Raychem Custom MI Heating Cable Applications Installation guide

Type
Installation guide
Installation Instructions for Custom MI
Heating Cable Applications
MI Heating Cable
System
ii | nVent.com/RAYCHEM
Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD.
nVent RAYCHEM MI Heating Cable Systems must be
installed correctly to ensure proper operation and to prevent
shock and fire. Read these important warnings and carefully
follow all the installation instructions.
To avoid damage to the heating cables, do not energize
cables until the installation has been completed.
To minimize the danger of fire from sustained electrical
arcing if the heating cable is damaged or improperly
installed, and to comply with nVent requirements, agency
certifications, and national electrical codes, ground-fault
equipment protection must be used on each heating cable
branch circuit. Arcing may not be stopped by conventional
circuit breakers.
Heating cables must be spaced at least 1/2 in (1.3 cm)
from any combustible surface.
Approvals and performance of the MI Heating Cable
Systems are based on the use of approved components
and accessories.
Cable terminations must be kept dry before, during, and
after installation.
Energized exposed heating cables are hot and can cause
burns. Take precautions to ensure that personnel in the
area do not contact an energized heating cable.
Damaged heating cable can cause electrical arcing or fire.
Damaged heating cable or terminations must be repaired
or replaced. Contact factory for assistance.
If the heating cable sheath is stainless steel, the metal
covering on the cable set shall be bonded to the circuit
bonding conductor, but shall not be used as the circuit
bonding means. Metallic structures or materials used
for the support of, or on which the heating cables are
installed, must be bonded to ground.
To prevent fire or explosion in hazardous locations, verify
that the maximum sheath temperature of the heating cable
is lower than the auto-ignition temperature of the gases
and vapors in the area. For further information, see the
project design specifications.
Reinforcing rod, mesh or other materials used for the
support of, or on which the heating cables are installed,
must be grounded in accordance with CSA Standard
C22.1, Section 10 or the National Electrical Code as
applicable.
Megohmmeters operate at high voltage. This voltage
is hazardous and possibly lethal. Read and follow all
instructions included with the instrument you are using.
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Table of Contents
1
General Information 1
1.1 Use of the Manual 1
1.2 MI Heating Cable Applications 3
1.3 Safety Guidelines 3
1.4 Electrical Codes 4
1.5 Approvals 4
1.6 Warranty 5
1.7 Heating Cable Configurations 5
1.8 Heating Cable Identification 6
2
General Installation Guidelines 8
2.1 Before You Start 8
2.2 Heating Cable Storage 8
2.3 Tools Required 8
2.4 Cable Testing Guidelines 8
2.5 General Installation Guidelines 9
2.6 Junction Boxes and Electrical Enclosures 12
2.7 Protecting the Heating Cable 12
2.8 Check Materials Received 12
2.9 Slab Temperature Sensor 13
2.10 Visual Inspection 13
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Table of Contents
3
Heating Cable Installation 15
3.1 Roof and Gutter Deicing 15
3.2 Surface Snow and Ice Melting Using
Heating Cables Installed Inside Pipe
24
3.3 Snow and Ice Melting on Exposed
Surfaces
35
3.4 Frost Heave Protection for Cryogenic
Storage Tanks
41
3.5 Tubular Heater Installation for Dam Gates 45
3.6 Soil Heating 50
3.7 Animal Pen Floor Heating 54
4
Accessory Installation 60
4.1 Junction Boxes 60
4.2 Temperature Controller Installation 66
5
Control, Monitoring and Power Distribution 68
5.1 Manual On/Off Control 68
5.2 Temperature Controller 68
5.3 Automatic Snow/Ice Melting Controller 69
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Table of Contents
6
Power Supply and Electrical Protection 70
6.1 Voltage Rating 70
6.2 Circuit Breaker Sizing 70
6.3 Ground-Fault Equipment Protection 71
6.4 Junction Box wiring 72
6.5 Typical Wiring Diagrams 73
7
Commissioning and Preventative Maintenance 77
7.1 System Tests 77
7.2 Preventative Maintenance 78
8
Test Procedures 80
8.1 Visual Inspection 80
8.2 Insulation Resistance Test – Test 1 81
8.3 Continuity (Resistance) Test – Test 2 82
8.4 Insulation Resistance and Continuity Test
Procedure
82
8.5 Power Check 84
8.6 Fault Location Testing 87
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Table of Contents
9
Troubleshooting Guide 88
10
Controllers and Accessories 92
11
Installation and Inspection Records 112
1
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1
General Information
1.1 Use of the Manual
This manual covers the installation of nVent
RAYCHEM Mineral Insulated (MI) heating cables in
nonhazardous areas for:
Roof and gutter deicing
Surface snow and ice melting using heating cables
installed inside pipe
Snow and ice melting on exposed surfaces
Soil heating
Animal pen floor heating
Tubular heaters used to prevent the formation of
ice around dam gates
The manual also covers the installation of MI
heating cables in hazardous areas for:
Roof and gutter deicing
Surface snow and ice melting using heating cables
installed inside pipe
Frost heave protection for cryogenic storage tanks
using heating cables installed inside pipe/conduit
The manual includes general heating cable
installation procedures and specific installation
details and provides information on testing and
periodic maintenance.
This manual assumes that a proper heating system
design has been completed according to nVent's
recommendations. The applications described in this
manual are approved by nVent for nVent RAYCHEM
MI heating cables and only when used with approved
accessories. The instructions in this manual and
the installation instructions included with the
control systems, power distribution systems, and
accessories must be followed for the nVent warranty
to apply.
1
General Information
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For design assistance, technical support, or
information regarding other applications not shown
here, please contact your nVent representative or
nVent directly.
nVent
7433 Harwin Drive
Houston, TX 77036
USA
Tel: +1.800.545.6258
Fax: +1.800.527.5703
nVent.com/RAYCHEM
Important: For the nVent warranty and
agency approvals to apply, the instructions
that are included in this manual and with
associated products must be followed.
1
General Information
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1.2 MI Heating Cable Applications
Specific installation instructions relating to each
application can be found on the pages following:
Section 3.1 - Roof and gutter deicing (ordinary and
hazardous locations)
Section 3.2 - Surface snow and ice melting, heating
cables installed inside pipe (ordinary and hazardous
locations)
Section 3.3 - Snow melting on exposed surfaces
(ordinary locations only)
Section 3.4 - Frost heave protection, heating cables
installed inside pipe/conduit for cryogenic storage
tanks (hazardous locations)
Section 3.5 - Tubular heaters for dam gate deicing
(ordinary locations only)
Section 3.6 - Soil heating (ordinary locations only)
Section 3.7 - Animal pen floor heating (ordinary
locations only)
1.3 Safety Guidelines
As with any electrical equipment, the safety and
reliability of any heat-tracing system depends on the
quality of the products selected and the manner in
which they are installed and maintained. Incorrect
design, handling, installation, or maintenance of
any of the system components could damage the
heating system and may result in inadequate heating
system performance, electric shock, or fire. To
minimize these risks and to ensure that the system
performs reliably, read and carefully follow the
information, warnings, and instructions in this guide.
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General Information
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Pay special attention to the following:
Notes are marked
Note
Important Instructions are marked
Important
Warnings are identified as
Warning
1.4 Electrical Codes
Articles 424 and 426 and Article 500 of the National
Electrical Code and Section 62 and Section 18 of
the Canadian Electrical Code, Part 1, govern the
installation of heating systems in nonhazardous and
hazardous locations. Installation of heating systems
must comply with all national and local codes.
In particular, ground-fault equipment protection
is required for all electric heating installations
to prevent arcing, fire, and shock if the cable is
improperly installed or damaged.
1.5 Approvals
MI heating cables are approved for use in
nonhazardous and hazardous locations.
For a complete list of approvals, refer to
product data sheets available on our website
at nVent.com/RAYCHEM or contact your
nVent representative.
H56990 – Copper and LSZH Jacketed Copper
Sheathed MI Cable for Commercial and Industrial
Applications data sheet
H56870 – XMI-A (Alloy 825) High Temperature
Constant Wattage Mineral Insulated Heating
Cables data sheet
1
General Information
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1.6 Warranty
nVent’s standard limited warranty applies to MI
Heating Cable System.
An extension of the limited warranty
period to ten (10) years from the date of
installation is available, except for the
control and distribution systems, if a
properly completed online warranty form
is submitted within thirty (30) days from the date of
installation. You can access the complete warranty
on our website at https://raychem.nvent.com/en-us/
support/warranty-information.
Note: This extended warranty is not available
for TH type tubular heaters used for dam gate
deicing.
1.7 Heating Cable Configurations
The heating cables are available as factory-terminated
units in the configurations shown in Figure 1. The “D”
design heating cable with a reversed gland and pulling
eye must be used for installations in pipe.
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General Information
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MI cable
design
Number of
conductors
Configuration
Heated length
Heated length
Cold lead length
Cold lead length
Cold lead length
NPT threaded
connector
Hot/cold
joint
NPT threaded
connector
Hot/cold
joint
Heated length
Cold lead length
NPT threaded
connector
Reversed gland
Hot/cold
joint
A Single
conductor
(61 series)
B Single
conductor
(61 series)
D Dual
conductor
(32 & 62
series)
TH Tubular
heater
series
NPT threaded
connector
Reversed gland
(optional)
Extreme
environment seal
Heated length
Cold lead length
Hot/cold
joint
Endcap
Pulling eye
(optional-only required for
cables in pipe)
(optional-only required for
cables in pipe)
Figure 1: Typical MI heating cable configurations
1.8 Heating Cable Identification
Each MI heating cable is supplied with an
identification tag on which the heating cable catalog
number is permanently printed. In addition to its
identification purposes, the catalog number provides
information regarding the heating cable length,
power output, and operating voltage. Also printed
on the tag are the designer’s circuit identification
number, serial number and the maximum
temperature the cable sheath may attain along with
other design information.
If the cable has been designed for a hazardous
location, the area classification is printed in the
“Hazardous Locations” section of the tag.
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General Information
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NVENT THERMAL CANADA LTD.
CATALOGUE NO:
NO. DE CATALOGUE:
DESIGN / CABLE REF. / LENGTH / WATTS / VOLTS / C.L. LENGTH / C.L. CODE /JOINT / GLAND
DESSIN / REF.DU CABLE / LONGUEUR / WATTS / VOLTS / C.L. LONG / CODE C.L. / JOINT / PRESSE-E-TOUPE
ORDER NO:
NO DE COMMANDE:
SERIAL NO:
NO DE SERIE:
OUTPUT POWER:
PUISSANCE DE SORTIE:
MAX SHEATH TEMP:
TEMP DE GAINE MAXIMALE:
DESIGN METHOD:
METHODE DE DESIGN:
CERTIFICATION REF:
NO DE CERTIFICATION:
HAZARDOUS LOCATIONS:
EMPLACEMENTS DANGEREUX:
FOLLOW INSTALLATION AND OPERATION INSTRUCTIONS FOR SAFE USE IN HARARDOUS AREA! SVP VOUS REFERER AUX
INSTRUCTIONS D’INSTALLATION.
CUSTOMER ORDER NO:
NO DE COMMANDE DU CLIENT:
CIRCUIT ID:
ID. DU CIRCUIT:
MAINTAIN TEMP OF:
TEMP.E MAINTIEN:
SHEATH REF TEMP:
TEMP DE REF DE LA GAINE:
USAGE CODE:
CODE D’UTILISATION:
T (CODE) / AIT:
T (CODE DE) / TAI:
(SEE OTHER SIDE -- VOIR AUVERSO)
THIS TAG MUST NOT BE REMOVED - N’ENLEVEZ PAS CETTE ETIQUETTE
727051
19-166341201
@ 130.0 V 120 W @
215ºC
PS
T2D
7038622
12-PASC-2152-0-01
157944
cCSAus CL I, II, III Div 1 Grp A,B,C,D,E,F,G Ex e IIC Class I Zone 1 Aex e IIC
D/32SA2275/50/120/130/7/LS23A/X/N12
Figure 2: Typical MI identification tag (front)
WARNING: Fire or explosion hazard. Ensure
that the information provided in the Hazardous
Locations and Max. Sheath Temp. [T (Code)/AIT]
fields comply with the area in which the heating
cable will be installed.
The heating cable catalog number may be broken
out as follows:
Pulling eye (optional)
1" Reversed gland (optional)
Gland size (NPT)
Hot/cold joint type
X - use for XMI-A Alloy 825 sheath
Y - use for copper sheath
Cold lead code
Cold lead length (in feet)
Metric: 2.1M = 2.1 meters
Heating cable voltage
Heating cable wattage
Heating cable length (in feet)
Metric: 10.7M = 10.7 meters
Heating cable reference
Heating cable design
configuration (A, B, D, TH)
D/32SA2200/35/200/120/7/LS23A/X/N12/RG1/PE
Figure 3: MI heating cable catalog number
2
General Installation Guidelines
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The guidelines in Section 2 are provided to assist
the installer throughout the installation process and
should be reviewed before the installation begins.
2.1 Before You Start
These heating systems are engineered systems that
have been designed for your application. To ensure
a smooth, efficient installation and start-up, obtain
all the relevant engineering information before
commencing work. Contact the general contractor,
owner, or owner’s representative to obtain a
statement of the project design basis, project
specifications the heating cable layout drawings.
2.2 Heating Cable Storage
Store the heating cables in a clean, dry location, in
their shipping containers.
Temperature range: –40°F to 140°F (–40°C to 60°C).
Protect the heating cable from mechanical damage.
2.3 Tools Required
The following tools are recommended for installing
MI heating cables.
Pliers
500 Vdc or 1000 Vdc megohmmeter
(1000 Vdc recommended)
Multimeter
Large adjustable wrench
Torque wrench
Pay-off reel (to uncoil long cables)
2.4 Cable Testing Guidelines
Insulation resistance (IR) testing is recommended
at four stages during the installation process and
as part of regularly scheduled maintenance. Further
details on Testing can be found in Section 8.
2
General Installation Guidelines
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When received (prior to installation) – minimum
100 MΩ
Continuously during placement of soil, concrete,
etc. – minimum 20
After the cables have been installed – minimum
20 MΩ
Prior to initial start-up (commissioning) – minimum
20 MΩ including branch circuit wiring
As part of the regular system inspection
After any maintenance or repair work
2.5 General Installation Guidelines
Avoid damage to the MI heating cable as follows:
Do not energize cables before the installation is
complete.
Use a pay-off reel to uncoil heating cable during
installation; do not pull cable out into a spiral
(Figure 4).
Right Wrong
Figure 4: Unreeling/uncoiling cable
Do not alter cable length.
Avoid damaging heating cables by cutting or
crushing (Figure 5).
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General Installation Guidelines
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Figure 5: Avoid cutting and crushing the heating cable
Minimum installation temperature:
Bare copper sheath and Alloy 825 sheath cables:
–76°F (–60°C)
LSZH jacketed copper sheath cables: –4°F
(–20°C) for UL, –22°F (–30°C) for CSA
Do not install so that heating cables are crossed,
overlapped, or grouped (Figure 6). Grouped heating
cables can cause localized overheating with a risk
of fire or cable failure.
Figure 6: Do not cross, overlap, or group heating cables
Do not repeatedly bend and straighten the cable.
Do not install heating cable in contact with
combustible materials.
Install heating cable at the recommended spacing
to ensure correct watt density.
For embedded applications, use a plank to tip
wheelbarrow on.
Handle the hot/cold joint carefully. Support the
joint on both sides when moving and positioning
the cold lead.
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General Installation Guidelines
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Position hot/cold joints 6 in (15 cm) in from edge of
heated areas and spaced at least 6 in (15 cm) apart
from each other (do not bunch hot/cold joints – see
Figure 7).
Wrong
hot/cold joints
installed on
slab edge
Wrong
hot/cold joints
bunched
Right
hot/cold joints
6 in (15 cm) apart
and 6 in (15 cm)
from slab edge
Figure 7: Positioning hot/cold joints
During installation, protect tails from breaking
where they emerge from brass pot by taping over
tails and pot with electrical tape.
Do not bend the heating cable or cold lead within
6 in (15 cm) of a splice, the hot/cold joint, or the
end cap.
Do not bend cable to an inside radius less than 6
times the outside diameter of the cable.
Do not space runs of heating cable closer than 3 in
(7.5 cm) together.
Do not use sharp objects such as shovels, rakes,
etc. when installing the cable (Figure 8).
Figure 8: Avoid damage by not using shovels or rakes
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General Installation Guidelines
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2.6 Junction Boxes and Electrical Enclosures
Junction boxes and enclosures used for electrical
connections to the heating cables must be listed
and approved for the environment in which they are
installed, such as ordinary, wet or hazardous areas.
Junction boxes should be mounted indoors or
above grade when possible.
Keep covers on junction boxes to prevent moisture
from entering them.
2.7 Protecting the Heating Cable
On many projects, there is a delay between
installation of the heating cables and final
completion work, such as covering the cables with
concrete or soil. If there is any delay at all, take the
following precautions to protect the installation until
the heating cables can be completely covered.
Do not energize the heating cables.
Mechanically protect the heating cables so that
they cannot be damaged by being walked on, run
over, painted, sandblasted, burned, welded, or cut.
2.8 Check Materials Received
Review the project specifications, drawings, and
schedules and compare the list of materials to the
catalog numbers of heating cables and components
received to confirm that proper materials are on site.
The heating cable catalog number, voltage, wattage,
and length are printed on the metal tag attached to
the cold lead.
Ensure that the heating cable voltage rating is
suitable for the power supply voltage available.
Inspect the heating cable and components for
in-transit damage.
Perform continuity and insulation resistance
testing (minimum 100 MΩ) on each cable as
detailed in Section 8 and record the results in the
Heating Cable Installation Record in Section 11.
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General Installation Guidelines
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2.9 Slab Temperature Sensor
All applications should be controlled with a
thermostat or electronic controller, including
embedded snow melting applications where the
heating cables may be controlled with an automatic
snow/ice melting controller. For snow/ice melting
applications, the thermostat or electronic controller
can be used to limit the maximum temperature
of the slab, improving energy efficiency. Some
applications, such as soil heating, animal pen floor
heating and frost heave protection, will require only a
thermostat or temperature controller to regulate the
temperature.
The temperature sensor should be installed in metal
or plastic conduit/pipe placed between two runs
of heating cable. Do not allow the conduit/pipe to
touch the heating cable. Cap the buried end of the
conduit/pipe so that it is watertight. Ensure that
the sensor can fit past all bends in the conduit/
pipe prior to installation of the conduit/pipe. The
conduit/pipe should be long enough to extend out to
approximately the middle of the area being heated.
2.10 Visual Inspection
A visual inspection of the heating system should
be made before placement of the concrete or
soil, connection into pipe, etc. to ensure proper
installation of the system.
Verify that there is no mechanical damage to the
heating cables (cuts, breaks, burns, scrapes, etc.).
Verify proper heating cable spacing, depth, etc. for
the application where applicable.
Verify proper heating cable fastening method (no
wire).
Ensure heating cable does not cross expansion
joints. If crossing expansion joints cannot be
avoided, contact nVent technical support.
For directly embedded heating cables, verify that
the cold leads are protected with nonmetallic
conduit where they emerge from the heated area.
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General Installation Guidelines
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For directly embedded heating cables, verify that
the hot/cold joints are 6 in (15 cm) in from the
edge of the heated area, are not bunched together,
and spaced at least 6 in (15 cm) apart from each
other (see Figure 7).
Verify that the junction boxes are properly installed
per manufacturer’s instructions and the details in
Section 4.
WARNING: Damaged heating cables can cause
sustained electrical arcing or fire. Do not energize
cables that have been damaged. Repair or replace
damaged heating cable or terminations before
energizing the circuit.
For installation assistance or technical support,
please contact your nVent representative or nVent
directly at (800) 545-6258.
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Raychem Custom MI Heating Cable Applications Installation guide

Type
Installation guide

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