Raychem TT1100-OHP Leak Detection Cable
Installation and Troubleshooting Guide
General Information
These instructions detail the installation and testing procedures for Raychem TT1100-OHP leak detection cables, primarily designed for suspended piping. The absorbent properties of the outer sheath allow it to capture and retain water droplets or runoff. A leak alarm is triggered when even a small section of the cable becomes wet. While the standard leak detection cable is better suited for flat surfaces, the TT1100-OHP is also suitable for applications with flat surfaces such as suspended ceilings, drip pans, sumps, trenches, and more.
Important Notes
The TT1100-OHP should be installed at the lowest point of the piping where leaks are most likely to occur. Typically, this is the "6 o'clock" position on a horizontal pipe, but specific situations may require different placements and fixing techniques. Pay close attention to pipe supports, fittings, T-junctions, valves, and other accessories. The installer is responsible for positioning the cable so that leaks flow onto it.
The leak detection cable cannot prevent a leak. In some installations, the materials or structures beneath the piping may be so valuable or critical that a drip pan is recommended in addition to the leak detection cable. The TT1100-OHP alerts the user to a leak but cannot prevent collateral damage if the leak is not contained or repaired immediately.
Tools and Accessories
| Tool/Accessory | Description | Other Accessories | Description |
|---|---|---|---|
| Cutting pliers | For cutting excess ties. | Ties | Provided by the installer and sized to fit around the pipe and leak detection cable. Estimate three ties per meter for horizontal cable sections, and special fixings for accessories. |
| PTB-1000 | Portable Test Box, battery-powered portable instrument specifically designed for testing and troubleshooting TraceTek systems. | Chiffons and appropriate cleaner | For drying and cleaning the bottom and sides of a pipe before installing the cable. |
| Ohmmeter with a resistance of 20 MΩ or higher | For measuring resistance. | ||
| TT-MAPPING CAP-PC | For replacing or supplementing the PTB 1000. Used to simulate leaks at connection points during commissioning and mapping. | ||
| TT-MLC-PC supplementary cable | Jumper cable. Used with the ohmmeter to facilitate connection to the leak detection cable for resistance measurements. | ||
| TT-MET-PC supplementary cable | Termination plug. Used during installation or fault detection to temporarily isolate a section of the detection cable to measure its resistance. |
General Recommendations
DO:
- Keep the cable dry in its original packaging until installation.
- Clean the pipe surface where the cable will be installed.
- Plan the leak detection cable installation as late as possible in the construction schedule to prevent damage by other trades.
- Remove the cable if the piping is to be threaded, welded, or undergo similar work.
DO NOT:
- Immerse the cable in water, paint, solvents, oil, or other contaminating products.
- Install damaged or contaminated detection cables.
- Expose the cable to water or contaminants after installation.
- Exceed the maximum tensile force of 100 kg (220 lbs).
- Use the cable as a sling for lifting or securing any object.
- Drop tools or heavy objects on the cable.
1. INSTALLATION
Clean and prepare the pipe surface or area where the cable will be installed. Ensure that the main construction is complete. Clean the underside and sides of the pipe where the cable will be installed, removing dirt, moisture, oil, and other contaminants. If the cable is to be laid in a drip pan, ensure the pan's surface is also cleaned beforehand.
Position the cable on the underside of the pipe, securing it with nylon ties at the lowest point of the conduit. Ties should be long enough to encircle the pipe and cable. Use a tie every 300 to 450 mm (12 to 18 inches), with additional ties for accessories and bends. Maximum offset should be 6 mm (0.25 inches).
Important Note: The installer is responsible for correctly positioning the leak detection cable. The cable must be installed at the lowest point of the pipe or fittings so that liquids flow onto the cable's surface. Do not install the cable on the top or sides of the pipe.
Exception: When used on a vertical pipe, the cable should be spiraled around it and secured with ties.
Diagram showing cable placement on a horizontal pipe with ties, and a close-up of a tie securing the cable.
2. INITIAL ENERGIZATION AND TESTING
Connect the cable to the selected instrument and test the system. Power on the TraceTek instrument and verify that the operating conditions are "normal." For TTC-1, TTSIM-1A, or TTSIM-2, a green diode should be illuminated without red or orange diodes. (For TTSIM-1A and TTSIM-2, the green diode blinks every 10 seconds.) For the TTSIM-1 model, "Normal" operation is indicated by a continuously illuminated green diode and a red diode blinking every 10 seconds. On the TTDM-128, the alphanumeric display shows a channel number and the text "SYSTEM NORMAL."
If a yellow diode illuminates on any of these instruments, or if "Cable Cut" or "Open Loop" is displayed, the cable should be checked. This could be due to open connectors or missing termination plugs. Verify cable continuity until "normal" operation is restored.
A leak test can be performed using a leak simulation tool (TT-MAPPING CAP-PC). This device simulates a leak at the point where it is introduced into the system.
For TTC-1, TTSIM-1, and TTSIM-2, a red diode indicates that the simulated leak has been detected. For TTSIM-2 and TTDM-128, in addition to the red diode, the leak location will be displayed in feet or meters (depending on the selected option).
For large circuits with TTDM-128 or TTSIM-2, the "MAPPING CAP" should be moved progressively from one accessible connector to another. Record the displayed distance on "as-built" diagrams. This data will serve as the basis for system mapping.
Diagram showing connection of various components: TT-MET-PC termination plug, TT1100-OHP cable, TT-MLC-PC jumper cable, TT-MBC-PC T-connector, and TTSIM-1A alarm module.
Note: The drawing is not to scale. Some components may not be necessary.
3. Connecting Cable Sections
Connect cable sections, connectors, and terminations to monitor the entire circuit and its branches. Note: All system components have male, female, or both plastic connectors. Male connectors face the control panel. New cable sections added to the trunk or main branch of a circuit typically terminate in an open female connector. At the end of each branch or trunk, a male end termination must be installed (see paragraph D below).
Initial Energization and Testing:
A. The TT1100-OHP is available in several standard factory-terminated lengths. Each cable has a female and a male connector. Cable sections interconnect like extension cords.
B. (Optional) A connector (P/N TT-MBC-PC) allows for "T" connections and branches. The T-connector has one male and two female connectors. To map the detection circuit, the cable connected to the center of the connector is counted first. Distance measurement continues from the second female connector to the rest of the system. A dummy length of 5m is added at the beginning and end of each branch.
C. (Optional) Multiple sub-branches may be needed for complete piping circuit tracing.
D. Install a termination (P/N TT-MET-PC) at the end of each main line and branch. (Note: A simple system check and bill of materials verification involves ensuring the total number of installed terminations equals the number of branch connectors plus one).
E. (Optional) If necessary, install jumper cables (P/N TT-MJC-xx-PC) to connect separate detection cable sections. Jumper cables are available in several standard factory-terminated lengths or on reels for situations where the detection cable and control unit are far apart.
F. Install a jumper cable (P/N TT-MLC-PC) between the detection cable and the control unit. The jumper cable has a standard length of 4m. It has a female connector on one end and four tinned conductors on the other, to be connected to the control unit's detection cable terminal block. In some installations, the distance between the control unit and the start of the detection cable exceeds 4 meters. In these cases, it is recommended to use a sufficiently long connection cable and cut off the male connector and excess cable. Connection cables and connection kits are also available for non-standard lengths.
G. Neatly wind and secure detection cables, connection cables, branch connectors, etc., using ties.
5. Initial Energization and Testing (Continued)
Connect the cable to the selected instrument and test the system. Power on the TraceTek instrument and verify that the operating conditions are "normal."
Indications on Instruments:
- TTC-1: Green diode ON (Normal); Red diode ON (Cable Break); Yellow diode ON (Leak).
- TTSIM-1A: Green diode ON (Normal); Red diode ON (Cable Break); Yellow diode ON (Leak).
- TTSIM-2: Green diode ON (Normal); Red diode ON (Cable Break); Yellow diode ON (Leak).
- TTSIM-1: Green diode ON (Normal); Red diode blinking every 10 seconds (Leak); Yellow diode ON (Cable Break).
- TTDM-128: "SYSTEM NORMAL" message displayed.
If a yellow diode illuminates or a "Cable Cut" or "Open Loop" message appears, check the cable, connectors, terminations, and connection cables. Repair or replace the cable if necessary. The TT-MET-PC termination can be used to isolate a damaged section, working from the instrument towards the end of the circuit.
If the red diode remains on after a leak is repaired, the cable and sheath may still be wet. Allow the cable to dry or re-inspect the leak area for accumulated water or moisture behind the detection cable.
If leak locations appear imprecise or unstable, verify that the simulated leak (MAPPING CAP) remains in place during mapping tests. Detection circuits require a stable leak location for accurate distance calculation. Removing the leak simulation device too quickly can lead to a wide error range.
If a true leak location appears imprecise, it may indicate multiple leaks or contamination in several places. If the system is monitored by a TTDM-128, check the history for nearby leaks or "Service Required" messages. If applicable, split the circuit into small segments using a termination, working from the beginning to the end of the circuit to progressively isolate each potential leak location.
A "Service Required" message on the TTDM-128 indicates that the cable is detecting moisture or contamination before a full leak occurs. The TTDM may display a location in brackets. If a location is shown, check if it is exposed to condensation, other contaminants, etc. Brackets indicate that the leak signal is not strong enough for precise localization, so indicated locations may contain errors.
Diagrams showing the TTC-1, TTSIM-1A, TTSIM-2, TTDM-128, and TTSIM-1 instruments with their respective indicator lights and messages.
6. TROUBLESHOOTING GUIDE
| Symptom | Possible Cause and Correction |
|---|---|
| Green diode off on TraceTek instrument | The system is not powered. Check the power supply. Verify that circuit breakers have not tripped. On the TTDM-128, check fuses and replace if necessary. |
| Yellow diode illuminated on TTC-1, TTSIM-1A, TTSIM-2, or orange diode blinking on TTSIM-1 | Cable break indication. Check connectors, terminations, connection cables, and the general condition of the cable. Repair or replace the cable if necessary. The TT-MET-PC termination can be used to isolate a damaged section starting from the instrument and working towards the end of the circuit, using the termination to temporarily end the circuit and then progressing towards the end of the circuit, adding one cable segment at a time. |
| Red diode does not turn off after leak repair | The cable and sheath are still wet. Allow the cable to dry or re-inspect the leak area to ensure no water is accumulating under or behind the detection cable. |
| Leak locations appear imprecise or unstable | Verify that the simulated leak (MAPPING CAP) remains in place during mapping tests. Detection circuits require a fixed leak location to accurately calculate distance. Removing the leak simulation device too quickly results in a wide error range. |
| A true leak location appears imprecise | It is possible that there are multiple leaks or that the cable has been contaminated in multiple places. If the system is monitored by a TTDM-128, check the history for any nearby leaks or "Service Required" messages. If applicable, split the circuit into small segments using a termination and proceed from the beginning to the end of the circuit to progressively isolate each potential leak location. |
| "Service Required" message (TTDM-128 only) | This early warning on the TTDM panel indicates that the cable is detecting moisture or contamination, but not yet at the leak stage. The TTDM panel sometimes displays a location in brackets. When a location is displayed, check if it is exposed to condensation, other contaminants, etc. Brackets indicate that the leak signal is not sufficient for precise localization, so the indicated locations may contain errors. |
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