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.

Figure 1: Typical cable construction

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

Figure 2: Typical installation of a heat cable

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.

Certificates and Approvals
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:

Table 1: Heat Cable Characteristics
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.

Table 2: Typical Cable Power Limits
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

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:
Check Delivered Materials:
Check Equipment to Which the Cable Will Be Installed:

3.2 Unpacking the Heat Cable from the Reel

3.3 Heat Cable Fastening

3.4 Heat Cable Cutting

3.5 Fastening Tape, Mesh, and Strips

3.6 Typical Installation

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:

4.1 Required Components

4.2 Component Installation Tips

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).

Temperature Limiter General Features:

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:

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:

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

6.2 Insulation Requirements

6.3 Marking

7. Power Supply and Electrical Protection

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.

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

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

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:

When Stabilized Design is Used:

When Design is Based on Control Device Operation:

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

9.4 Pipe System Repair and Maintenance

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.

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:
  1. Electrical fault:
    • a. Damaged heat cable
    • b. Faulty splices
    • c. Cold lead connections
  2. Excessive heating circuit load
  3. Faulty circuit breaker
  4. Startup below minimum design temperature (copper conductor only)
Remedy:
  1. Identify and repair the fault.
  2. Redesign or re-engineer.
  3. Replace.

B. Problem: Residual current device trips.

Possible Causes:
  1. Earth leakage:
    • a. Damaged heat cable
    • b. Faulty splices
    • c. Cold lead connections
  2. Excessive moisture:
    • a. Junction boxes
    • b. Splices and cold lead connections
  3. Excessive leakage current due to a combination of a long supply cable and heat cable.
  4. Faulty residual current device.
  5. Electrical network interference.
Remedy:
  1. Identify and repair the fault.
  2. Dry and reseal, or reinstall and perform insulation resistance test.
  3. Redesign.
  4. Replace.
  5. Redesign the power supply.

C. Problem: No power.

Possible Causes:
  1. Temperature limiter has tripped.
  2. 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)
  3. Faulty temperature controller.

D. Problem: Low pipe temperature.

Possible Causes:
  1. Thermal insulation is wet.
  2. Incorrect setting or use of controllers, e.g., thermostats.
  3. Design error.

Notes:

Locate faults as follows:

  1. Visually inspect to ensure that connections and splices are installed correctly.
  2. Check the following for damage:
    • a. Valves, pumps, flanges, and supports
    • b. Locations where repair or maintenance work has recently been performed.
  3. Inspect the entire pipe for crushed or damaged insulation and insulation cladding.
  4. 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

  1. Identify the cause, restore normal conditions, and re-install removed parts.
  2. 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.
  3. Identify the cause and replace the equipment.

Remedy

  1. Remove wet insulation and install dry insulation that meets technical requirements. Ensure weather protection.
  2. Repair or reset to the correct setting.
  3. Check the design with the designer and make the necessary modifications according to Chemelex recommendations.

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