Installation & Maintenance - Emerson
Installation &MaintenanceSELF-REGULATINGHEATER CABLE
CONTENTSCONTENTS . 2GENERAL INFORMATION . 4How Heating Systems Work. 4PRODUCT SELECTION . 4RECEIPT & STORAGE . 4Receipt . 4Storage . 4Withdrawal from Storage . 4CONDITIONS OF SAFE USE . 5INSTALLATION . 7Scheduling . 7Pre-Installation Check . 7Heater Handling. 7Heater Cable Location . 8Straight Tracing . 8Spiraling. 8Attachment . 9Cutting the Heater Cable . 9Installation Details . 9SYSTEM COMPONENTS . 12Accessories . 12THERMAL INSULATION . 13Pre-Installation Checks . 13Installation . 13Marking . 13THERMOSTATS & SENSORS . 14ELECTRICAL REQUIREMENTS . 14Voltage Rating . 14Electrical Loading . 14Protection Requirements for Branch Circuits . 14Waterproofing . 15Testing . 15Procedure . 16START-UP . 19Heat-up Time . 19Diversity Factor . 19OPERATION & MAINTENANCE. 19TULSA, OK 74101GA-1765 Rev. 9Sheet 2 of 22August 2016 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
System Design, Installation & Documentation . 19Preventive Maintenance . 19Visual Inspections . 19Frequency . 19Personnel Training . 19Maintenance . 20Piping Repairs . 20DAMAGED PRODUCTS . 20TROUBLESHOOTING . 21TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.comGA-1765 Rev. 9Sheet 3 of 22August 2016
GENERAL INFORMATIONThe Installation and Maintenance Manual is intended for use with Nelson Heat Trace self-regulating heatingcable and component system on insulated pipes and vessels only. These instructions are suitable for use withthe heating cables and components listed on sheets 5, 6 and 13. For applications not specifically addressed,please contact your local representative.How Heating Systems WorkAn electric heating cable system uses the heater cable to replace the heat that is lost through the thermalinsulation system. Replacing the lost heat allows the pipe and product inside the pipe to be kept at a constanttemperature. This will keep water from freezing and bursting a pipe, or a liquid from setting up and plugging thepipe. Simple systems may turn the entire system on with a contactor or switch, while others will use a thermostator controller with each heater cable to regulate the temperature.InsulationHeater CablePipeFigure 1PRODUCT SELECTIONCheck and verify that the proper heater cables are being installed on each pipe and vessel. If nodesign/installation documents exist, check Nelson Heat Trace Design & Selection Guides to determine theproper equipment for the application.RECEIPT & STORAGEReceipt Compare the material received against the shipping bill to verify receipt of the correct product and quantities. Inspect heating cable and components for any shipping damage. Insulation resistance tests on each spool ofcable are recommended. If design documents (line lists or per circuit bills of material) exist, check the received material against thelists to verify all needed materials. If no design documents exist, keep a receipt log of all materials received. Record Lot Numbers on the Heat Trace Installation Record (see Figure 15) for product traceability. Lotnumber coding is printed on the heating core of HLT and QLT cables, and on the first electrical jacket of allother cables. The last 2 digits designate the year of manufacture and the preceding digits represent thesequential lot numbering format. Example: 35407 would represent lot number 354 manufactured in 2007. Lotnumbers are repeated every 30.5cm (12.0”). Lot numbers can also be located on each shipping spoolidentification label.StorageCable and system components should be stored in a clean, dry area. The equipment should be protected frommechanical damage during storage. The storage temperature range is -40 C to 60 C (-40 F to 140 F).Withdrawal from StorageIt is recommended that a check out record be kept (in conjunction with the receipt records) on equipment as it isremoved from storage. This will serve to identify material shortages before they happen as project additionsoften cause the use of material for other than designated piping.TULSA, OK 74101GA-1765 Rev. 9Sheet 4 of 22August 2016 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
CONDITIONS OF SAFE USEOrdinary Locations:For ordinary location approvals, please refer to marking on respective product or contact manufacturer.Hazardous Locations:Compliance with Safety Requirements has been assured by compliance with:NEC 2014; NFPA 70: National Electrical Code , International Electrical Code SeriesIEEE Std 515 -2011 Standard for the Testing, Design, Installation, and Maintenance of Electrical ResistanceHeat Tracing for Industrial ApplicationsIEEE Std 515.1 -2012 Standard for the Testing, Design, Installation, and Maintenance of Electrical ResistanceHeat Tracing for Commercial ApplicationsULCertificate -LT:E49805D1-HLT:E49805D1-XLT:E49805Class I, Division 2, Group ABCD.Class II, Division 2, Group FG. Class IIIClass I, Zone 1 and 2, Group IICClass I, Division 2, Group ABCD.Class II, Division 2, Group FG. Class IIIClass I, Zone 1 and 2, Group IICClass I, Division 2, Group ABCD.Class II, Division 2, Group FG. Class IIIClass I, Zone 1 and 2, Group IICClass I, Division 2, Group ABCD.Class II, Division 2, Group FG. Class IIIClass I, Division 1, Group BCD.Class II, Division 1 Group EFG. Class IIIClass I, Division 1, Group BCD.Class II, Division 1 Group EFG. Class IIIClass I, Division 1, Group BCD.Class II, Division 1 Group EFG. Class IIIFMCertificate T:3004655Class I, Division 2, Group BCD.Class II, Division 2, Group G. Class IIIClass I, Zone 1, Group IICClass I, Division 2, Group BCD.Class II, Division 2, Group G. Class IIIClass I, Zone 1, Group IICClass I, Division 1, Group BCDClass I, Zone 1, Group IIBClass I, Division 1, Group BCD.Class I, Zone 1, Group IIBCSACertificate No.CodingLT:LR 42104HLT:LR 42104XLT:LR 42104LLT:LR 42104TULSA, OK 74101Class I, Division 1 and 2, Group BCD.Class II, Division 1 and 2, Group EFG.Class I, Zone 1 and 2, Ex e IIC T6** (T5**).Class I, Division 1 and 2, Group BCD.Class II, Division 1 and 2, Group EFG.Class I, Zone 1 and 2, Ex e IIC T3.Class I, Division 1 and 2, Group BCD.Class II, Division 1 and 2, Group EFG.Class I, Zone 1 and 2, Ex e IIC T3.Class I, Division 1 and 2, Group BCD. (US only)Class II, Division 1 and 2, Group EFG. (US only)Class I, Zone 1 and 2, Ex e IIC T3. (US only) TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.comGA-1765 Rev. 9Sheet 5 of 22August 2016
Compliance with the Essential Health and Safety Requirements has been assured by compliance with:ATEX: EN 60079-0:2012 A11:2013, EN 60079-30-1:2007, EN 60079-31:2014IECEx: IEC 60079-0:2011, IEC 60079-30-1:2007, IEC 60079-31:2013KEMACertificate No.LT / UT-1:CodingKEMA 07ATEX0124II 2 G Ex e IIC T6** Gb (LT3, LT23, LT5, LT25)II 2 D Ex tb IIIC T 80ºC Db0344II 2 G Ex e IIC T5** Gb (LT8, LT28, LT10, LT210, UT-1)II 2 D Ex tb IIIC T 95ºC DbQLT:KEMA 07ATEX0124II 2 G Ex e IIC T3 Gb0344HLT:KEMA 07ATEX0124XLT:KEMA 07ATEX0124LLT:DEKRA 15ATEX006403440344II 2 G Ex e IIC T3 GbII 2 D Ex tb IIIC T 195ºC DbII 2 G Ex e IIC T3 GbII 2 D Ex tb IIIC T 195ºC DbII 2 G Ex e IIC T5 Gb0344UT-2:II 2 D Ex tb IIIC T 195ºC DbDEKRA 15ATEX0064II 2 D Ex IIIC T 95ºC DbII 2 G Ex e IIC T5 Gb0344II 2 D Ex IIIC T 95ºC DbIECExCertificate No.LT / UT-1:CodingIECEx KEM 07.0041Ex e IIC T6** Gb (LT3, LT23, LT5, LT25)Ex tb IIIC T 80ºC DbEx e IIC T5** Gb (LT8, LT28, LT10, LT210, UT-1)Ex tb IIIC T 95ºC DbQLT:IECEx KEM 07.0041HLT:IECEx KEM 07.0041XLT:IECEx KEM 07.0041LLT:IECEx DEK15.0032UT-2:IECEx DEK15.0032Ex e IIC T3 GbEx tb IIIC T 195ºC DbEx e IIC T3 GbEx tb IIIC T 195ºC DbEx e IIC T3 GbEx tb IIIC T 195ºC DbEx e IIC T5 GbEx tb IIIC T 95ºC DbEx e IIC T5 GbEx tb IIIC T 95ºC Db** For more specific details on approvals, please refer to marking on respective product or contact manufacturer.Electrical Data:ProductLT, QLT, HLT, D1-LT, D1-HLTLT2, QLT2, HLT2, UT-1, D1-LT2,D1-HLT2XLTXLT2LLT / UT-2Rated VoltageMaximum OvercurrentProtectionMaximum Steady-StateCurrent100V, 110V, 120V200V, 208V, 220V, 230V, 240V, 277V40 Amps40 Amps18 Amps18 Amps100V, 110V, 120V200V, 208V, 220V, 230V, 240V, 277V200V, 208V, 220V, 230V, 240V, 277V40 Amps40 Amps60 Amps25 Amps25 Amps38 AmpsSpecifications:LT / UT-1QLTHLTD1-LTD1-HLTLLT / UT-2XLTMaximum Maintain 50ºF)Maximum Continuous Exposure Temperature(continuous power ximum Intermittent Exposure Temperature(1000 hours cumulative ºF)T6** (3, 5)T5** (8, 10)T3T3T6** (3, 5)T5** (8, 10)T3 (3 - 15)T2C (18, 0ºF)25.0 mm(1.0 in)25.0 mm(1.0 in)25.0 mm(1.0 in)25.0 mm(1.0 in)25.0 mm(1.0 in)25.0 mm(1.0 in)25.0 mm(1.0 in)Temperature Classification(Cable wattage if applicable)Minimum Installation TemperatureMinimum Bend Radius at -40ºC (-40 F)TULSA, OK 74101GA-1765 Rev. 9Sheet 6 of 22August 2016 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
INSTALLATIONGeneral InformationWhile there are many acceptable ways of installing Nelson Heat Trace electric heating equipment, certainactions can be dangerous to personnel and your installations. Please take care to avoid the following problems: Do not twist the bus wires together at either end of the heater cable. Each of these wires has avoltage or neutral applied to it; twisting them together will cause a short circuit. Insulate the black polymer surrounding the bus wires. The black compound around the bus wiresis electrically conductive and should be treated as a conductor. De-energize all power circuits before installation or servicing. Keep ends of the heating cable and kit components dry before and during installation. To prevent electrical arcing and fire hazard, all cable connections and electrical wiring connectionsshould be sealed against moisture. This includes the use of proper cable sealing kits and themoisture proofing of all wire connections. The metal sheath/braid of the heater cable must be connected to a suitable ground path. Do not use products containing plasticizers, such as vinyl electrical tape, or duct tape wheninstalling self-regulating heater cables. Do not expose heater cables to temperatures above their maximum ratings. Higher temperaturescan greatly shorten the life of a heater cable. Immediately replace any damaged heater cable or components. Failure to replace any damagedcomponents (heater cable, components, or thermal insulation) will result in system failure. Classified areas (explosive dust or gases) require the use of special electrical components. Anyarea having explosive gases (such as chemical / petrochemical installations) or explosive dusts(such as coal handling or granaries) require special cable, connection components and controlcomponents that are approved for use in these areas. Installation of non-approved products canresult in fires or explosions. Installation on plastic pipe requires special considerations in selections & installation. See theNelson Heat Trace Design Guide for details in design and selection. To prevent creases it shall be assured that the minimum bending radius is 25 mm (1.0inch). All the self-regulating heating cables have minimum installation temperature of - 40ºC (- 40ºF).SchedulingThe installation of the electric heat tracing requires coordination with the piping, insulation, electrical andinstrument groups. Cable installation should begin only after the majority of mechanical construction is complete.Pressure testing of the pipe and installation of the instruments should be complete prior to the start of the heatercable installation.Pre-Installation CheckWalk the piping system and plan the routing of the heater cable. This action is used to verify completion of allinstrumentation and mechanical work. All coatings (paint, etc.) and surfaces must be dry before attempting theheater cable installation.Heater Handling To avoid damage, use a reel holder to roll out the heater cable.Keep the cable strung loosely and close to the pipe being traced. This will avoid interference with supports and otherequipment.Leave an extra 30-46cm (12-18”) of heater cable at all power connections, tee splices and end seal connections tofacilitate ease of working with the connections.Additional heater cable is required on valves, pipe supports and other equipment. See the installation detailsection for exact lengths and method of installation.When handling the heater cable, avoid pulling it over or installing against sharp edges.Do not kink or crush the cable, including walking on it or driving over it with equipment.TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.comGA-1765 Rev. 9Sheet 7 of 22August 2016
Heater Cable LocationThe heater cable may be installed in either straight runs or spiraled around the pipe. Spiraling is generally usedwhen a limited number of cable types are available. Where possible, the heating cable shall be applied flat to theheated object.Straight TracingWhen straight tracing is used, install the heater cable on the lower quadrant of the pipe. This helps preventphysical damage to the heater cable from falling objects and from being walked on.Alternate Locations120 Install heater cable at the4 or 8 o'clock positionsFigure 2SpiralingSpiraling increases the length of heater cable installed per foot of pipe. Installed cable length Pipe Length XSpiral Factor.The following example and table will allow you to determine the correct pitch for each pipe size and spiral factor:Example: When using .43m (1.4ft) of heater cable on 102mm (4”)IPS pipe, the Pitch (P) would be 356mm (14”)PITCH (P)in inchesFigure 3Table ISpiral Pitch Table (Inches)SPIRAL FACTORPipe Size(IPS)(feet of heater cable per foot of 8.059413328241 inch 25mmTULSA, OK 74101GA-1765 Rev. 9Sheet 8 of 22August 2016 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
AttachmentFor normal installations, the heater cable may be attached with fiberglass tape. Plastic wire ties may also beused provided the plastic has a maximum temperature rating equal to or better than the system requirements.The cable should f
Ex e IIC T5** Gb (LT8, LT28, LT10, LT210, UT-1) Ex tb IIIC T 95ºC Db QLT: IECEx KEM 07.0041 Ex e IIC T3 Gb Ex tb IIIC T 195ºC Db HLT: IECEx KEM 07.0041 Ex e IIC T3 Gb Ex tb IIIC T 195ºC Db XLT: IECEx KEM 07.0041 Ex e IIC T3 Gb Ex tb IIIC
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