ASSEMBLY AND COMMISSIONING INSTRUCTIONS FOR ELECTRIC HEATING TAPE

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Ashlyn Sherman
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1 ASSEMBLY AND COMMISSIONING INSTRUCTIONS FOR ELECTRIC HEATING TAPE Page 1/28

2 CONTENTS I. Basic system... 4 II. Storage... 4 III. Preliminary Checks... 4 IV. Preparation... 4 V. Method... 5 VI. Assembly... 6 VII. Electrical connections...20 VIII. Commissioning and Maintenance...23 VIII. 1. General information...23 VIII. 2. Implementation...23 VIII. 3. Power supply and electrical protection...23 VIII. 4. Tests...25 VIII. 5. Operation and maintenance...25 VIII. 6. Fault-finding guide...26 Page 2/28

3 I. Basic system The complete electric tracing device generally consists of: A set of heating tapes Tape finishing kits (where applicable) Attaching accessories Junction boxes with supports and connection pieces Regulation equipment An electric control and protection box Thermal insulation These components must be implemented in conformity with the current regulation and with professional practice rules. The following recommendations concern only implementation of heating tape and its effect on the other equipment. II Storage Generally, our heating tape is packed on reels or in rolls for small lengths which must be stored in A DRY PLACE AT A MINIMUM OF 0 C (unless agreed to otherwise). III Preliminary Checks Before performing installation, the following actions are essential: Checking of equipment part numbers Checking of resistance continuity Insulation test at 500 V DC 10 megohms minimum Checking of assembly compatibility between devices CAUTION: Use tape rated at 13 W/m maximum on plastic piping. IV Preparation Identify the locations of the junction boxes and thermostats. The conduits must be free of burrs or rough edges liable to damage the heating tape. Assign the tape to the pipe sections Read the following pages with care in order to ensure correct tracing. The following table indicates the pitch between turns of spiral wound tape. Page 3/28

4 SPIRAL TRACING Approximate turn pitch in millimetres Diameter Ratio: Meter of tape per meter of pipe Inches mm / / / / / Turn pitch in mm V. Method CAUTION: INSTALLATION IN AN EXPLOSIVE ENVIRONMENT MUST BE CARRIED OUT WITH APPROPRIATE EQUIPMENT IN CONFORMITY WITH INSPECTION OR APPROVAL CERTIFICATES 1. Attach the junction boxes and thermostats in the designated places. 2. Pay out and attach the heating tape on the pipes, depending on the type of assembly. 3. Tracing the supports, flanges and valves (see models on the following pages) 4. If necessary, assemble any crossings through the insulation. 5. If necessary, form the terminations of the parallel conductor tapes in accordance with the specifications of the various termination kits. 6. Connect the heating tape to the junction boxes or the thermostats boxes. 7. Cable the tape and make the various electrical and ground connections. 8. BEFORE INSTALLING THE INSULATION, check the continuity of the resistances and their insulation at 500 V DC. It must be greater than 10 Megohms. 9. Install the heat insulation 10. Perform a final continuity and insulation check Page 4/28

5 VI. Assembly CORRECT ASSEMBLY IN CORRECT ASSEMBLY OBSERVATIONS Superimposition No drawback using selfregulating heating tape. Twisted No drawback using selfregulating heating tape. Uniform spiral Irregular spiral No drawback using selfregulating heating tape. Problem avoided with "parallel" tape cut to length on-site 2 heated tapes forming a Tee or a branch Power doubled on tap No drawback using selfregulating heating tape. Allowing Tee connections useing than a "parallel" heating tape avoids the creation of a power supply point. Page 5/28

6 CORRECT ASSEMBLY IN CORRECT ASSEMBLY OBSERVATIONS Passage on outside of bend Tape captive in heat insulation No destructive drawback for self-regulating tape Regular turn pitch Adjacent turns No destructive drawback for selfregulating tape Single or double straight trace Direct contact with steam tracer Page 6/28

7 CORRECT ASSEMBLY IN CORRECT ASSEMBLY OBSERVATIONS Double straight trace Spiral tracing on adjacent pipes No destructive drawback for self-regulating tape Attachments by adhesive tape Metal attaching parts Heat insulation outputs for tape with or without protection braid Sheet metal crossing not protected Page 7/28

8 STRAIGHT TRACING Protection of sharp angles on flanges (if necessary) Attachment by adhesive tape SPIRAL TRACING Attachment by adhesive tape FLANGE PASSAGES 1 tape 2 tapes 3 tapes Page 8/28

9 Continuous attachment by adhesive or at intervals Diameter greater than 2 in. (60 mm) = = 2 HEATED TAPES = Diameter less than 2 in. (60 mm) = = 3 HEATED TAPES = ADJACENT CONDUITS Steam tracer Thermostatic sensor Page 9/28

10 SPACED ATTACHMENT Pitch between turns Pitch between turns 1 meter maximum Adhesive CONTINUOUS ATTACHMENT Efficiency improved by better application of heating tape Elimination of risks of hot spots on heating tape RECOMMENDED ATTACHMENT FOR FLANGES, VALVES AND CLAPPERS Page 10/28

11 STRAIGHT TRACING Application of heating tape to outside of bend SPIRAL TRACING The turns must be spaced out evenly Page 11/28

12 SCREW-ON COLLAR WELDED FLAT STRIP 3 times support length WELDED COLUMN Page 12/28

13 NOTE : - It must be possible to remove the valve with ease by releasing a loop of heating tape Page 13/28

14 Junction box Heat lagging Heat lagging output Ref.: ELSC Heating tape Support with plate POWER SUPPLY TYPE ASSEMBLY COMBINED WITH SUPPORT AND PLATE Page 14/28

15 Junction box Heating tape Direct inlet support POWER SUPPLY BOX TYPE ASSEMBLY COMBINED WITH DIRECT INLET SUPPORT Page 15/28

16 Junction box Heat lagging Heat lagging outlet P/N: ELSC-E Support with plate Heating tape Page 16/28

17 Junction Boîte de box jonction ELBE-3 ELBE-6 ELBE-8 ELBE-10 ELBA-4 d ELBA-4 e ELBA-6 d ELBA-6 e Terminals Terminaisons included comprises in kit: dans kit : ELKSR-1 ELKSR-1 d/e ELKA-1 ELKA-1 d/e ELKS-1 Forward Ruban and chauffant return heating en tape aller if et tap retour < 3m si piquage < 3 m Kit Tape de terminating terminaison kit de ruban (dans (in box) la boîte) ELKSR-1 ELKSR-1 ELKSR-1 d/e d/e ELKA-1 ELKA-1 d/e ELKS-1 Support with avec plate platine Sortie de calorifuge ELSP-2 ELSP-3 Heat lagging outlet ELSC ELSC-E Identification label Etiquette de repérage ELET ELET Direct inlet support Support à entrée directe ELSP ELSP-1 ELSP ELSP-1 Page 17/28

18 Heat Sortie lagging de calorifuge outlet ELSC-E Sonde Temperature de température sensor Thermostat ELTE-1 ELTE-2 ELTH-1 ELTH-2 Page 18/28

19 VII Electrical connections Typical connection diagram for thermostats having part numbers: ELTH-A1 / A2 / A Thermostat Junction box Heating tape Network DIRECT CUTOFF POWER SUPPLY Network Thermostat Electric cabinet Junction box Heating tape POWER SUPPLY RELAYED IN CABINET É Page 19/28

20 Typical connection diagram for thermostats having part numbers: ELTE-1 / ELTE-2 PT100 L N N L PT100 L N N L PT 100 Heating element Maxi : 15A / 230V DIRECT CUTOFF POWER SUPPLY N L PT 100 Network Control cabinet N L Junction box Heating element POWER SUPPLY RELAYED IN CABINET Page 20/28

21 Typical connection diagram for thermostats having part numbers: ELTH-2 Internal wiring version with 2 thermostats Internal wiring version thermostat plus limiter Page 21/28

22 VIII. Commissioning and Maintenance VIII. 1. General information This guide is intended solely for the operation and maintenance of self-regulating constant power and electric heating tapes on heat-insulated pipes and equipment. For any information concerning other applications, please contact your eltrace dealer. VIII. 2. Implementation: Our equipment must be installed in accordance with our assembly instructions and the specifications defined during the installation study. The installation must comply with the current standards type NF C VIII. 3. Power supply and electrical protection Power supply voltage: ESR, ESR-W, ESR-H : 230 V ELP-S, ELP-SB, ELP-E, ELP-A : 230 or 400 V depending on model. ELK-PTFE, ELK-SOL, ELK-MI : 12 or 400 V depending on model. Rév.2 03/10/02 Internet : info@eltrace.fr Page 22/28

23 Maximum length of tracing circuits: Tape Max. length Voltage Tape Max. length Voltage Traceco M 230V TRACECO m 230 V 50 C : 180 m 400 V ELP-E-20-3 TRACECO m 230 V 100 C : 166 m 400 V TRACECO m 230 V 50 C : 147 m 400 V ELP-E-30-3 TRACECO m 230 V 100 C : 135 m 400 V TRACECO- W m 230 V 100 C : 153 m 230 V TRACECO- W m 230 V ELP-A C : 142 m 230 V ESR-H-BO m 230 V 200 C : 133 m 230 V ESR-H-BO m 230 V 100 C : 108 m 230 V ELP-S m 230 V ELP-A C : 100 m 230 V ELP-S m 230 V 200 C : 95 m 230 V ELP-S m 230 V 100 C : 88 m 230 V ELP-A-30 ELP-S m 400 V 150 C : 82 m 230 V ELP-S m 400 V 100 C : 77 m 230 V ELP-A-40 ELP-SB m 230 V 150 C : 68 m 230 V ELP-SB m 230 V 100 C : 68 m 230 V ELP-A-50 ELP-SB m 230 V 150 C : 63 m 230 V ELP-SB m 230 V ELP-E-10 ELP-E-20 ELP-E-30 ELP-E C : 186 m 400 V 50 C : 150 m 230 V ELP-A C : 175 m 400 V 100 C : 146 m 230 V 200 C : 163 m 400 V 50 C : 105 m 230 V 100 C : 152 m 400 V ELP-A C : 95 m 230 V 150 C : 142 m 400 V 50 C : 85 m 230 V 100 C : 131 m 400 V ELP-A C : 78 m 230 V 150 C : 123 m 400 V 50 C : 255 m 400 V 100 C : 235 m 400 V ELP-A C : 118 m 400 V Electrical protection will be provided by a 30 ma curved C or D type differential circuit breaker. The circuit breaker ratings will be defined according to the number of circuits they protect. Maximum number of circuits per circuit breaker: 3 Rév.2 03/10/02 Internet : info@eltrace.fr Page 23/28

24 Commissioning: For hot water systems, run hot water through the system before engaging the circuit breakers. VIII. 4. Tests After completing the installation of the heating tape, check the insulation resistance of each circuit between the conducting wires and the metal braid or the metal piping, using a Megger set to 500 V DC minimum. VIII. 5. Operation and maintenance Tests The exposure temperature must not exceed the temperature specified in the product technical documentation. Exceeding the limits will shorten the life of the tape and risk inflicting permanent damage to the heating tape. The heat insulation must be complete and dry to maintain the right temperature. Periodic inspection Visually and periodically inspect the heating tape and the heat insulation to check for any mechanical damage. Regularly check the insulation resistance. Installations protected from freezing must be checked before each winter. For temperature maintenance, check at least twice each year. Regularly check the performance of the protections and the thermostats. Pipe repairs and maintenance Disconnect the heating tape and protect it from any mechanical or thermal aggression during repair works on the piping. Check the installation of the heating tape after repairing the piping and put the heat insulation back in place. Ensure that the electrical protection is operational. Rév.2 03/10/02 Internet : info@eltrace.fr Page 24/28

25 VIII. 6. Fault-finding guide Differential circuit breaker tripping Causes Remedies Ground fault a. heating tape damaged a. Locate and repair b. bad line or branch junction b. Locate and repair c. bad termination c. Locate and repair d. bad connection d. Locate and repair Excessive moisture a. junction boxes a. Dry and close hermetically. b. bad line and/or branch junction b. Dry and redo immediately. c. termination c. Dry and redo immediately. Rerun the insulation tests (10 MΩ minimum) Interference across main terminals Redefine using available Eltrace instructions. Differential protection circuit-breaker fault Replace Impossible to trip circuit-breaker Check temperature control of domestic hot water systems Rév.2 03/10/02 Internet : info@eltrace.fr Page 25/28

26 Heating tape power very low or zero Causes Remedies a. terminal blocks loose in junction boxes. a. tighten the terminal blocks N.B. replace the terminal blocks or swage if overheated b. power supply cable discontinuity (ex. cable cut) b. locate and repair the damaged section. The control thermostat s connected in the open position Connect normally in the closed position High connection resistance Locate and act by a. at the junction box a. tightening b. at line or branch junctions b. repairing N.B. replace the terminal blocks or swage if overheated Pipe temperature less than design value Causes Heat insulation wet Design error Remedies Remove and replace by dry heat insulation depending on specification and ensure total protection. Check the design parameters. Bring into conformity Incorrect adjustment or operation Repair or adjust The heating tape has been exposed to excessive tempertures Replace Rév.2 03/10/02 Internet : info@eltrace.fr Page 26/28

27 Rév.2 03/10/02 Internet : info@eltrace.fr Page 27/28

28 ELTRACE RANGE: Self-regulating heating tapes Constant power heating tapes Series heating tapes Flexible heating lines Heating belts Heating panels Regulation Electric cabinets A FEW ELTRACE REFERENCES BUILDING CDG Roissy Airport (95) Bibliothèque de France (75) Montparnasse Station (75) Hôtel Intercontinental at Neuilly/Seine (92) EDF Headquarters in St-Denis (93) Technocentre Renault Guyancourt (78) Toyota Valenciennes (59) HOSPITAL ENVIRONMENT C.H.U. Rouen hospital (76) Nevers hospital (58) Diaconesses hospital (75) Henri Dunant hospital (75) Rothschild hospital (75) Cardio-Vascular Center - Villeneuve-St-Denis (77) Chatellerault hospital (86) INDUSTRY Cereol (59) Cimenterie d'origny (80) Danone (59) Rhône Poullenc (02) Rhodia (59) (60) Usinor Belgium Yoplait (60) Rév.2 03/10/02 Internet : info@eltrace.fr Page 28/28

Identification - electrical services

Identification - electrical services Aesthetic All live phase cable sheathing to be brown coloured and neutral phase cable sheathing to be blue coloured, all labelled L1, L2, L3 & N respectively in accordance