warmtrace tm systems for hot water temperature maintenance · of heat tracing required by...

WarmTraceWarmTraceWarmTraceWarmTraceWarmTrace TM

Systems for Hot Water Temperature Maintenance

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The Heat Tracing SpecialistsR



INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

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Commercial Products

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONSWarmTraceWarmTraceWarmTraceWarmTraceWarmTraceTM



ContentsContentsContentsContentsContents

Safety Precautions ............................................................ 2

Using the Guide ................................................................. 2

End Terminations ............................................................. 10

Preinstallation Checklist .................................................... 3

TracePlus Quick Connection Kits ................................... 8-9

Cable Installation ............................................................ 6-7

Identifying the Materials Recieved ................................. 3-5

Recieving and Storing Cable ............................................. 3

Cable Testing ................................................................... 11

Thermal Insulation ...................................................... 11-12

Connection to Power ....................................................... 13

System Start-Up/Maintenance ......................................... 13

Troubleshooting .......................................................... 15-16

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The Heat Tracing Specialists R

LIC SMK2408

Appendix ......................................................................... 17

1.



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Safety Comes First...Safety Comes First...Safety Comes First...Safety Comes First...Safety Comes First...

The safety and performance of a heat tracingsystem depends on how the sustem was designed,installed and eventually maintained. Improperhandling, installation or maintenance of the systemcould result in underheating or overheating of thewater or damage of the heat tracing cable. Thisdamage could result in electrical shock, fire orsystem failure. The information, instructions,testing procedures and warnings addressed in thisguide are important. To minimize these risks, readthis guide prior to starting any heating cable orcomponent installation and follow the instructionscarefully.

Approvals/Code Compliance...Approvals/Code Compliance...Approvals/Code Compliance...Approvals/Code Compliance...Approvals/Code Compliance...

Thermon’s WarmTrace system com-prised of HSX 2100 heating cable andaccessories carry Australian StandardCertified Product Approvals (AS/ANSIIEEE 515.1 LIC SMK 2408) and is alsoapproved for hot water temperaturemaintenance by:

R

Underwriters Laboratories Inc.134N E56615

R

Canadian Standard AssociationDesignation 3A

WarmTrace systems comply with the applicablerequirements of the following code agencies:

- BS 7671:1992- NEC- Uniform Plumbing Code- BOCA- Southern Building Code Congress- National Standard Plumbing Code

Be sure the eletrical power connections complywith the National Electrical Code (NEC) article 427and any other applicable national (AS/NZ Codes),state or local codes.WarmTrace systems also meet or exceed therequirements of the IEEE Recommended Practicefor the Testing, Design, Installation, and mainte-nance of ElectricalResistance Heat Tracing forCommercial Applications, IEEE Standard 515.1-1995

How to Use this Guide...How to Use this Guide...How to Use this Guide...How to Use this Guide...How to Use this Guide...

This installation, operation and start-up guide isbroken up into sections outlined in the index onpage 1. Familiarize yourself with the entire guideprior to installing any heating cable or components.Throughout this guide, The following symbols willappear to emphasize a particular key point or aninstallation tip:

This symbol is intended to alert the userto the presence of important installation,operation or maintenance instructionswithin the guide.Thermon (recommended) InstallationProcedure. Identifies an installation,operation or start-up tip that could savetime, installation materials or make foran improved system.

Tools Required for Installation...Tools Required for Installation...Tools Required for Installation...Tools Required for Installation...Tools Required for Installation...

The following hand tools are recommended for aproper installation of a WarmTrace system:

In addition to the hand tools listed, a DC voltage“Megger” will be required to test the cable atvarious times during the installation process. Referto the Cable Testing Section (pg. 10-11) for detailson the equipment necessary to accomplish thisprocedure.

Note: All circuit testing, power connection andcommissioning must be done by a qualifiedelectrical tradesperson.

1.

2.

3.

1. Scissors2. Utility knife3. Cable cutters

Reg. No: 3701 to 3706

2.


Upon Receiving Heating Cable...Upon Receiving Heating Cable...Upon Receiving Heating Cable...Upon Receiving Heating Cable...Upon Receiving Heating Cable...

Inspect materials for damage incurred duringshipping. Report any damages to the carrier forsettlement.

Indentify the cable to ensure the proper type andquantity has been recieved. The catalogue numberof the heating cable is printed on the cable jacketalong with numerous additional information.

To locate the catalogue number look immediatelyafter the words “SELF-REGULATING HEATER” asshown below.

The cable should be identified within the list below.

Cable Type(Catalogue No.)

Outer JacketColour

Service Voltage(Vac)

HSX 2105-2 Blue 240

HSX 2120-2 Green 240

HSX 2140-2 Red 240

Caution: Do not connect power toheating cable while it is still on thereel or in shipping carton.

Storing Cable Prior to Installation...Storing Cable Prior to Installation...Storing Cable Prior to Installation...Storing Cable Prior to Installation...Storing Cable Prior to Installation...

Store cable and accessories in a clean and dryplace where temperatures will be between -40 Cand +60 C.

o

o

Do not allow water ingress to cableends.

Prior to Installation Cable...Prior to Installation Cable...Prior to Installation Cable...Prior to Installation Cable...Prior to Installation Cable...

Step 1:Verify electrical resistance with a Megger

- Refer to the Cable Testing Section (pg.10) these installation instruction for details.

Step 2: Inspect the Piping to be Heat Traced.

- Verify that the pipe has been pressure tested, and that all pipe supports are in place.

- Compare layout of the installed piping vs. plumbing drawings.

Step 3: Plan the Installation

- Not every metre of hot water supply piping will require heating cable. Note the extent of heat tracing required by reviewing.

1. Project specification 2. Plumbing drawings 3. Drawings supplied by Thermon (if a drawing package was part of the heat

trace system)

- Allow sufficient cable to cover the longest runs to minimize spoils first. This will ensure that no additional cable or splice

kits will be required.

- The extent of heat tracing, location of power connection points, splices and end

terminations can be temporarily indentified with marking ribbon or spray paint.

Step 4: Identify the Heat Trace Materials

- The cable should have already been identified using the table at left. Be sure to make note that not more than one water

maintain temperature is required, and therefore more than one HSX 2100 cable, may be required for the project.

- Familiarize yourself with the connection kits and accessory components included

with the bill of materials.

- Use the drawings and descriptions located on page 4 and 5 to match the catalogue

number and description with the items received as part of the bill of materials.

3.



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1. Cable Termination Assembly2. Pipe Attachment Straps3. ET-6 End Cap4. RTV Adhesive5. Labels (End Termination & UL)6. Cable attachment mounts7. Gland

TracePlus PowerSnap 1 (Circuit Fabrication - 1 Cable)TracePlus PowerSnap 1 (Circuit Fabrication - 1 Cable)TracePlus PowerSnap 1 (Circuit Fabrication - 1 Cable)TracePlus PowerSnap 1 (Circuit Fabrication - 1 Cable)TracePlus PowerSnap 1 (Circuit Fabrication - 1 Cable)

TracePlus PowerSnap 2 (Circuit Fabrication - 2 Cable)TracePlus PowerSnap 2 (Circuit Fabrication - 2 Cable)TracePlus PowerSnap 2 (Circuit Fabrication - 2 Cable)TracePlus PowerSnap 2 (Circuit Fabrication - 2 Cable)TracePlus PowerSnap 2 (Circuit Fabrication - 2 Cable)

1. Cable Termination Assembly2. Pipe Attachment Straps3. ET-6 End Cap (2)4. RTV Adhesive5. Labels (End Termination (2) & UL)6. Cable attachment mounts7. Gland

1. Cable Termination Assembly2. Pipe Attachment Straps3. ET-6 End Cap4. RTV Adhesive5. Labels (End/Splice Termination & UL)6. Cable attachment mounts

TracePlus TeeSnap (Connects 3 Cables)TracePlus TeeSnap (Connects 3 Cables)TracePlus TeeSnap (Connects 3 Cables)TracePlus TeeSnap (Connects 3 Cables)TracePlus TeeSnap (Connects 3 Cables)

1. Cable Termination Assembly2. Pipe Attachment Straps3. ET-6 End Cap4. RTV Adhesive5. Labels (End/Splice Termination & UL)

TracePlus SpliceSnap (Connects 2 Cables)TracePlus SpliceSnap (Connects 2 Cables)TracePlus SpliceSnap (Connects 2 Cables)TracePlus SpliceSnap (Connects 2 Cables)TracePlus SpliceSnap (Connects 2 Cables)

1.

5.

2.

3.

4.

TracePlus Quick Connection Kits...TracePlus Quick Connection Kits...TracePlus Quick Connection Kits...TracePlus Quick Connection Kits...TracePlus Quick Connection Kits...

1.

7.

5.2.

3.

4.

6.

5.

6.

1.

2.3.

4.

6.

7.

All warning labels must be applied andcorrectly positioned on fittings and onthe piping/insulation.

4.1.

2.3.

5.

4.


- Temperature resistant polyester fibre tape.- Used to attach cable to pipe every 300mm.

PF-1 TapePF-1 TapePF-1 TapePF-1 TapePF-1 Tape

General Installation Accessories...General Installation Accessories...General Installation Accessories...General Installation Accessories...General Installation Accessories...

- Placed every 3m along heat traced pipework.

Caution LabelCaution LabelCaution LabelCaution LabelCaution Label

- Includes RTV, ET-6, Caution Label.- Terminate cabel at dead ends.

ET-6C-Com End TerminationET-6C-Com End TerminationET-6C-Com End TerminationET-6C-Com End TerminationET-6C-Com End Termination

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Installing Cable on Pipe...Installing Cable on Pipe...Installing Cable on Pipe...Installing Cable on Pipe...Installing Cable on Pipe...

The HSX 2100 cable will be installed on the pipe ina parallel pass. There is no need for spiral wrap-ping. Locate the cable in the 4 or 8 o’clock postionwherever possible.

Attaching Cable to the Pipe...Attaching Cable to the Pipe...Attaching Cable to the Pipe...Attaching Cable to the Pipe...Attaching Cable to the Pipe...

HSX 2100 cable is held in place with temperaturerated polyester fiber tape (catalogue number PF-1).Pipe should be pressure tested clean and free ofgrease. Circumferential bands of tape should beinstalled at 300mm intervals to ensure the cablemaintains proper contact with the pipe.

Tape Allowance Chart...Tape Allowance Chart...Tape Allowance Chart...Tape Allowance Chart...Tape Allowance Chart...

Pipe Size(mm) 13 32 38 50 64 75

Metres ofPipe/Roll of

Tape110 79 67 55 50 45

Where space is a problem, Thermon approvedplastic cable ties may be used on the same inter-vals as tape. Do not over tighten cable ties.

Caution: Do NOT attach cable to pipewith metal hose clamps, metal strap-ping, tie wire or similar materials.Damage to the cable and systemcould result.

Avoid pinch points when installing cable.Over the course of time, the pipe will movedue to vibration, thermal expansion, contrac-tion and building settling. Do not allow theheating cable to bind between items such as:

Pipe Supports: Run the heating cable on theoutside of any pipe hanger or support that comes incontact with the pipe. Thermon recommends the use ofinsulated pipe supports to prevent additional heat loss atthe point of support.

Wall or Floor Penetrations: The heating cable mustbe protected when passing between floors or through awall. This can be accomplished with pieces of conduit orchannel. If the penetration requires fire protection, theconduit or channel may be caulked with an approvedcaulking material.

Install Cable like this... Not This...

Pipe Support: Cork or Polyeurethane insulation insert.Cut small hole for cable to be passed through.

Cut out for cable

6.


Locating Power, Tee & End Termina-Locating Power, Tee & End Termina-Locating Power, Tee & End Termina-Locating Power, Tee & End Termina-Locating Power, Tee & End Termina-tions...tions...tions...tions...tions...

Refer to the plumbing, electrical or Thermonsupplied drawings to determine the locations forconnections and terminations. The symbols beloware routinely used to show the various compo-nents of a heat traced hot water supply system.(Note that the electrical drawings will typically onlyshow the power connection points.)

Power Connection Points: The power (electri-cal) connection points must remain accessible,even after the building is completed. If the facilitywill be finished out with a suspended ceiling, powerconnection points can be located anywhere that isconvenient ( and accessible to electrical power).Should the finished ceiling be permanent, eachpower connection point must be located withinreach from an access door.

Tee Splice Connections and End Terminations:Per the NEC and Thermon’s UL Listing, tee spliceconnections and end terminations do not requireaccessibility and therefore do not require accessdoors. Thermon does recommend that whereverpossible, all connections and terminations belocated in areas that allow future access shouldchanges or additions to the plumbing system beneeded.

Maximum Circuit Lengths...Maximum Circuit Lengths...Maximum Circuit Lengths...Maximum Circuit Lengths...Maximum Circuit Lengths...

To prevent excessive electrical currents at thebranch circuit breaker supplying power to theheating cable, the maximum circuit length shownin the chart below must be observed.

CatalogNumber

ServiceVoltage(VAC)

Steady-StateCurrent Draw

amps/m

Breaker Size

15 Amp 20 Amp

HSX 2105-2(Blue) 240 0.020 350m 425m

HSX 2120-2(Green) 240 0.050 125m 175m

HSX 2140-2(Red) 240 0.060 93m 130m

These maximum circuit lengths aredefined as the total length of cable thatcan be fed from a single power connectionpoint, inclusive of all splices.Note that longer circuit lengths may requirelarger circuit breakers.

Be sure to verify the available amperagesof the branch circuit breakers supplyingpower to the heat tracing.

If the power supply voltage will be differentthan that listed in the chart above, contactThermon or your Thermon factoryrepresentative before installing any cable.

1.

2.

3.

4.

5. Any number of shorter heat tracing circuitscan be energized from a single branchcircuit breaker so long as the totalmetreage of heating cable does not exceedthe metreage stated for a given branchcircuit breaker’s amperage rating.

Notes:

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Installations With TracePlus Quick Con-Installations With TracePlus Quick Con-Installations With TracePlus Quick Con-Installations With TracePlus Quick Con-Installations With TracePlus Quick Con-nection Kits...nection Kits...nection Kits...nection Kits...nection Kits...

The following steps detail the fabrication of thefollowing TracePlus quick connection kits.

PowerSnap 1 Circuit Fabrication Kit (for connect-ing power to one HSX heating cable.PowerSnap 2 Circuit Fabrication Kit (for connect-ing power to two heating cables.TeeSnap Tee Splice Fabrication Kit (for connectingthree HSX heating cables)SpliceSnap Inline Splice Fabrication Kit (forconnecting two HSX heating cable)The following steps detail the fabrication of thefollowing TracePlus quick connection kits.

Preparing and terminating the HSX cable isthe same for each of the kits, simply repeatsteps 1 through 9 outilned

To Make an End Termination, Go To Pg. 9.To Make an End Termination, Go To Pg. 9.To Make an End Termination, Go To Pg. 9.To Make an End Termination, Go To Pg. 9.To Make an End Termination, Go To Pg. 9.

1. Powersnap 12. TeeSnap3. ET-6 End Cap4. HSX 2100 Heating Cable5. PF-1 Attachment Tape6. Pipe Attachment Straps7. Incoming Power

1.

2.

3.

4.5.

6.

7.Typical InstallationTypical InstallationTypical InstallationTypical InstallationTypical Installation

Locating the Kits: Install the Snap kits in thepositions shown in the typical installation above.Should space or accessibility constraints preventthis placement, the kits may be installed on theunderside of the piping or at either side. Do notinstall the kits on adjacent piping and allow theheating cable to run through the air between thepipe.

Begin installation at thepower supplypoint and layout heating cable on thepipe. For each heat tracing circuit orarea within the facility, install all of thecable and then go back and make upthe terminations.

1. Each unit is shipped assembled and must be partially disassembled to facilitate installation. the major components are:

Body

Bushing

Cover

Lever (red)

2. To remove the cover,place a small screw-driver into the slotlocated on each sideand gently pry whilelifting the cover. As thecover opens, slide itaway from the body. Aslight shake will expelthe bushing from thebody. Open, but do notremove the red cableclamping lever.

3. Determine and mark the location of the fitting onthe pipework.

Both PowerSnap 1 and 2 employsegregated separate compartmentsfor connection of the power cable andthe heat trace cable.

8.


4. Cut the heating cable to the proper length usingthe white reference stripe (arrow) located oneither side of the kit’s body. The cut should besquare to the cable.

5. Slide the cover 75mm- 100mm over theheating cable fol-lowed by the bushing.The tapered end ofthe bushing shouldface the cut end ofthe cable. Leave30mm of cable pastthe end of the bush-ing.

6. With a utility knife,remove 30mm of theheating cable outerjacket. Do not applyso much pressure asto cut or damage themetallic braid.

30

7. Fold the metallicbraid back over thebushing. Keep thebraid clear of thebottom side of thebushing to allowproper ground con-tact when the bushingis inserted into thebody.

9. Insert the prepared cable end and bushing intothe base while the red cable clamp lever israised. Push the cable in past the strain reliefpoint (white tabs) until it touches the red lever.The bushing will fill the recess when the cable isproperly seated.

8. Gently score thealuminium foil with tipof utility knife andpeel away, beforeinserting into fitting.Do not remove any ofthe gray primarydieletric insulationcovering the heatingcable.

Aluminium foil barrier is conductive andmust be removed before terminationsare completed.

10. Close the red cable clamping lever (1.) andmaintain pressure on the lever while sliding thecover (2.) until the gasketed swivel end fits intothe recess in the body. Release pressure on thelever while closing the cover (3.) manipulatefitting by rolling side to side in hands to aligncover and apply pressure on the cover until itSNAPS in place.

1.

3.

2.

Repeat Steps 1 Through 11 for Each Leg of aPowerSnap 2 or TeeSnap kit. Attach UL label tocover.Heating cable must be megger tested beforeconnecting to power. Refer to the Cable TestingSection (pg. 10-11) of these Installation Instruc-tions for details.

Aluminiumfoil

11. Use mounting straps provided to fix fitting topipe.

Cover must snap shut firmly be surethis procedure is followed.

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The following steps detail the procedure forterminating the ends of HSX 2100 circuits. Followthese steps for TracePlus Quick Connection Kits(PowerSnap 1, PowerSnap 2, SpiceSnap andTeeSnap).

To make an end termination the following parts(included with each of the above mentioned kits)will be needed:

1. ET-6 End Cap 2. RTV adhesive

End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...

1. 2.

Caution: The end of each run ofheating cable must be properly termi-nated. DO NOT use electrical tape,wire nuts or other means to terminatethe cable.

1. After determining thelocation of the end of aheat tracing circuit cutthe cable square to therun of the cable.

2. With a utility knife,remove 15mm of theheating cable outerjacket and trim awaythe exposed metallicbraid with scissors.Gently score the alu-minium foil layer andpeel away. Do notremove any of the grayprimary dielectricinsulation.

15

Caution: Do NOT connect the buswires together at the end termination.Doing so will result in a direct shortand could damage the cable

Aluminiumfoil

3. Apply a generouscoating of RTV sealantto both the cable end( the 15mm of trimmedcable plus 15mm of theouter jacketed cable)and the inside of theET-6 end cap. With atwisting motion, slidethe end cap over thecable until itcomplestely covers theover jacket. Squeezeout any air pockets thatare trapped in the endcap.

Record the location of end terminationson the plumbing drawings after eachtermination has been completed. Thiswill ensure that no terminations areoverlooked and will document theextent of heat tracing on the drawings

Cable Testing...Cable Testing...Cable Testing...Cable Testing...Cable Testing...

At various times during the installation process,the heating cable should be tested to ensureelectrical resistance integrity. HSX 2100 heatingcable should be tested with a 2,500 Vdc ismegohmeter (megger) between the heating cablebus wires and the heating cable’s metallic braid.While a 2,500 Vdc megger is remommended, theminimum acceptable level for testing is 1,000 Vdc.Specifically, these megger tests should be con-ducted:

To be carried out ony by QualifiedElectrical Trades Personnel only.

a. While the cable is still on the reel(s), prior toinstallation;

b. After installation of heating cable andcompletion of circuit fabrication kits (includ-ing any splice kits) but prior to installation ofthermal insulation;

c. After installation of thermal insulation butprior to installation of wall or ceiling materi-als;

d. Prior to connection of power of the heatingcable circuit; and

10.


Cable Testing cont...Cable Testing cont...Cable Testing cont...Cable Testing cont...Cable Testing cont...

e. As part of a routine maintenance programthat includes testing after any work (repairsor alterations) is performed on or near theheat traced piping.

Caution: Megohmeters produce highDC voltage potential and can emitelectrical shocks. Read and follow theoperation procedures for the meggerbeing used

Step 1: Connecting the negative (-) lead of themegger to the heating cable’s metallicbraid;

Megger testing is a pass/fail test with minimumacceptable level being 20 megohoms regardlessof the length of the circuit

The test consists of:

Step 2: Connecting the postitive (+) lead of themegger to the heating cable bus wires.

Step 3: Applying DC voltage potential to thecable at the stated level; and

Step 4: Measuring, recording and documentingthe resistance level for verification to theconstruction manager and the Thermonfactory representative (required forproduct warranty).

To perform the megger test on HSX 2100 cablefollow the example that matches the stage ofinstallation and the style of connection kit beingused. Record and document the tests results forfuture use. QC-3-Com (See appendix)

While cable is still on the reel...While cable is still on the reel...While cable is still on the reel...While cable is still on the reel...While cable is still on the reel...

Prepare test end of cable by removing 75mm -100mm of outerjacket, twisting braid into a pigtail,removing 25mm - 50mm of gray primary dielectric,stripping the black matrix from the bus wires andtwisting the bus wires together. The reel end ofthe cable must be checked to ensure that themetallic braid is separated from the area of thebus wires and the black conductive matrix.

Testing PowerSnap Fittings...Testing PowerSnap Fittings...Testing PowerSnap Fittings...Testing PowerSnap Fittings...Testing PowerSnap Fittings...

Remove the cover tothe terminal block areaof the PowerSnap.Connect the negativelead to the centerground terminal andthe positive lead toone of the bus wireterminals. Test andrepeat for the other busterminal.As part of routine maintenance or afterAs part of routine maintenance or afterAs part of routine maintenance or afterAs part of routine maintenance or afterAs part of routine maintenance or afterrepairs...repairs...repairs...repairs...repairs...

This megger test should be conducted at thepower distribution panel by a qualified electrician.

Thermal Insulation...Thermal Insulation...Thermal Insulation...Thermal Insulation...Thermal Insulation...

Thermal insulation is critical to the overall perform-ance of a heat traced hot water supply system.The following insulation schedule must be fol-lowed to ensure maintain temperatures are withinthe desired range. Variations to this insulationschedule could result in maintenance tempera-tures different than designed and required.

Foil Faced Fibreglass (SPI) Insulation Schedule for WarmTrace Systems

45 C, 50 C, 60 Co o o

InsulationThickness

Nominal Pipe Size

NominalInsulation Size

25mm15mm20mm25mm

20mm25mm32mm

38mm32mm40mm50mm

40mm40mm50mm

50mm65mm80mm100mm

65mm80mm100mm

Cable test details to be recorded onform QC-3-Com document see page17.

The supply earth must not bedisconnedted from the Earth braidwhile the heat tracing is still ener-gised

Notes:Variations of insulation type and thickness mustbe referred to Thermon for advice.

1.

11.



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Caution: Do NOT use staples tosecure the insulation vapor barrier.Damage to the cable could occur.

After the thermal insulation is installed, labelsidentifying the presence of heat tracing must beinstalled. At all accessible points of the installation,including access doors to ducts and serviceareas.These lables are typically installed onalternate sides of the pipe at 3m intervals. Addition-ally,

Caution: Final electrical connectionsfor the heating cable should be per-formed by a qualified electrician.

Connecting to Power...Connecting to Power...Connecting to Power...Connecting to Power...Connecting to Power...

“Thermon Self-Regulating Heater” and the specificcable catalogue number (i.e. 240 Vac)

Verify the cable catalogue number, and the lengthof the heat tracing circuit. Using the chart belowverify that the maximum circuit length is notexceeded for the circuit breaker feeding power tothe heat tracing.

CatalogNumber

ServiceVoltage(VAC)

Steady-StateCurrent Draw

amps/m

Breaker Size

15 Amp 20 Amp

HSX 2105-2(Blue) 240 0.020 350m 425m

HSX 2120-2(Green) 240 0.050 125m 175m

HSX 2140-2(Red) 240 0.060 93m 130m

Attention: the 1996 NEC code, Article427-22, Equipment Protection, states“Ground -fault protection of equip-ment shall be provided for each

To meet this code requirement Thermon recom-mends the use of branch circuit breakersequipped with 30 mA protection. 5 mA GFCIshould not be used as nuisance tripping mayresult.

The power supply to the heat tracing will be 240Vac. The voltage of the installed HSX 2100 cablecan be verified by reading the cable identificationprinted on the cable jacket. Following the word

A moisture proof weather barriersurrounding the thermal insulationmust be provided for outdoor applica-tions.

Insulation to be installed to manufac-tures recommendations ensure com-plete closure of all joints and seemsto avoid heat loss.

Ensure insulationseam is at least 90o

from cable position.

labels identifying splicesand end terminations areincluded with each kit andshould be installed at theappropriate location forfuture reference.

Nominal insulation size is increased by one pipediameter for piping 32mm and smaller toacoomodate the heating cable.

1.

Insulation to be installed as per manufacturesrecommendations.

2.

Complete closure of insulation joints is requiredto ensure no heat loss occurs

3.

branch circuit supplying electric heating equip-ment. Under AS3000 wiring code RCD’s are notmandatory for hot water installations.Thermon’s policy is that RCD’s are ‘HighlyRecommeded

Termal Insulation cont...Termal Insulation cont...Termal Insulation cont...Termal Insulation cont...Termal Insulation cont...

Earth (main supply) must not bedisconnected whilst heat tracingcircuit is energised.

12


When a WarmTrace system has been installedper this guide, start-up is easy. Simply followthe steps listed below. Please note that theoperating current for the cable will be higherduring start-up than during normal operatingconditions. This is because the water in theheat traced piping is usually at the building’sambient temperature. This condition has beenaccounted for in the breaker sizing and circuitlength tables provided so long as the ambient isat or above 15 C.

1. The assembled kit should look like the drawingbelow. No exposed end(s) of heating cableshould be visible.

End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...End of Circuit Terminations...

PowerSnap1

PowerSnap 2 will havetwo cables running isopposite directions.

2. Remove the 4 screwson the terminal blockcover to expose theintegral terminal block.The raised centerscrew is for thecircuit’s ground path.the two outboardterminals are foractive and Neutralconnections.

3. The heating cable should be megger testedprior to connecting power (see Cable Testing onpage 10-11).

4. Either hard wire to supply source or utilize 3core flex connection to GPO.

Caution: The black matrix heatingelement is ELECTRICALLY CONDUC-TIVE. It is not an insulator.

o

1. On the closed loop systems a valve or fixtureshould be partially opened to prevent excessivepressure accumulation as temperature rises.

2. Energize the heating cable and allow thesystem to reach its equilibrium temperature (the building’s water heater should be operatingand the building’s environment should be at anambient temperature between 22 - 27 C).oo

3. The water heater/mixing valve which controlsthe water supply temperature should be set atthe minimum storage temperature of 60o C (AS/NZ Std 3500.4) do not exceed 65o C.

4. Using a calibrated thermometer check the watertemperature at the water heater heater to becertain that it is within the desired range.

5. Again, using a calibrated thermometer checkthe water temperature at various fixture loca-tions that are heat traced. Allow sufficient timefor water to pass any unheated portion of waterline.

6. Test for ground-fault protection by manuallytripping the push-to-test button on the device(remember to reset after the test).

If start-up is not successful, refer to the TroubleShooting section (pages 15-16) of this guide forassistance.

Caution: Disconnect power to heatingcable (turn off circuit breakers) duringwater heater start-up and hot watersystem purging if water temperatureswill exceed 65 C.

o

Start-Up Procedure...Start-Up Procedure...Start-Up Procedure...Start-Up Procedure...Start-Up Procedure...

As part of an annual maintenance program orafter any work ( repair or alterations) have beenperformed on or near the heat traced piping, thefollowing steps should be performed.

Maintenance Checklist...Maintenance Checklist...Maintenance Checklist...Maintenance Checklist...Maintenance Checklist...

1. Visually inspect the pipe’s thermal insulationlooking for any areas where the insulation hasbeen removed, damaged or where the insula-tion appears repaired or replaced. Any suspectareas should be examined for damage to theheating cable. Verify that any new/repairedinsulation meets the specification.

2. While inspecting the insulation, verify that it iscompletely dry. Wet insulation will not onlycause temperature maintenance problems, butcould also signal a more serious problemthatcould cause damage to the cable and thefacility.

3. Test for ground fault protection by manuallytripping the push-to-test button on the device(remember to reset after the test).

13.



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4. Using a calibrated thermomteter check thewater temperature at the water heater to becertain that it is within the desired range. (refermaximum temperature settings page 13)

5. Again, using a calibrated thermometer checkthe water temperature at various fixtures loca-tions that are heat traced. Allow sufficient timefor water to pass any unheated portion of waterline.

6. Heating cable should be tested with amegohmeter (megger) at the power distributionpanel by a qualified electrician (see page 11 fordetails on megger testing).

7. Record any observations on the projects’s as-built drawings and any maintenance log kept forthe facility (QC-3-Com)

Caution: Do NOT enter any powerconnection point, cable splice or endtermination while heating cable isenergized. Disconnect power toheating cable and seek qualifiedassistance.

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The following information is intended to assist inmaintaining and troubleshooting a heat tracedhot water supply system. The primary goal of aheat tracing system is to provide an efficientsupply of hot water closer to the point of usethan is possible with a recirculated system.

Like many other systems installed in a facility,the successful installation of a heat tracingsystem will require coordination among severaltrades involved in the construction process.Mechanical, electrical and insulation contractorsmust each provide services that are critical tothe proper operation of the system.

Troubleshooting...Troubleshooting...Troubleshooting...Troubleshooting...Troubleshooting...

Before calling your heat tracing vendor whenthings aren’t going right, make a visual inspection;perhaps the thermal insulation is wet, damaged ormissing. Also, consider the possibility that repairsor maintenance of nearby equipment may haveresulted in damage to the heat tracing or its powersupply. These are common causes of heat tracingproblems, and they are often over looked. Anumber of other possibilities are listed below, withtheir symptoms and remedies.

If at any time you feel that the heating cable hasbeen damaged, a dielectric insulation resistancetest with a megohmeter (megger) is recom-mended. (See page 11 for test details.)

Possible Causes... Remedy...

1. Water heater/mixing valve setpoint too low.

Reset water heater temperature level, maximum temperature 65o C.

2. No power to heating cable Check power distribution panel to ensure breakers are energized orhave not tripped

3. Splice connection missed duringinstallation

Using drawings and visual inspection, check to see if any spliceconnection has been overlooked. This may be evident if one area ofa heat traced circuit is “cold”.

4. Compressed, missing or wetinsulation

Replaced missing or damaged insulation, ensure that pipe andinsulation have not been forced against other pipes to cause heatsinks along it’s length.

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5. Pipes were not properly insulated Ensure that insulation is per the table on page 11. Reinsulate whereneeded.

6. No heating cable installed in area Verify that the pipe in question was scheduled for heating cable

7. Ambient temperature too low Measure ambient temperature in intersititial space where the heattraced pipe is located. If the temperature is below 22 C for a 50 Cor 60 C system (24 C for a 45 C system), the ambient is too cool.Raise the ambient temperature.

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8. Cable not powered at correctvoltage

Verify the proper design voltage and compare with measured valueat power connection point.

9. Heat loss at temperature limitingvalve

In some TLV’s heat loss can occur between the hot and cold inletsvia the non return valves. Check that dirt from system is not causingmalfunction of the non return valves. Supply and install filter screensat inlets to valve body.

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1. Water heater/mixing valve setpoint too high

2. Pipes were not properly insulated Ensure that insulation is per the table on page 11. Reinsulate whereneeded.

3. Ambient temperature too high Measure ambient temperature in interstitial space where the heattraced pipe is located. If the temperature is above 27o C, the ambi-ent is too high. Lower the temperature in the interstitial space.

4. Cable not powered at correctvoltage

Verify the proper design voltage and comparewith measured valueat power connection point. Refer QC-3-Com fabrication sheet ifavailable

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Reset water heater temperature level, maximum temperature settingis 65o C


1. Improper electrical connection Cable could be damaged or improperly connected. Visually inspectheating cable, connections and terminations. Test cable with megger.

2. Maximum circuit length exceeded Verify the length of the heating cable, including all cable located ontee splices. Compare this metreage with the maximum circuit lengthand circuit breaker sizing chart located on page 7. Increase breakersize or add additional circuits if needed.

3. Piping/building is too cold duringstart-up

The building and the water in the pipe must be greater than 16o C.Raise building temperature or purge hot water lines.

4. Damaged power feed wire leadingto power connection

Disconnect heating cable at power connection and test power feedwires running back to power distribution panel.

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5. Faulty branch circuit breaker Replace breaker and energize heating cable.

Caution: Replace all damaged heat-ing cable. Do not reconnect power tocable that has been exposed to exces-sive heat or moisture. Failure toreplace damaged cable can causearcing or fire.

Caution: Disconnect power to heatingcable (turn off circuit breakers) whenworking on heat traced pipes, or heattracing systems.

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warmtrace tm systems for hot water temperature maintenance · of heat tracing required by...

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