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Raychem XL-Trace, Installation And Operation Manual

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38

Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN     18/01

7

 

Test Procedures

7.1 

System Tests

The following tests must be done after installing the 

connection kits, but before the thermal insulation is 

applied to the pipe:
1.  Visual inspection
2.  Insulation resistance test

After the thermal insulation has been installed on 

the pipe, the following tests must be performed:
1.  Visual inspection
2.  Insulation resistance test
3.  Circuit length verification (Capacitance test)
4.  Power test
5.  Temperature test

All test procedures are described in this manual. 

It is the installer’s responsibility to perform these 

tests or have an electrician perform them. Record 

the results in the Installation and Inspection Record 

in Section 10.

Visual Inspection Test

•  Check inside all power, splice, and tee kits for 

proper installation, overheating, corrosion, mois-

ture, or loose connections.

•  Check the electrical connections to ensure that 

ground and bus wires are insulated over their full 

length.

•  Check for damaged, missing, or wet thermal 

insulation.

•  Check that end seals, splices, and tees are prop-

erly labeled on insulation cladding.

•  Check the controller for proper setpoint and 

operation. Refer to its installation and operation 

manual for details.

Insulation resistance Test

frequency

Insulation resistance testing is required during the 

installation process and as part of regularly sched-

uled maintenance, as follows:
•  Before installing the heating cable

Summary of Contents for XL-Trace

Page 1: ...XL Trace System Installation and Operation manual for pipe freeze protection and flow maintenance Thermal management WWW PENTAIRTHERMAL COM ...

Page 2: ... electrical tape Bus wires will short if they contact each other Keep bus wires separated Connection kits and cable ends must be kept dry before and during installation The black heating cable core is conductive and can short It must be properly insulated and kept dry Damaged bus wires can overheat or short Do not break bus wire strands when preparing the cable for connection Damaged heating cable...

Page 3: ...ion 25 3 1 Insulating the System 25 3 2 Insulation Installation 25 4 Power Supply and Electrical Protection 28 4 1 Voltage Rating 28 4 2 Circuit Breaker Sizing 28 4 3 Electrical Loading 28 4 4 Ground Fault Protection 28 4 5 Important Power Supply Safeguards 29 5 Control Monitoring and Power Distribution 30 5 1 Control Systems 30 5 2 Power Distribution 33 6 Commissioning and Preventive Maintenance ...

Page 4: ...iv Raychem IM H58033 XLTracePipeFreezeProtectionCOM EN 18 01 ...

Page 5: ...has been completed according to the Pipe Freeze Protection and Flow Maintenance Design Guide H55838 Only the applications described in Section 1 2 are approved by Thermal Management for XL Trace systems when used with approved Raychem connection kits The instructions in this manual and the installation instructions included with the connection kits control systems power dis tribution systems and a...

Page 6: ...ing containing 2 fuel oil For heating cable applications other than those listed above please see your Thermal Management repre sentative or call us at 800 545 6258 1 3 Safety Guidelines As with any electrical equipment the safety and reli ability of any system depends on the quality of the products selected and the manner in which they are installed and maintained Incorrect design handling instal...

Page 7: ...ecific applica tion refer to the Pipe Freeze Protection and Flow Maintenance design guide H55838 Warranty Thermal Management standard limited warranty applies to all products An extension of the limited warranty period to ten 10 years from the date of installation is available if a properly completed online warranty form is submit ted within thirty 30 days from the date of installa tion You can ac...

Page 8: ...og number Review the heating cable design and compare the list of materials to the catalog numbers of the heating cables and connection kits received to confirm that the proper materials are on site The heating cable type is printed on its jacket Ensure that the service voltage available is correct for the XL Trace heating cable selection Inspect the heating cable and connection kits to ensure the...

Page 9: ...F 18 C Heating cable installation involves three basic steps 1 Paying out the heating cable 2 Attaching the heating cable to the pipe 3 Wrapping heat sinks Paying out the heating cable Mount the reel on a holder and place it near either end of the pipe run to be traced Use a reel holder that pays out smoothly with little tension as shown in Figure 2 Avoid jerking the heating cable while pulling Pa...

Page 10: ...maged heating cable Connection kits and heat ing cable ends must be kept dry before and during installation Attaching the heating cable Once the heating cable has been run for the entire section begin fastening it to the pipe Start at the end and work toward the reel The additional heat ing cable required for valves and other heat sinks is shown in Table 1 and Table 2 Refer to Table 3 for the addi...

Page 11: ...7 Raychem IM H58033 XLTracePipeFreezeProtectionCOM EN 18 01 2 Installation Guidelines Figure 3 Attaching the heating cable ...

Page 12: ...10 5 6 1 7 12 5 9 1 9 14 7 3 2 2 18 9 4 2 9 20 10 5 3 2 Table 2 Additional Heating Cable for Pipe Supports and Flanges Support Additional heating cable Pipe hangers insulated No additional heating cable Pipe hangers noninsulated and U bolt supports Add 2x pipe diameter Welded support shoes Add 3x the length of the shoe Flanges Add 2x pipe diameter Note For applications where more than one heating ...

Page 13: ...r pipe hanger Pipe hanger under insulation Pipe hanger over insulation Insulation over pipe hanger Heating cable Figure 4 Pipe hanger with heating cable Figure 5 Single pipe floor penetration When making floor or wall penetrations make sure the hole is large enough to accommodate the pipe and the thermal insulation When sealing around pipes at floor penetrations avoid damag ing or cutting the heat...

Page 14: ... pipes so it will not be damaged if the pipe hits the side of the floor penetration Run the heating cable over the outside of the pipe support Do not clamp the heating cable to the pipe with the pipe support In high rise construction it may be necessary to install the XL Trace system 10 or 12 floors at a time to fit into the construction schedule If so the end of the heating cable should be sealed...

Page 15: ...ting cable to the pipe make sure all heat tracing allowances for flanges valves supports and other connection kits have been verified Use one of the following attachment methods to secure the heating cable onto the pipe GT 66 or GS 54 glass cloth tape AT 180 aluminum tape or plastic cable ties Glass clotH adHesiVe tape GT 66 66 foot roll general purpose tape for installation at 40 F 4 C and above ...

Page 16: ... AT 180 aluminum tape over heating cable Required for proper output for plastic pipe applications Heating cable Pipe AT 180 aluminum tape Figure 8 attaching the heating cable caBle ties Recommended in applications where the pipe sur face prevents proper tape adhesion Use plastic cable ties only Cable ties must be hand tightened only to prevent damage to heating cable Bending Crossing Cutting the h...

Page 17: ...ting or burning out cuttinG tHe HeatinG caBle Cut the heating cable to the desired length after it is attached to the pipe XL Trace can be cut to length without affecting the heat output per foot Wrapping the heat Sinks Once the straight sections are secured the heating cable can be secured to the heat sinks Attach the heating cable to the heat sinks according to Figure 10 below The length of heat...

Page 18: ...ssovers allowed for self regulating cables Single crossover only allowed for power limiting cables Glass tape Pipe Heating cable Pipe Heating cable Note Cable loop length varies depending on heat loss Figure 10 Valve Glass tape typical Heating cable Loop length is twice the diameter of the pipe Figure 11 Flange ...

Page 19: ... EN 18 01 2 Installation guidelines Heating cable Glass tape Pipe Figure 12 Pressure gauge Glass tape Pump discharge Pump body Heating cable Pump suction Use AT 180 tape Motor To power connection Pump body Pump body Figure 13 Split case centrifugal pump ...

Page 20: ...guidelines Heating cable secured to pipe Glass tape Heating cable loop Support shoe Pipe Figure 14 Pipe support shoe Heating cable Glass tape typical For pipe diameters of 2 and larger the heating cable should be installed on the outside long radius of the elbow Figure 15 elbow ...

Page 21: ...eground applications and Table 4 for belowground applications to select the appropriate connection kits When practical mount connection kits on top of the pipe Electrical conduit leading to power connection kits must have low point drains installed to avoid condensation entry into the heating system All heat ing cable connections must be mounted above grade level If your design has an exposure tem...

Page 22: ...on box EC TS electronic thermostat RayClic S splice RayClic T tee Insulation RayClic LE lighted end seal optional RayClic E end seal Figure 17 aboveground Xl Trace System Use Table 3 for general aboveground piping sprin kler piping and grease and fuel lines Allow extra heating cable for ease of connection kit installation ...

Page 23: ...on and end seal kit use 1 per circuit Standard pkg 1 2 ft 0 6 m FTC P4 5 Power connection and end seal kit use 1 per circuit Standard pkg 1 Junction box not included 2 ft 0 6 m RayClic S2 3 6 Splice used to join two sections of heating cable Standard pkg 1 2 ft 0 6 m RayClic T2 6 Tee kit with end seal use as needed for pipe branches Standard pkg 1 2 ft 0 6 m RayClic LE Alternate lighted end seal S...

Page 24: ...9 m RayClic E3 Replacement end seal Standard pkg 1 0 3 ft 0 1 m 1 For ease of component installation allow extra heating cable 2 Powered splice powered tee and cross tee with three legs connections are also available 3 For grease and fuel lines install RayClic LE or end seal off the pipe in junction box 4 Not permitted with grease or fuel lines 5 Use for circuits supplied with 40 A circuit breaker...

Page 25: ...pe for attaching heating cable to pipe at 40 F 4 C or above See Table 7 66 ft GS 54 Glass cloth adhesive tape for attaching heating cable to pipe above 40 F 40 C See Table 7 54 ft AT 180 Aluminum tape Required for attaching heating cable to plastic pipe use 1 foot of tape per foot of heating cable 180 ft RayClic SB 04 Pipe mounting bracket Required for mounting the kits off the pipe for exposure t...

Page 26: ...nd seal Ground Wall RayClic LE RayClic PC Junction box RayClic E end seal Conduit Wall with wall mounting bracket with wall mountiung bracket FTC XC power connection To protect the heating cable run it inside Convolex tubing between the conduit and the RayClic connection kits Figure 18 Buried pipe Xl Trace System WarnIng all heating cable connections power splice tee and end termination are made a...

Page 27: ...allowance FTC XC Power connection and end seal Junction box supplied by customer Use 1 per circuit Standard pkg 1 2 ft 0 6 m 3 1 8 RayClic PC Power connection and end seal kit Standard pkg 1 RayClic E Replacement end seal Standard pkg 1 0 3 ft 0 1 m RayClic LE Alternate lighted end seal Standard pkg 1 2 ft 0 6 m For ease of connection kit installation allow extra heating cable ...

Page 28: ...pe at 40 F 4 C or above See Table 7 66 ft GS 54 Glass cloth adhesive tape for attaching heating cable to pipe above 40 F 40 C See Table 7 54 ft AT 180 Aluminum tape Required for attaching heating cable to plastic pipe use 1 foot of tape per foot of heating cable 180 ft RayClic SB 02 Wall mounting bracket 1 Table 7 Quantity of Glass Cloth Adhesive Tape Required attach at 1 foot intervals Pipe size ...

Page 29: ...e and thickness is correct Insulate the pipes immediately after the heating cable is installed and has passed all tests to mini mize damage to the heating cable Insulate the pipe at floor and wall penetrations Failure to do so will cause cold spots in the water system and could lead to damage to the heating cable If local codes do not allow this the heating cable should be run through a conduit or...

Page 30: ...tant thermal insulation Mark the location of splices tees and end seals on the outside of the insulation with labels pro vided in the kits while installing the insulation Use large diameter insulation or sheets to cover splices tees or service loops Figure 20 Installing connection kits below insulation Figure 21 Installing connection kits above insulation ...

Page 31: ...ire properly installed and dry thermal insulation Uninsulated or wet sections of pipe can result in cold spots or frozen sections After installing insulation electrical codes require that you install Electric Traced labels along the piping at suitable intervals 10 foot intervals rec ommended on alternate sides WARNING Use only fire resistant insulation materials such as fiberglass wrap or flame re...

Page 32: ...e appropriate current draw 4 4 Ground Fault Protection If the heating cable is improperly installed or physi cally damaged to the point that water contacts the bus wires sustained arcing or fire could result If arcing does occur the fault current may be too low to trip conventional circuit breakers Thermal Management and national electrical codes require both ground fault protection of equipment a...

Page 33: ... rating of the control sys tem selected Check the design drawings for the heating cable load The electrical conduit that feeds wiring to the control device must have a low point drain so condensation will not enter the thermostat enclosure Make sure that the line voltage you are con necting to the control system is correct For proper wiring follow the installation instructions enclosed with the co...

Page 34: ...e by means of a sensor attached to the pipe and con nected to the device Install the sensor on the pipe at 90 degrees from the heating cable so that the heating cable does not thermally interfere with the sensor Be sure the sensor is firmly attached with aluminum tape to the pipe in order to get good thermal contact between the bulb and the pipe Locate the sensor at least 3 feet 1 meter from any h...

Page 35: ...m 100 to 277 V and can switch current up to 30 Amperes The ECW GF is complete with a 25 ft 7 6 m temperature sensor and is housed in a NEMA 4X rated enclosure The controller features an AC DC dry alarm contact relay An optional ground fault display panel ECW GF DP can be added to provide ground fault or alarm indication in applications where the controller is mounted in inaccessible locations elec...

Page 36: ...nterface terminal The ACS PCM2 5 panel can directly control up to 5 individual heat tracing circuits using electromechanical relays rated at 30 A up to 277 V RTDs Stainless steel jacketed three wire RTD Resistance Temperature Detector used with Raychem C910 485 and ACS 30 controllers RTD 200 3 in 76 mm temperature sensor with a 6 ft 1 8 m lead wire and 1 2 in NPT bushing RTD3CS temperature sensor ...

Page 37: ...gh the tempera ture control through external contactors or through HTPG power distribution panels Typical Wiring Schematics Single circuit control Temperature controller 1 pole GFEP breaker 1 N G Heating cable ø ø supply Heating cable sheath braid or ground Figure 22 Single circuit control Group control C Temperature controller Contactor 1 pole GFEP breaker N G Typ 3 ø2 ø1 ø3 3 phase 4 wire supply...

Page 38: ... OFF AUTO 1 2 3 4 5 6 7 8 9 10 11 12 Main circuit breaker Main contactor Distribution panelboard Fuse holder C POWER ON TB 1 TB 2 AR R Ground bus bar Selector switch Alarm relay optional Terminals optional Push button for light testing Alarm horn optional Alarm option shown above Door disconnect optional Figure 24 HTPG power distribution panel ...

Page 39: ...ith 30 mA ground fault trip 120 277 Vac Two pole with 30 mA ground fault trip 208 240 Vac Power connection Heating cable Alarm remote annunciation with alarm option End seal Heating cable circuit Heating cable circuit Heating cable shealth braid or ground N Ø1 Panel energized Contactor coil C NC External controller thermostat Hand Auto Off Ø3 Ø2 G Figure 25 HTPG schematic ...

Page 40: ...n and connections to the heating cable for physical damage Check that no moisture is present electrical connections are tight and grounded insulation is dry and sealed and control and monitoring systems are operational and properly set Damaged heating cable must be replaced Insulation Resistance Insulation Resistance IR testing is used to verify the integrity of the heating cable inner and outer j...

Page 41: ...tput to previous readings The heating cable power output per foot is calculated by dividing the total wattage by the total length of a circuit The current voltage operation temperature and length must be known Circuit length can be determined from as built drawings meter marks on the heating cable or with the capacitance test The watts per foot can be compared to the heating cable output in Figure...

Page 42: ...have an electrician perform them Record the results in the Installation and Inspection Record in Section 10 Visual Inspection Test Check inside all power splice and tee kits for proper installation overheating corrosion mois ture or loose connections Check the electrical connections to ensure that ground and bus wires are insulated over their full length Check for damaged missing or wet thermal in...

Page 43: ...ot allow test leads to touch junction box which can cause inaccurate readings Important System tests and regular maintenance procedures require that insulation resistance testing be performed Test directly from the controller or the junction box closest to the power connection insulation resistance criteria A clean dry properly installed circuit should measure thousands of megohms regardless of th...

Page 44: ...40 Raychem IM H58033 XLTracePipeFreezeProtectionCOM EN 18 01 7 Test Procedures Test A Test B Attach to pipe L2 L1 Figure 26 Insulation resistance test ...

Page 45: ...d 2500 Vdc 9 Turn off the megohmmeter 10 If the megohmmeter does not self discharge discharge phase connection to ground with a suitable grounding rod Disconnect the megohmmeter 11 Repeat this test between braid and pipe 12 Reconnect bus wires to terminal block 13 Reconnect the temperature controller Circuit length verification capacitance test Connect the capacitance meter negative lead to both b...

Page 46: ...or 2 hours then measure current and voltage at the junction box If a controller is used refer to details below 2 Check the pipe temperature under the thermal insulation at several locations 3 Calculate the power of the heating cable by multiplying the current by the input voltage and dividing by the actual circuit length Power w ft or m Volts Vac x Current Amps ________________________ Length ft o...

Page 47: ... a section of heating cable 1 Ratio method 2 Conductance method 3 Capacitance method Ratio Method The ratio method uses resistance measurements taken at each end of the heating cable to approxi mate the location of a bus wire short A shorted heating cable could result in a tripped circuit break er If the resistance can be read on a standard ohm meter this method can also be used to find a fault fr...

Page 48: ...A B Example A 1 2 ohms B 1 8 ohms Fault location D 1 2 1 2 1 8 x 100 40 To locate a low resistance ground fault measure between bus and braid A B A B A B Braid Figure 30 Low resistance ground fault test The approximate location of the fault expressed as a percentage of the heating cable length from the front end is Fault location D A x 100 ________ A B Example A 1 2 ohms B 1 8 ohms Fault location ...

Page 49: ... calculations must be made using the conductance of the heating cable A B A B A B Braid Figure 31 Heating cable resistance measurement The approximate location of the fault expressed as a percentage of the heating cable length from the front end is Fault location D 1 A x 100 ________ 1 A 1 B Example A 100 ohms B 25 ohms Fault location D 1 100 1 100 1 25 x 100 20 The fault is located 20 from the fr...

Page 50: ...ng example Example 5XL2 CR 16 2 nF Capacitance factor 5 0 ft nF Fault location 42 2 nF x 5 0 ft nF 211 ft 64 m The ratio of one capacitance value taken from one end A divided by the sum of both A and B A B and then multiplied by 100 yields the distance from the first end expressed as a percentage of the total heating cable circuit length See Table 9 on page 41 for capacitance factors Fault locatio...

Page 51: ...47 Raychem IM H58033 XLTracePipeFreezeProtectionCOM EN 18 01 7 Test Procedures ...

Page 52: ...circuit Nick or cut exists in heating cable or power feed wire with moisture pres ent or moisture in connections Replace the heati the connection an insulation resista GFPD is undersized 5 mA used instead of 30 mA or miswired Replace undersiz GFPD wiring instr Low or inconsistent insulation resistance Nicks or cuts in the heating cable Short between the braid and heating cable core or the braid an...

Page 53: ...ture pres onnections Replace the heating cable as necessary Dry out and reseal the connection and splices Using a megohmmeter retest insulation resistance 5 mA used r miswired Replace undersized GFPD with 30 mA GFPD Check the GFPD wiring instructions heating cable braid and heating aid and pipe If heating cable is not yet insulated visually inspect the entire length for damage especially at elbows...

Page 54: ...406 419 298 314 40 270 210 470 490 530 370 399 390 420 20 F 15 134 100 232 237 244 173 182 20 178 133 309 315 325 231 243 30 270 200 464 473 488 346 365 40 270 210 470 490 530 370 462 390 486 40 F 15 160 119 278 283 292 206 217 20 214 159 370 378 390 275 290 30 270 210 470 490 530 370 416 390 438 40 270 210 470 490 530 370 554 390 584 50 F buried 15 228 240 20 304 320 30 457 481 40 609 641 65 F in...

Page 55: ...06 419 298 314 331 239 244 252 490 530 370 399 390 420 420 443 319 326 336 237 244 173 182 192 126 129 133 315 325 231 243 257 169 172 177 473 488 346 365 385 253 258 266 490 530 370 462 390 486 420 513 340 349 344 355 283 292 206 217 229 142 145 150 378 390 275 290 306 190 194 200 490 530 370 416 390 438 420 462 285 291 300 490 530 370 554 390 584 420 616 349 398 360 406 380 419 228 240 254 152 1...

Page 56: ... 124 128 91 96 40 82 210 143 149 162 113 122 119 128 7 C 15 41 100 71 72 74 53 56 20 54 133 94 96 99 70 74 30 82 200 141 144 149 106 111 40 82 210 143 149 162 113 141 119 148 40 C 15 49 119 85 86 89 63 66 20 65 159 113 115 119 84 88 30 82 210 143 149 162 113 127 119 134 40 82 210 143 149 162 113 169 119 178 10 C buried grease 15 70 73 20 93 98 30 139 147 40 186 195 18 C indoors grease 15 83 87 20 ...

Page 57: ...7 49 50 51 124 128 91 96 101 73 74 77 149 162 113 122 119 128 128 135 97 99 102 72 74 53 56 59 39 39 41 96 99 70 74 78 51 52 54 144 149 106 111 117 77 79 81 149 162 113 141 119 148 128 156 104 106 105 108 86 89 63 66 70 43 44 46 115 119 84 88 93 58 59 61 149 162 113 127 119 134 128 141 87 89 91 149 162 113 169 119 178 128 188 104 121 110 124 116 128 70 73 77 46 47 49 93 98 103 62 63 65 139 147 155...

Page 58: ... 057 0 080 0 076 20 0 090 0 120 0 052 0 051 0 049 0 069 0 066 40 0 075 0 101 0 043 0 042 0 041 0 058 0 055 50 0 053 0 050 65 0 044 0 042 Table A4 Transformer Sizing Amperes meter Minimum start up temperature C 5XL1 8XL1 5XL2 8XL1 120 V 120 V 208 V 240 V 277 V 208 V 240 V 20 0 391 0 521 0 226 0 221 0 215 0 301 0 286 18 0 343 0 457 0 198 0 194 0 188 0 264 0 251 7 0 294 0 394 0 170 0 166 0 161 0 227 ...

Page 59: ...95 0 093 0 090 3 0 042 0 041 0 058 0 055 0 052 0 084 0 083 0 080 0 053 0 050 0 047 0 079 0 077 0 075 0 044 0 042 0 040 0 072 0 070 0 067 s meter 5XL2 8XL1 12XL2 V 240 V 277 V 208 V 240 V 277 V 208 V 240 V 277 V 6 0 221 0 215 0 301 0 286 0 270 0 354 0 347 0 336 8 0 194 0 188 0 264 0 251 0 238 0 329 0 322 0 312 0 0 166 0 161 0 227 0 216 0 205 0 311 0 305 0 296 2 0 139 0 135 0 191 0 181 0 172 0 276 0...

Page 60: ...n ground and bus wires insulated over full length Damaged or missing thermal insulation damaged missing cracked lagging or weatherproofing Covered end seals splices and tees properly labeled on insulation Check controllers for moisture corrosion setpoint switch operation Insulation resistance test M Ohms Bus to braid Test A 500 Vdc 1000 Vdc 2500 Vdc Braid to pipe Test B 500 Vdc 1000 Vdc 2500 Vdc C...

Page 61: ...eezeProtectionCOM EN 18 01 10 Installation and Inspection Record ating function overheating corrosion wires insulated over aged missing cracked labeled on insulation point switch operation M Ohms ce nF x Vac Amps F C th watts ft watts m ...

Page 62: ...nfo pentair com Pentair RayClic and XL Trace are owned by Pentair or its global affili ates All other trademarks are the property of their respective owners Pentair reserves the right to change specifications without prior notice 2008 2018 Pentair Thermal management Raychem IM H58033 XLTracePipeFreezeProtectionCOM EN 18 01 ...

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