Raychem Polymer Insulated (PI) Constant Wattage Heat Cable Systems
Installation, Maintenance, and Operation Guide
1. General Information
This installation and maintenance guide is intended for Raychem constant wattage heating cable systems used in heat-traced pipelines, tanks, and equipment. It specifically refers to Polymer Insulated (PI) heat cable systems with design-parameter-matched power, cable length, and voltage. The guide provides general information and an overview of common installation methods and applications for PI heat cables. Project-specific instructions must be followed in all cases if they differ from the information in this guide.
Outer jacket hybrid structure
Tinned or nickel-plated copper strands for protective braid (max. 25 Ω/km)
PTFE/polymer layer structure
High-temperature resistant conductor
Ground conductors
Grommet seal
Heat cable
Cold lead cable
Cable connection between heat cable and cold lead cable
Connection wires
For more information, refer to the product data sheet. If you need information on other applications, please contact your Chemelex representative.
Important: Raychem's warranty is valid only if the instructions in this guide and on the product packaging are followed. Installation must also comply with national regulations for electric heat tracing systems and other international standards (e.g., IEC 60079). Personnel involved in the installation, testing, and maintenance of electric heat tracing systems must have appropriate training in all necessary specialized methods and general electrical installation work. Supervisors with experience in electric heat tracing systems must oversee all work, and appropriate tools, as described in Raychem product and installation instructions, must be used for all installation work.
Classification – Normal Areas
Raychem XPI-F, XPI, and XPI-S
Classification – Hazardous Areas, Zone 1 or 2
Limitations:
1. Maximum exposure temperature for XPI and XPI-S cables is +260°C, and for XPI-F cables and CS-150-xx-PI cold-applied connection and splice kits is +200°C.
2. The maximum permissible operating voltage for XPI cables is mentioned in the component description.
3. Minimum installation temperature for XPI and XPI-S cables is -70°C. For XPI-F cables and CS-150-xx-PI cold-applied connection and splice kits, it is -50°C.
4. Minimum cable spacing must be 20 mm.
5. The minimum bending radius for XPI and XPI-S cables is 2.5 times the cable diameter for cables up to 6 mm, and 6 times the cable diameter for cables over 6 mm. The minimum bending radius for XPI-F cables is 7.5 times the cable diameter.
6. XPI or XPI-F cables are intended for areas with a low risk of mechanical damage, so appropriate attention must be paid to their installation. XPI-S cables are used in areas with a normal risk of mechanical damage.
7. CS-150-xx-PI cold-applied connection and splice kits must be secured to the object after installation. To prevent tension, heat, and supply cables should be secured in place immediately next to the connection or splice.
NOTE: XPI cables are suitable only for applications with a low risk of mechanical damage (e.g., under insulation). If there is a high risk of mechanical impact, use XPI-S cable or a protective conduit.
Certificate No. | Approval Code | |
---|---|---|
XPI-F, XPI, and XPI-S System Approval | PTB 08 ATEX 1102X BAS21UKEX0652X IECEX PTB 08.0051X |
Ex II 2G Ex eb 60079-30-1 IIC T2...T6 Gb II 2 D Ex tb 60079-30-1 IIIC T260...T90°C Db Ex eb 60079-30-1 IIC T2...T6 Gb Ex tb 60079-30-1 IIIC T260...T90°C Db |
XPI-F, XPI, and XPI-S Cable by the Meter Approval | Baseefa15ATEX0158U BAS21UKEX0522U IECEX BAS 15.0105U |
Ex II 2G Ex 60079-30-1 IIC Gb Ex II 2D Ex 60079-30-1 IIIC Db Ex 60079-30-1 IIC Gb Ex 60079-30-1 IIIC Db |
XPI and XPI-S EAC Ex | ЕАЭС RU С-ВЕ.АД07.В.04186/22 ООО «Центр Сертификации ВЕЛЕС» 1Ex e IIC T6 (80°C)...T2 (290°C) Gb X Ex tb IIIC T80°C...290°C Db X IP66 Ta -70°C...+56°C |
|
XPI-F EAC Ex | ЕАЭС RU C-ВЕ.АД07.В.04186/22 ООО «Центр Сертификации ВЕЛЕС» 1Ex e IIC T4 Gb X Ex tb IIIC T110°C Db X IP66 Ta -60°C...+56°C |
Manufacturing Information
All cables have approval and manufacturing information printed every meter, along with meter markings. The last 4 digits before the meter marking indicate the week and year of manufacture. Example: Raychem (R) XPI-xxx Ohm/km 450/750 V <approval information> 215669875643 - 15/18 3587
2. Heat Cable Selection and Storage
The selection of the most suitable heat cable and its components for the application must be checked against product information and technical data. The most important characteristics are presented in the table below:
Heat Cable Type | XPI-F | XPI | XPI-S |
---|---|---|---|
Maximum Voltage Uo/U (VAC) | 300/500 | 450/750 | 450/750 |
Heat Resistance (°C) | 90 | 260 | 260 |
Short-term Heat Exposure (°C) | 100 | 300 | 300 |
Temperature Class | T4-T6 | T2-T6 | T2-T6 |
Minimum Spacing (mm) (*) | 20 | 20 | 20 |
Impact Resistance (J) | 4 | 4 | 7 |
Lowest Installation Temperature (°C) | -60 | -70 | -70 |
Minimum Bending Radius at Lowest Installation Temperature | 7.5 x Ø | 2.5 x Ø (Ø< 6 mm) / 6 x Ø (Ø≥ 6 mm) | 2.5 x Ø (Ø< 6 mm) / 6 x Ø (Ø≥ 6 mm) |
Maximum Power (W/m) | Refer to the table below or use Raychem software | ||
Chemical Resistance (*) | High temperature resistant | High temperature resistant | High temperature resistant |
(*) Check product data sheet for details or contact Chemelex.
Maintenance Temperature (°C) | Typical Maximum Cable Load (W/m) | |||
---|---|---|---|---|
Good Contact (XPI/XPI-S) | XPI-F | Good Contact (XPI/XPI-S) | XPI-F | |
≤ 10 | 30 | 25 | 25 | 20 |
+ 11...30 | 25 | 20 | 20 | 15 |
+ 31...50 | 21 | 18 | 18 | 13 |
+ 51...75 | 18 | 15 | - | - |
+ 76...100 | 15 | 12 | - | - |
+ 101...125 | 12 | 10 | - | - |
+ 126...150 | 10 | 8 | - | - |
+ 151...200 | 8 | 5 | - | - |
The typical power of the cable is shown in Table 2 above according to the application. The maximum power of the cable is directly dependent on the application and the control method used. The actual power limits for PI heat cables in a specific application are shown in Raychem's design software (e.g., TraceCalc Pro design software). For more information, please contact Chemelex. Ensure that the maximum voltage of the heat cable is suitable for the available operating voltage and that the temperature range specified for the cable design is suitable for the application. Changing important design parameters such as voltage or cable length will alter the output power, potentially requiring the entire system to be redesigned. To avoid overheating the heat cable or the risk of fire or explosion in hazardous areas, ensure that the maximum temperature of the heat cable jacket is below the temperature class (T) or the auto-ignition temperature of any gases and/or dust present in the environment. For more information, refer to the design guide (e.g., TraceCalc Pro reports).
Check the design guide to ensure that the heat cable to be installed in each pipe or tank is suitable for the application. Raychem product information allows you to select the appropriate heat cable for all environments, considering temperature, chemical presence, and electrical and mechanical environment.
Storage and Transport
- Transport and store the product in a clean and dry place.
- Temperature range: Minimum for XPI and ZPI-S cables is -70°C, for XPI-F cables it is -56°C. The upper limit for all cables is +60°C.
- Protect the heat cable from moisture and mechanical impact.
3. Heat Cable Installation
WARNING: As with all electrical equipment operating at mains voltage or cabling, damage to the heat cable and its components or incorrect installation (allowing moisture or dirt into the system) can lead to leakage current, arcing, or fire hazards. Unconnected cable ends that are accessible must be protected appropriately.
3.1 Pre-installation Checks
Design-related Inspection Recommendations:
- Ensure you have all the design information required for the installation.
- Check for any special instructions in the design information (e.g., fastening method, use of metal mesh).
- Verify that the hazardous area information mentioned in the design guide matches the classification of the installation location.
Check Delivered Materials:
- Check that the heat cable and components have not been damaged during transport.
- Verify the heat cable installation plan and compare it with the delivery list of heat cables and electrical components, ensuring that the correct materials have been delivered for the installation site. The type of heat cable and its hazardous area marking are on the cable's outer jacket. Hazardous area information and corresponding design data for each heating circuit are indicated on the hazardous area marking (see Section 7.3).
- Measure and record the electrical resistance and insulation resistance of the cable. Compare these values with those mentioned in the design guide (see Chapter 8).
Check Equipment to Which the Cable Will Be Installed:
- Verify the pipeline/tank identification data and dimensions, actual temperatures, and insulation properties against the design documents.
- Ensure that the pipeline/tank pressure test has been completed and the surface paint is touch-dry.
- Route the system end-to-end, planning the heat cable path on the pipe, considering heat loss sources such as valves, flanges, supports, and drains.
- Ensure that pipes are free of welding spatter, rough surfaces, sharp edges, etc., which could damage the heat cable. Grind the surface or cover it with fiberglass tape, aluminum foil, or rubber profiles (e.g., G-02).
3.2 Unpacking the Heat Cable from the Reel
- Heat Cable Installation Tip: Use a reel stand to unwind the cable evenly without excessive tension.
- Figure 3: Correct cable unwinding direction
- Avoid twisting or kinking the cable.
- When unwinding the heat cable from the reel, avoid:
- Sharp edges
- Excessive pulling force
- Kinking and crushing
- Walking on the cable or dragging equipment over the cable.
- Install the heat cable loosely next to the heated pipe so that it does not snag on brackets or other accessories.
- Allow for extra cable length to ensure it is sufficient to run past connectors, brackets, and other accessories as specified in the design guide.
- Leave sufficient heat cable at all connection points, splices, and T-junctions. (Refer to component installation instructions.)
- Calculate the required meterage and mark it (e.g., with tape) on the cable, with the final length still on the reel (use the printed meter markings on the XPI cable to track the length).
3.3 Heat Cable Fastening
- Do not use metal fasteners, wire, vinyl tape, or duct tape, as they can damage the cable. Use only fasteners specified in the design guide. Fasten the cable by wrapping at least two turns of suitable self-adhesive fiberglass tape, metal mesh, or fastening strap every 300 mm, or more frequently if necessary. The design guide may also specify other fasteners (e.g., aluminum tape).
- The cable must be installed and fastened so that it can move during heating but does not move freely under its own weight. Heat cables can be installed directly, with multiple cables side-by-side, according to the design guide.
- Fasten the cable to the lower quadrant of the horizontal pipe as shown in the figure, not to the bottom of the pipe.
- Figure 4: Cable position on the pipe
3.4 Heat Cable Cutting
- Before cutting the cable, check the required minimum length and installation allowances.
- Changes in heating circuit characteristics will alter the output power, requiring a review of the design data.
- Cut the heat cable to the correct length only after it has been fastened to the pipe.
3.5 Fastening Tape, Mesh, and Strips
- GT-66 - Fiberglass tape for fastening the heat cable to the pipe. Not suitable for stainless steel pipes or installation temperatures below 5°C.
- GS-54 - Fiberglass tape for fastening the heat cable to the pipe. For stainless steel pipes or installation temperatures below 5°C.
- ATE-180 - Aluminum tape for fastening the cable to tanks. For all surfaces and installation temperatures above 0°C.
- HWA-METAL-MESH-SS-50MM-10M: Stainless steel mesh for fastening the heat cable to valves, pumps, or other irregularly shaped surfaces. HWA-PI-FIX-SS-xMM-10M: Stainless steel strip for fastening the heat cable to pipes, ensuring regular fastening intervals (e.g., for three-phase systems).
- Long straight sections may require expansion loops to accommodate pipe thermal expansion, preventing the cable from becoming too tight. The design guide may specify other fastening methods. In such cases, follow the design guide.
3.6 Typical Installation
- The following shows how to fasten the heat cable to pipe fittings in a typical installation.
- Figure 7: Typical cable installation allowance at a pipe support
- Figure 8: Typical cable installation allowance at a valve
PI heat cables must not cross each other, and the minimum cable spacing must be observed. For more information, refer to the design guide or contact Chemelex.
3.7 Installation Allowances
All parts of the supplied system that increase the surface area of a normally insulated pipe/tank, or protruding metal ribs on the insulation (e.g., supports), increase the overall heat loss. For areas with higher heat loss, this must be compensated for by using higher safety factors or by adding more cable. In such cases, the meterage of the cable must be increased to allow for at least the removal of fittings, valves, etc. (service loop). If the pipe requires multiple cable runs, use the full compensation allowance for each run at the fitting or support, within the limits of the space. PI heat cables must not touch each other or cross, and the minimum cable spacing must be observed. In some applications, fastening the recommended installation allowance directly to the bracket or support may be physically impossible. In such cases, install additional cable on top of the pipe, on both sides of the bracket or support, or distribute the additional cable evenly along the entire circuit length if a lower local temperature is acceptable. Seek assistance from Chemelex if necessary.
For more information on installation allowances for specific applications, refer to the design guide or Raychem's design software (e.g., TraceCalc Pro reports).
4. Component Selection and Installation
General Notes:
- Select the necessary components according to the technical specifications for the design.
- Raychem's component kits must be used for installation to comply with standards, regulatory approvals, and Chemelex warranty conditions. Follow the installation instructions included with the kits, including preparation of heat cable connections. Check the suitability of the kit for the heat cable and environment before installation using the tables included in the installation instructions. Certified components for use with XPI-F, XPI, and XPI-S heat cables include: Raychem CS-150-2.5-PI, CS-150-6-PI, CS-150-25-PI, and CS-150-UNI-PI.
4.1 Required Components
- Follow the installation instructions for each component when installing them.
- Each heat cable termination requires a cold lead connection and a pass-through insulation kit.
- If necessary, splice kits and accessories (fastening tape, junction boxes, pipe straps, labels, etc.).
4.2 Component Installation Tips
- If possible, position junction boxes below the pipe in horizontal pipelines.
- Position junction boxes in an easily accessible location, but away from areas prone to mechanical damage.
- Position junction boxes so that the inlet openings for the supply cable and heat cable face downwards to prevent water from entering the insulation.
- Ensure that the junction box seals and end caps are suitable for the application and are properly sealed.
- Install the heat cable between the junction box and the insulation pass-through point so that the cable is not exposed to mechanical damage.
- Do not stretch the heat cable at the inlet/outlet points of junction boxes and insulation pass-throughs.
- Ensure that the heat cable is fastened, for example, to the pipe straps used on the junction box legs, to prevent possible mechanical damage.
- Figure 15: Cable installation over supports and pipe straps
- Cable splices (joints) may only be placed in locations where the cable does not bend or is not exposed to mechanical stress.
5. Temperature Control and Limitation
5.1 General Provisions
Raychem's PI series heat cables are constant wattage heat cables that generally require temperature control, unless otherwise specified. Good installation practices and local regulations may also require separate temperature limiters. The selection of these devices depends on the environmental conditions (normal or hazardous areas).
- In hazardous area applications, stabilized design or thermostat control can be used in conjunction with a temperature limiter according to the EN 60079-30 standard to limit the surface temperature of the heat cable.
- If stabilized design is not used, the control thermostat ensures that the heating system switches off when the maintenance temperature is reached under normal conditions.
- A separate temperature limiter switches off the heating in case of thermostat failure, ensuring that the surface temperature of the heat cable does not exceed the maximum permissible surface temperature in a hazardous area.
Temperature Limiter General Features:
- Lockout function ensures heating remains off until the fault is corrected and normal conditions are restored.
- Lockout function is reset manually.
- A tool (e.g., a key to open the electrical cabinet or a software password) is required for reset.
- The setpoint must be protected against accidental changes.
- The limiter must permanently switch off the power in case of sensor malfunction.
- The limiter's operation complies with all relevant standards (e.g., EN60730 or DIN3440, etc.).
- Follow the installation instructions provided with the thermostat and/or limiter.
- Use the appropriate wiring diagram and desired control method for heat cable installation.
- The limiter must be set so that the maximum surface temperature of the cable does not exceed the T-class or the maximum permissible operating temperature of the heating system at a given power in the worst-case scenario.
WARNING: As with all temperature measuring devices, actual temperatures may be displayed incorrectly due to heat loss from the sensor itself, which can lead to erroneous temperature readings or tripping of safety limiters. The setpoint may need to be adjusted accordingly. Contact Chemelex or the temperature limiter supplier for more information on adjusting the offset values of limiter devices.
5.2 Sensor Placement: Temperature Control Device
The placement of the control device sensor depends on factors such as:
- Fluid flow direction: best placement is downstream.
- Influence of heat loss sources, such as brackets, etc.: best placement is close to the heat loss source.
- Stack effect of large vertical pipes: best placement is at the bottom.
- Accessibility for maintenance: best placement is at floor level.
- Influence of heat sources, such as the sun, etc.: best placement is on the cold side of the pipe.
For more information, refer to the design guide.
5.3 Sensor Placement: Limiter Device
The sensor is typically placed on the cable section that is insulated from the pipe by the insulation material, creating a "non-artificial hot spot". The placement of the limiter sensor depends on factors such as:
- Fluid flow direction: best placement is upstream.
- Influence of heat sinks, such as brackets, etc.: best placement is away from the heat sink.
- Accessibility for maintenance: best placement is at floor level.
- Stack effect of large vertical pipes: best placement is at the top.
- Influence of heat sources, such as the sun, etc.: best placement is on the hot side of the pipe.
It is the installer's responsibility to ensure that these regulations are followed as closely as possible. For more information, refer to the design guide.
6. Thermal Insulation and Marking
6.1 Pre-insulation Checks
- Visually inspect to ensure that the heat cable and components are installed correctly and are intact. (If damage is found, refer to Chapter 10.)
- An insulation resistance test (see Chapter 8) is highly recommended before applying thermal insulation to the pipe.
6.2 Insulation Requirements
- Proper temperature maintenance requires correctly installed and dry thermal insulation.
- Check that the entire pipeline, including wall penetrations and other points, is well insulated.
- Perform thermal insulation and weather protection according to the technical requirements of the design.
- Polymer-insulated heat cables must be protected against mechanical damage. Insulation cladding is considered sufficient mechanical protection.
- Avoid damaging the heat cable during the installation of the lining with drills, drill screws, or sharp edges of the lining.
- When using a stabilized design, the properties (material and thickness) of the thermal insulation must meet the design requirements and must be checked and recorded in the installation records to ensure compliance with approval requirements.
- Ensure that the insulation material is not placed between the object and the cable under any circumstances, as this will prevent heat from being conducted to the object as intended and may result in cable overheating.
- For a properly installed heating system, wrap metal foil around it before installing the thermal insulation. This is particularly important for points where close contact between the heat tracing cable and the heated surface is not possible, such as at valves and flanges, where suitable heat-conductive metal foil can be used to provide heat conduction. Local insulation standards may provide additional information.
- Check that all insulation pass-throughs are installed correctly or that other protective devices (e.g., G-02 rubber profiles) are used as needed.
- Ensure that all points where thermostat capillary tubes, sensor cables, or brackets pass through the insulation cladding are sealed.
6.3 Marking
- Attach warning labels indicating electrical heating at appropriate intervals (recommended every 3-5 meters) on both sides of the pipe, alternating sides.
- Mark the locations of heat cable components, such as connections and splices, on the outside of the insulation.
7. Power Supply and Electrical Protection
- Do not connect power to the cable if it is coiled or on the reel.
- The metal jacket/braid of this heat cable must be connected to a suitable grounding terminal.
7.1 General
When installing in hazardous areas, each circuit must be disconnectable from the supply in a all-pole manner.
7.2 Electrical Protection
Size the circuit protection devices according to the technical specifications of the design and/or local regulations.
7.3 Residual Current Protection (Earth Leakage Protection)
Each heating circuit must have a correctly sized residual current device. For safety and to prevent fire hazards, Chemelex requires the use of a 30 mA residual current device.
- If the design results in leakage current, the recommended tripping value can be set on devices to 30 mA above the capacitive leakage current indicated by the manufacturer for the heating element, or alternatively, the next typical available fixed tripping value of a maximum of 100 mA or 300 mA (depending on the zone classification).
- All safety aspects must be documented.
- The use of a residual current device is mandatory for all heat cables installed in hazardous areas, based on electrical installation regulations and standards.
7.4 Heating Circuit Marking
Ensure that in all hazardous area installations, the system is appropriately marked with the hazardous area marking (e.g., PI-LABEL-EX), in addition to the markings related to the design by the installer responsible for the installation. The results obtained from the design guide (TraceCalc Pro) can be used here.
8. System Testing and Commissioning
WARNING: Fire hazard in hazardous areas. Insulation resistance testing can cause sparking. Ensure that the area is free of flammable vapors before starting the test (hot work permit required).
NOTE: Disconnect power from all electrical circuits before installation or maintenance.
8.1 Insulation Resistance and Conductor Resistance Testing
- Chemelex recommends performing an insulation resistance test:
- before heat cable installation
- before thermal insulation installation
- before initial startup / after thermal insulation installation
- during periodic maintenance (see Section 9.2). The electrical resistance of the heating circuit must be measured and the value compared to the design guide before initial startup.
8.2 Performing Insulation Resistance Test
After installing the heat cable, the insulation resistance between the conductor and the braid must be checked (see Section 6.1). The minimum required test voltage is 500 Vdc, but the standard EN60079-30 for heat tracing strongly recommends using a test voltage of 2500 Vdc. Therefore, Chemelex uses a test voltage of 2500 Vdc for acceptance testing, and the measured value must be at least 20 MΩ, regardless of the heat cable length. The installer must record the values for each heating circuit in the installation log. Tip: Discharge the heat cable before disconnecting it from the measuring device.
8.3 Commissioning
- Ensure the system is documented according to "9.1 Documentation".
- Record and keep all measured insulation resistance values during and after installation according to the Measurement Log in this document.
9. Documentation, Operation, Maintenance, and Repair
WARNING: Heat cables can reach high temperatures during operation and may cause burns if touched. Avoid touching the cable when power is connected. Insulate the pipe before connecting power to the cable. All work must be performed by properly trained personnel.
NOTE: Heat cables must be marked with warning labels or other markings at appropriate locations and/or at frequent intervals along the entire length of the heating circuit.
9.1 Documentation
Documentation for each circuit of the heat tracing system must be retained for as long as the system is in use. The documents must include at least the following information:
- Circuit identifier
- Heat cable type
- Operating voltage
- Heat cable length and overall dimensions
- (This information is also found on the value plate attached to the heat cable circuit).
When Stabilized Design is Used:
- Maintenance temperature or maximum process/exposure temperature
- Maximum object temperature
- Temperature class or maximum jacket/cable surface temperature according to the application
- (This design and temperature information is also indicated on the value plate attached to the heat cable circuit)
- Maximum ambient temperature
- Duty cycle
- Pipe size or object dimensions
- Type, size, and thickness of thermal insulation
- Material specification for insulation cladding, if applicable
- (This information is generally part of as-built documents or detailed calculation reports obtained from design software such as TraceCalc Pro, TracerLunx, etc.)
When Design is Based on Control Device Operation:
- Maintenance temperature or maximum process/exposure temperature
- Temperature class or maximum jacket/cable surface temperature according to the application
- (This design and temperature information is also found on the value plate attached to the heat cable circuit)
- Heat tracing system design parameters
- Maximum ambient temperature
- Duty cycle
- Temperature controller/limiter setpoint
- Location of the temperature controller/limiter sensor on the pipe/object
- Details of the temperature sensor installation
- Details related to fault detection and monitoring (alarm or limiter lockout)
- (This information is generally part of as-built documents.)
9.2 Heat Cable Operation
The heat exposure of the cable must be within the limits specified in the product's technical data. Exceeding these limits will shorten the service life and may permanently damage the heat cable. Maintaining the correct temperature requires the pipe to be pre-insulated and dry.
9.3 Inspection and Maintenance
- Visual inspection: The visible heat cable must be regularly inspected for mechanical damage.
- Insulation resistance measurement: The system must be tested regularly. Ensure in advance that the hazardous area conditions permit insulation resistance testing. A hot work permit may be required. When measuring insulation resistance from the electrical panel, the measurement is taken between terminals L and PE. Another measurement can optionally be taken between the braid and the pipe (disconnect the heat cable ends).
- Electrical protection function test: Circuit breakers and residual current devices must be tested at least once a year or according to the manufacturer's instructions.
- Temperature control device function test: Tests must be performed at regular intervals depending on how critical temperature control is for process requirements and how critical the temperature limitation is for hazardous area requirements. The installation log sheets on the following pages must be completed during the maintenance of each heating circuit of the system. Freeze protection systems must be tested annually before the start of winter (see Chapter 8). Temperature maintenance systems must be tested at least twice a year.
9.4 Pipe System Repair and Maintenance
- Disconnect the heating circuit from the central panel and protect the cable from mechanical or thermal damage during pipe repair.
- After repairing the pipe, check the heat cable installation and ensure that the thermal insulation has been restored according to the recommendations in Chapter 6. Verify that all relevant electrical protection systems are functioning correctly.
10. Troubleshooting
WARNING: Damage to cables or components can cause prolonged electrical arcing or fire. Do not apply power to heat cables if they are damaged. Damaged heat cables, splices, and connections must be repaired or replaced. Damaged cables may only be repaired by qualified personnel.
- Assess the severity of the damage to determine if the cable can be repaired or must be replaced entirely.
- Refer to the troubleshooting instructions on the following pages. If the problem persists after the suggested corrective actions, contact Chemelex.
NOTE: Consult the heat tracing system documentation before performing maintenance/repair/modification.
After maintenance/repair/modification, test the operation of the residual current device for each circuit. If the circuit breaker or residual current device trips, it must not be reset until the cause of the trip has been identified by qualified personnel. After maintenance/repair/modification, the insulation resistance must be measured and the results recorded. The insulation resistance must be at least 20 Megaohms.
Troubleshooting Guide
A. Problem: Circuit breaker trips.
Possible Causes:
- Electrical fault:
- a. Damaged heat cable
- b. Faulty splices
- c. Cold lead connections
- Excessive heating circuit load
- Faulty circuit breaker
- Startup below minimum design temperature (copper conductor only)
Remedy:
- Identify and repair the fault.
- Redesign or re-engineer.
- Replace.
B. Problem: Residual current device trips.
Possible Causes:
- Earth leakage:
- a. Damaged heat cable
- b. Faulty splices
- c. Cold lead connections
- Excessive moisture:
- a. Junction boxes
- b. Splices and cold lead connections
- Excessive leakage current due to a combination of a long supply cable and heat cable.
- Faulty residual current device.
- Electrical network interference.
Remedy:
- Identify and repair the fault.
- Dry and reseal, or reinstall and perform insulation resistance test.
- Redesign.
- Replace.
- Redesign the power supply.
C. Problem: No power.
Possible Causes:
- Temperature limiter has tripped.
- No operating voltage, because:
- a. Circuit breaker or residual current device has operated
- b. Loose terminals in junction box, poor splice
- c. Supply cable is not conducting electricity (short circuit caused by damage)
- Faulty temperature controller.
D. Problem: Low pipe temperature.
Possible Causes:
- Thermal insulation is wet.
- Incorrect setting or use of controllers, e.g., thermostats.
- Design error.
Notes:
Locate faults as follows:
- Visually inspect to ensure that connections and splices are installed correctly.
- Check the following for damage:
- a. Valves, pumps, flanges, and supports
- b. Locations where repair or maintenance work has recently been performed.
- Inspect the entire pipe for crushed or damaged insulation and insulation cladding.
- If the fault cannot be found using items 1, 2, and 3 above:
- a. Contact Chemelex.
- b. If local practices and conditions permit (e.g., normal areas), insulate the two halves of the heat cable from each other by cutting the cable in half and testing (e.g., with an insulation resistance measurement) each half until the approximate location of the fault is found. Remove the insulation from the faulty area.
Remedy
- Identify the cause, restore normal conditions, and re-install removed parts.
- Connect operating voltage.
- a. After items A and B
- b. Tighten terminals, replace splice. Note: If excessive heat is due to high resistance, replace terminals or splice sleeves.
- c. Locate and repair the fault.
- Identify the cause and replace the equipment.
Remedy
- Remove wet insulation and install dry insulation that meets technical requirements. Ensure weather protection.
- Repair or reset to the correct setting.
- Check the design with the designer and make the necessary modifications according to Chemelex recommendations.