimum 500 VDC, recommended 2500 VDC
• Independent of the heating circuit length, the insulation resistance must not be lower than 20 MOhm. In case of a lower insulation resistance, the source of detect hast to be determined and eliminated.
• Any damage that hast occured must be repaired immediately. For short heating circuits by replacing the heating cable and for longer heating cable lenghts by cut ting out the damaged area and inserting a new heating cable section (see assembly instructions for connection set).
• Repeat the tests after the terminal insulation has been applied.
ELSR- & ELP heating cables QAA 023
Installation manual
Revision 10
OPERATION & MAINTENANCE
DANGER
NOTE
• Damaged heating circuits shall not be operated. This is the case when:
Trace heaters ELSR-… and ELP-… generally operate maintenance free. However, it is recommended that the system be checked by qualified personnel in regular intervals for visual damages and insulation resistance.
• During operation of the system, local laws and regulations for the use of electrical trace heaters in hazardous areas as well as all other applicable standards and safety regulations are to be followed.
• The permissible operating conditions according to the rating plate / data sheet must be observed.
• The maximum operating temperature given on the label
• Heater or attached leads show damage or deformation.
• The circuit is electrically defective (open circuit, high lea kage current).
• There is a risk of damage to the heating cable as a result of previous work or damage to the heated part of the system.
• After thermal or mechanical overstress.
• After failure of temperature controll.
MARKING (by customer) must not be exceeded.
• Covers and cable entries of connected controllers, junction boxes and connection sleeves must be closed or tightened in accordance with the manufacturer´s instructions.
ATTENTION
• Installed trace heaters has to be protected against damge that may occur during repair work on heated components.
• After completion of the repair, the heating circuit will once again need to be tested.
• Readings of ohmic resistance and insulation resistance are to be taken from cold heaters only.
• Temperature control units and controls must be checked annually by trained specialists.
Contact us: +49 2736 4413-0 • info@eltherm.com
Customer-side labeling with an identification plate is pos sible
eltherm GmbH
Ernst-Heinkel-Straße 6 -10 57299 Burbach. Germany
T.: +49 2736 4413-0 F.: +49 2736 4413-50 info@eltherm.com
This document can also be found on the eltherm website.
Visit our download area.
www.eltherm.com
86430402001XX Operation manual ELSR- and ELP Trace heaters (QAA-023) EN – subject to technical changes without notice.
Documents / Resources
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eltherm ELSR Self Regulating and Parallel Heating Cables [pdf] Instruction Manual ELSR Self Regulating and Parallel Heating Cables, ELSR, Self Regulating and Parallel Heating Cables, Parallel Heating Cables, Heating Cables |
