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CWM 8-1CT
Installation Manual
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Chromalox CWM 4-1CT, CWM 8-1CT, CWM 12-1CT, CWM 4-2CT, CWM 8-2CT Installation Manual

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Page 1
Installation Instructions
Industrial Heating Cable
Products
PJ438-26
161-057884-010
May, 2021
Page 2
Table of Contents
Important Safeguards and Warnings ..................................................................................... 3
System Components ............................................................................................................... 4
Chromalox Cable Types .......................................................................................................... 5
General Information ................................................................................................................ 6
Storage ................................................................................................................................ 6
Installation ................................................................................................................................ 7
Typical Installation Details .................................................................................................... 12
Wiring ...................................................................................................................................... 16
Heating Cable Components ................................................................................................. 18
Connection Kits ................................................................................................................. 18
Accessories ....................................................................................................................... 22
Control Systems .................................................................................................................... 23
Controllers ......................................................................................................................... 26
Thermal Insulation ................................................................................................................. 28
Commission Testing .............................................................................................................. 28
Specifications ........................................................................................................................ 29
Troubleshooting ..................................................................................................................... 31
Locating Faults .................................................................................................................. 32
Insulation Resistance (Megger) Test .................................................................................. 34
Installation and Maintenance Log........................................................................................ 35
Page 3
Important Safeguards and Warnings
• Never use tie-wire or pipe straps to secure Self­regulating or Constant Wattage heating cables,
FIRE HAZARD. Failure to follow these guidelines could result in property damage or personal injury.
• Disconnect all power sources before installing or servicing heating cable. Failure to do so could result in personal injury or property damage.
• Heating cable must be installed by a qualified person in accordance with the National Electri­cal Code, NFPA 70.
• Each heating cable branch circuit must be effec­tively grounded in accordance with the National Electrical Code to eliminate shock hazard.
• Never attempt to use damaged heating cables or connection kits. If cable damage is observed, ei­ther replace the complete heating cable, or cut out the damaged section and replace using the proper splice connection kit. Do not attempt to repair damaged heating cable.
• Never energize the cable when it is coiled or on a reel. Test only when it is laid out straight.
• Handle coils and reels utilizing equipment de­signed for that purpose.
• Do not drop coils or reels, especially from trans­porting equipment.
• Lift or handle reels so that the lifting/handling device does not come in contact with the cable or it’s protective covering. Coils should be placed on a skid.
• Handle reels so that the deterioration or physical damage of cable is prevented.
• Do not install heating cable on equipment which could become hotter than the heating cable’s maximum exposure temperature.
• Do not install heating cable in an area or on equipment which contains potentially corrosive materials without having a suitable protective jacket on the cable. Observe all published speci­fications.
• Do not expose cables to temperatures above their specified maximums. Do not run cables lon­ger than specified maximum circuit lengths. See tables provided in this installation manual for de­tails.
as this may damage the cable.
• Keep bus wires separated to avoid shorting the cable.
• Keep cable ends and connection kits dry before and during installation.
• Be careful not to break bus wire strands when preparing the cable, as damaged bus wires can overheat and short.
• The presence of heating devices must be evident by the posting of caution signs or markings at ap­propriate locations and/or at frequent intervals along the circuit.
• Users should install adequate controls and safe­ty devices with their electric heating equipment. Where the consequences of failure may be se­vere, back-up controls are essential. Although the safety of the installation is responsibility of the user, Chromalox will be glad to assist in mak­ing equipment recommendations
• Insulate the pipe immediately after installing the heating cable, using only fire-resistant insulation materials.
• Ground fault equipment protection is required for each circuit
• Heating cables require a Class A ground-fault cir­cuit-interrupter and any metallic components in contact with the heating device shall be bonded to ground.
A ground fault protection device must be used with this heating device.
Ce produit doit être utilisé avec une protection de mise à la terre.
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System Components
A complete electric heat trace system includes the follow­ing system components – See the figure below for a typical system.
1. Electric Heat Tracing (Self-regulating, Constant Wattage)
2. Termination Accessories A. Power Connection B. Splice/Tee C. End Seal (under insulation, above insulation or signal
light type) D. Control Thermostat or RTD Sensor E. Attachments i. Fiberglass tape ii. Aluminum tape for plastic pipe install iii. Pipe clamps for termination accessories iv. Electric Trace Caution Label
3. Controls A. Thermostats B. Digital Thermostats C. Single/Dual Loop Panels D. Weather Trace Panels E. IntelliTrace Panels
4. Thermal Insulation
5. Weather Barrier for Insulation
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Chromalox Cable Types
Table 1 – Cable Type Overview
Self-Regulating
Wattage
Hazardous ratings available Yes Yes Yes Yes
Usable on plastic pipe Yes* No No No
Can be cut to length in eld Ye s Yes** No Yes
Can be single overlapped Yes No No No
Constant
* SRL only on plastic pipe. ** Must be cut at module point to avoid cold leads.
Table 2 – Maximum Temperatures
Cable Type
Max. Maintain
(Power On)
Max. Exposure
(Power Off) Voltage Rating
SRL 150˚F 185˚F 120, 208-277
SRP 230˚F 275˚F 120, 208-277
SRM/E 302˚F 420˚F 120, 208-277
CWM 320˚F* 392˚F 120, 208-277, 480
SLL 302˚F 450˚F 120, 208-277, 480, 600
MI 1112˚F 1200˚F 120-600
* See Table 15 for maximum maintenance temperatures at each output.
Mineral
Insulated
Long Line
Series
Overcoat Over
Braid (Optional)
Buss Wires
Self-Regulating
Alloy 825 Sheath
Mineral Insulation
Mineral Insulated
Densely
Compacted
Tinned Copper
Braid (Optional)
Jacket
Conductive Matrix
Twin (Shown) or Single
Resistance Wires
Resistance Wire
Binder
Buss Wires
Constant Wattage
High Temperature
Fluoropolymer
Overjacket
16, 14, 12,10 AWG
Copper Buss Wires
SLL Long Line
Module Point
Primary Insulation
Tinned Copper Braid (Optional)
Overcoat Over Braid (Optional)
Metallic Braid
High Temperature Fluoropolymer Jacket
High Temperature Fluoropolymer Core Matrix
Approvals
Chromalox heating cables and components approved for use in hazardous and nonhazardous locations. Refer to the spe­cific product data sheets for details.
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Page 6
General Information
Use of Manual
These instructions are to be followed when installing Chro­malox heating cables on pipes in ordinary locations. Consult factory for installation of braided cable in hazardous loca­tions. This manual discusses the installation of two types of heating cables: parallel cables (SRL, SRP, SRM/E) and series cables (CWM, MI, SLL). Although they are all resistance type cables, they have different operating characteristics. These characteristics may make one type of cable more suitable for a particular application than another. This manual, how­ever, is not intended as a product selection manual. Refer to appropriate application design guide for product selection guidelines. A chart high-lighting certain characteristics for Chromalox heating cables can be found on page 5.
For customer support, design assistance, or information re­garding any other Chromalox products, please contact your local Chromalox representative or use the information below.
Chromalox, Inc. 103 Gamma Drive Pittsburgh, PA 15238 Tel: +1 (412) 967-3800 Fax: +1 (412) 967-5148 Email: is@chromalox.com www.chromalox.com
Storage
The heating cables should be stored in their shipping cartons or on reels in a dry atmosphere until they are ready to be in­stalled. They should be stored in a clean location, where they are protected from mechanical damage.
Storage temperature range: 0°F(-18°C) to 140°F(60°C).
Important Installation Notes
The following notes should be reviewed prior to installation.
• Always install tracing at the 4 or 8 o’clock position on a pipe.
• Do not attempt to heat trace any piece of equipment which will not be insulated.
• Allow a minimum of 2” between cable runs.
• Always install heat tracing on the outside radius of el­bows.
• Never install heat tracing over expansion joints without leaving slack in the cable.
• Pumps and small vessels should be heat traced and con­trolled with the piping on the inflow end. The cable on the pump or vessel should be physically separate to permit disconnection during maintenance or removal.
• Use aluminum foil tape to cover the heating cable when­ever the cable is not in good contact with the pipe (i.e. at supports, valves, pumps, etc.).
• Separately controlled circuits should be provided on dead end legs and closed bypasses.
• No heat tracing circuit should extend more than two feet beyond a point where two or more pipes join when such junctions permit optional flow paths. In such cases, sepa­rately controlled traces should be used.
• The minimum installation temperature for all Chromalox heating cables is -76˚F (-60˚C).
• Chromalox Type SRL heating cables are well suited for heat tracing plastic pipes. Consult “Chromalox Design Guide for Heat Tracing Products” for design recommen­dations. Installation details apply for plastic pipe only when Type SRL heating cable is used. Consult factory for applications involving other products.
• Always ensure that the heating cable load is compatible with the rating of the selected control systems.
• Only install control devices where the electrical conduit has a low-point drain that prevents condensation from entering the thermostat enclosure.
NOTICE
STORE IN DRY AREA
These products may be become damaged by moisture. Damage to electrical components, electrical properties, corrosion or other damage may occur if equipment is not stored in a dry location. Visual inspection and electrical checks must be performed prior to installation to ensure safety and proper operation. See equipment installation manual or contact the factory for more information. 800-443-2640 or www.chromalox.com.
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Installation
Pre-Installation Guidelines
Before attempting to install the heating cable, read this in­struction sheet and those enclosed with the accessories to familiarize yourself with the products. Complete the following pre-installation steps:
• Verify that the selection of heating cable type and rating is in accordance with the procedures located in the ap­plicable application design guide.
• Ensure that the voltage rating of the heating cable is ac­ceptable for the available service voltage.
• Walk along the pipe segment that is to be traced and plan out the path for the heating cable on the pipe.
• Remove any obstacles or sharp edges that are present along the pipe segment.
• Open package and visually check for breaks or nicks in the cable jacket. File claim with carrier if any damage is found.
• After removing the cable from the carton or wrapping, measure the insulation resistance of the unit from buss wires to braid at 2,500 VDC to assure the cables have not been damaged during shipping and handling. If the cable has no braid, uncoil the cable onto a metal surface and check resistance between the buss wires and the metal surface. See Table 4 for acceptable minimum insulation resistance readings and page 32 for a detailed explana­tion on how to conduct the insulation resistance test.
ELECTRIC SHOCK HAZARD. Any cable with an in­sulation resistance reading less than 20 megohms before installation should not be installed. Contact your local Chromalox representative.
• Ensure all pipes, tanks etc. have been hydrostatically tested prior to the installation of the heating cable.
• Ensure all cable ends, connections, and surfaces are dry prior to installation.
ELECTRIC SHOCK HAZARD. Disconnect all power before installing or servicing heating cable. Failure to do so could result in personal injury or property damage. Heaters must be installed by a qualified person in accordance with IEC 62086-2:2001.
Any installation involving electric heating must be effectively grounded in accordance with IEC 62086­2:2001 to eliminate shock hazard.
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Installation Guide: Single Run of Cable
If installing a single run of heating cable on a pipe, follow the steps below:
1. Mount the reel of cable on a holder and place near one end of the pipe run to be traced. Choose the end from which it will be the easiest to pay out the cable.
2. Pay out the cable from the reel and loosely string along the piping, making sure the cable is always next to the pipe when crossing obstacles. For example, if the heater is on the wrong side of a crossing pipe, you will have to restring the cable or cut and splice it.
To prevent damage to cable, avoid such things as: — Pulling the cable over sharp edges. — Forcibly pulling the cable free if it snags while
being paid out.
— Walking on or subjecting the cable to other abuse
which could cause mechanical damage.
3. When you reach the end of the circuit, secure the heating cable to the pipe using glass tape or plastic cable tie with a temperature rating compatible with the heater cable.
If this end is to have an end seal installed, remember to
leave about a foot of extra cable. If it is a power connec­tion, leave about two feet of extra heater cable.
4. If the heater cable is to be spiraled, go to step 4a.
Begin attaching the cable to the pipe about every foot (0.3
meters).
Place the cable on the bottom half of the pipe at the 4 or
8 o’clock position. Refer to installation detail AD1. Go to step 5.
a. Note the path of the heater cable and the spiral factor
of the design. A simple way to think about spiral factor is: A 1.1 spiral factor means install 11 feet of heating cable on every 10 feet of pipe, etc. At about every 10 feet of pipe, pull the required amount of cable and let hang in a loop, and attach the cable to the pipe.
b. Rotate the loops around the pipe until all the slack has
been taken up. Even out the spirals of the heater cable and secure to the pipe as necessary to obtain good contact. The entire circuit can be installed with hang­ing loops with the spiraling on the pipe being done when you trace the heat sinks. Refer to installation de­tail AD3.
5. At a heat sink (pipe supports, valves, pumps, reducers, gauges, bucket strainers, etc.), attach the heater cable to the pipe just before the heat sink. Refer to the design specs or Table 3 to determine the amount of heater cable you need to install on the heat sink. Pull this amount of cable into a loop, attach the heater cable on the other side of the heat sink and continue attaching the cable down the pipe as before.
6. When you reach the heater cable reel, you should have the heater cable attached all along the pipe, with the cor­rect amount of heater cable pulled in loops at all heat sinks. Attach the cable to the pipe, (leave an extra foot if at an end seal, two feet if at a power connection) and cut the heater cable from the reel.
7. Install the heater cable loops on the heat sinks. Refer to the proper installation detail AD5-AD12 for a general idea of how to install the cable, but remember:
• It is important to get the proper amount of heater ca-
ble on the heat sink, rather than exactly as the detail shows. The detail is just a guide.
• Self-regulating heater cables are very flexible and can
be single overlapped for installation ease. Feel free to use this feature when you can.
• By having the cable installed this way, it can be re-
moved easily from the heat sink without cutting of ac­cess to, or removal of the heat sink is required.
Note: If a tee is designed into the system, or if you are using two or more short cable lengths to complete a circuit, allow two or three feet of each cable to overlap. This will allow flex­ibility in assembling the connection kit and locating it on the pipe.
FIRE HAZARD. Do not overlap constant wattage heating cables.
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Installation Guide: Multiple Cable Runs
There are two cases where you will need to install more than one heater cable on a pipe:
• When the design calls for more than one cable.
• When the lines being heat traced are considered impor­tant enough to install a backup (redundant) heat tracing system.
The installation requirements are different for these cases.
Installing Multiple Heater Cables for Design Requirement
The most common multiple cable requirement is two cables on a pipe. Below are the recommended techniques for the two cable systems. They also apply to installations where three or more cables are to be installed on a pipe.
There are two ways of paying out two heater cables along a pipe. The first is to locate two reels of heater cable and supply one cable from each. This method works for all types of piping runs. However, it may increase material waste by leaving unusable lengths from two reels. The second way is to supply both cables from one reel. This method is gener­ally the easiest for relatively straight, simple piping runs. For each circuit, decide which method to use and then go to the appropriate part below.
1. Supplying cable from two reels
The general procedure here is the same as given earlier,
but there are a few things to do to make sure the system is correctly done.
a. At each heat sink, the easiest thing to do is supply the
extra heater called for by the design drawing from only one heater cable. This avoids having to measure out half of the requirement from each cable.
b. When doing the previous step, leave a small loop in
the other cable at equipment which may be serviced, such as pumps, valves, instruments, etc. This is so both heater cables may be removed enough for future access.
2. Supplying cable from one reel
The general procedure is the same as given earlier, but
there are a few things to do to make sure the system is correctly done.
a. With this method, a loop is pulled for the entire circuit.
To do this, attach the end of the heater cable to the pipe near the heater cable reel. Remember to leave enough extra cable for the type of connection to be installed.
b. Begin pulling the cable off the reel in a large loop down
the piping run. Be sure to keep the cable next to the pipe. Moving down the run, continue attaching the ca­ble to the pipe, leaving the side of the loop going back to the reel unattached.
c. You will want both sides of the loop to be about the
same length to avoid future problems. Also, it is easier to install the extra cable required at each heat sink from only one cable. Therefore, pull the right amount of extra heater cable needed at every second heat sink from the side of the loop you are attaching to the pipe. At the remaining serviceable heat sinks (pumps, valves, instruments, etc.) do not forget to leave a short loop of cable for slack when access to the equipment is needed.
d. When the end of the piping run is reached, pull the
proper amount of extra cable for the connection to be installed.
e. Now, begin working the remaining side of the loop
back toward the reel, installing it on the pipe and heat sinks as required.
Installing Backup (Redundant) Systems
The purpose of a backup system is to provide the proper amount of heat from the second heater cable if there are problems with the first. Therefore, each cable must be in­stalled so it can do the job alone. The simplest way to do this is to install the first heater cable as described in the Installa­tion Guide: Single Run of Cable section. Then, go back and install the backup heater cable the same way.
There are several things to keep in mind:
• The power connections and end seals for the two cables are often designed to be at opposite ends of the run in a redundant system. Remember to leave the proper amount of extra cable for the connection to be installed on each cable at that end.
• On piping one inch IPS or smaller, it can be difficult to apply both heater cables with good contact at all places. The main thing is to get the correct amount of cable in­stalled. However, try to get as much contact with the pip­ing and heat sinks from both cables as possible.
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Supplementary Instructions: ATEX and IECEx Applications
SRL and SRM/E Self-Regulating Heating Cables, U Series Connection Accessories Type DTS-HAZ, UPC, UMC, UES and RTES
• Do not bend the cable for a length of 300mm from the cable gland inlet.
• Connection and termination of Chromalolx ATEX and IECEx certified cable must be carried out by using the U Series of certified cable connection kits as supplied by Chromalox, Inc. These are only to be used for the opera­tions for which they were designed.
• The supply circuit to the heating cables must be pro­tected by a safety differential device or equivalent ground fault protection.
• The earthing braid of the heat trace cable must be bond-
• The minimum cable installation temperature for SRL and
• The certified minimum cable exposure temperature for
ed to a suitable earth terminal.
SRM/E cable is -40˚C (-40˚F).
SRL and SRM/E cable is -60˚C (-76˚F).
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Other Installation Considerations
Bending the Heating Cable
Pipe Hanger
When using a pipe hanger, ensure that the heating cable is not pinched between the pipe and the hanger. Damage to the cable can result in electrical arcing, arc faults, and arc flashes.
Slab Penetrations
Before installing heating cables on a pipe that penetrates a concrete floor or wall, be sure that the hole comfortably fits both the pipe, cable, and insulation. Do not damage or cut the heating cable during installation. Make sure that the cable is not pinched between the pipe and the concrete floor and wall when the hole is sealed. When fire stopping around floor and wall penetrations, aviod damaging or cutting the heating cable. The heating cable should be protected by a tube or conduit and should not be installed directly into the sealing material.
Do not attempt to bend the heating cable in the flat plane, as it may be damaged. The minimum bending radius for all Chromalox heating cables is six times the minor diameter.
Heat Sinks
Refer to the design specs or Table 3 to determine the amount of heater cable you need to install on each heat sink. Install the heater cable on the heat sinks as explained in installation details AD5-AD12. However, remember that the detail is just a guide. It is important to get the proper amount of heater ca­ble on the heat sink, rather than exactly as the detail shows.
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Table 3 – Additional Cable Lengths Required for In-Line Components (Based on Iron Pipe Size)
Piping Size Gate Valve
1/2 in. 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.30
3/4 in. 1.50 1.00 1.00 1.00 1.50 1.00 1.00 0.30
1 in. 2.00 1.00 1.00 1.00 1.50 1.00 1.00 0.30
1-1/2 in. 2.50 1.50 1.50 1.50 2.00 2.00 2.00 0.30
2 in. 2.50 2.00 2.00 2.00 2.00 2.00 2.00 0.30
2-1/2 in. 2.50 2.00 2.00 2.00 2.00 2.00 2.00 0.30
3 in. 3.00 2.50 2.50 2.50 2.00 2.00 2.00 0.50
4 in. 4.00 3.00 3.00 3.00 2.50 2.50 2.50 0.50
6 in. 5.00 3.50 3.50 3.50 2.50 2.50 2.50 0.80
8 in. 7.00 4.00 4.00 4.00 2.50 2.50 2.50 0.80
10 in. 8.00 4.50 4.50 4.50 3.00 3.00 3.00 0.80
12 in. 9.00 5.00 5.00 5.00 3.00 3.00 3.00 0.80
14 in. 10.00 5.50 5.50 5.50 3.00 3.00 3.00 1.00
16 in. 11.00 6.00 6.00 6.00 3.50 3.50 3.50 1.00
18 in. 12.00 7.00 7.00 7.00 3.50 3.50 3.50 1.00
20 in. 13.00 7.50 7.50 7.50 3.50 3.50 3.50 1.00
22 in. 13.00 7.50 7.50 7.50 3.50 3.50 3.50 1.00
24 in. 15.00 8.00 8.00 8.00 4.00 4.00 4.00 1.00
Globe
Valve Ball Valve
Butterfly
Valve
Dimensions in Feet (Ft.)
Support
Shoe
Hanger
Support
Sleeper
Support
Flange
Pair
Typical Installation Detail
AD1 - One Run of Cable AD2 - Two Runs of Cable
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Page 13
AD3 - One Cable-Spiralling Method
AD4 - One Run of Cable at Pipe Elbow
AD5 - Orifice Flange
AD6 - Expansion Joint
AD7 - Welded Support AD8 - Shoe Support
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Page 14
AD9 - Valve
AD10 - Pressure Gauge
AD11 - Diaphragm Pressure Gauge
AD13 - U Series Power Connection
AD12 - Level Gauge
AD14 - U Series Splice & Tee Connection
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Page 15
AD15 - EL Series Splice and Tee Kit
AD16- DL Series Below Insulation End Seal
AD17 - DL Series Power ConnectionAD16-2 U Series Above Insulation End Seal
15
AD19 - Sensor PlacementAD18 - DL Series Splice & Tee Connection
Page 16
Wiring
ELECTRIC SHOCK HAZARD. Disconnect all power before installing or servicing heating cable. Failure to do so could result in personal injury or property damage. Heater must be installed by a qualified per­son in accordance with the National Electrical Code, NFPA 70.
ELECTRIC SHOCK HAZARD. Any installation involv­ing electric heating cables must be performed by a qualified person and must be effectively grounded in accordance with the National Electrical Code to eliminate shock hazard.
ACCESSORIES:
• Selection of installation accessories should be in accor­dance with ChromaTrace 4 design software program. En­sure accessories are rated for the area where they are lo­cated. If Chromalox accessories are not used with cable, all third-party approvals are voided.
• Only use Chromalox installation kits and use them only for the operations for which they are designed.
• The instructions included in the Chromalox installation accessories must be followed for the third-party approv­als (UL, FM, CSA, ATEX, IECEx, etc.) to apply.
• Junction boxes must be in accordance with the require­ments of the area classification.
• All outdoor junction boxes must be located above grade level. Covers should be kept on the boxes at all time when not being worked in.
• All terminations must be protected from the weather and from physical damage by locating them either under the weather-proof insulation or inside an appropriate junction box.
• All equipment must be properly grounded.
• Install installation accessories according to the instruc­tions included in the kits and per installation details AD13 through AD19.
To prevent equipment damage, Circuits fed from overhead lines should be protected by secondary lighting arrestors.
CONTROLS:
• All heating circuits should have temperature controls. Temperature control of the pipeline can be obtained through various Chromalox temperature controls.
• Contactors must be used when load currents exceed the rating of the thermostat contacts. Equipment protection ground fault (30 mA EPD) thermal breakers are recom­mended with types SRL, SRP, SRM/E, SLL, and CWM.
• The temperature control should be mounted in a location where it will not be subjected to excessive shock or vibra­tion.
• Line sensing temperature sensors should be mounted in accordance with installation detail AD19.
• Ambient sensing temperature sensors should be located at a point where the lowest ambient temperature is ex­pected.
To prevent equipment damage, handle and secure temperature sensors, especially thermostat bulbs and capillaries with care to avoid distortion or crimping which might impair control accuracy.
• Exposed thermostat capillaries should have mechanical protection.
End Cap
Buss Wire
Heat Generating Matrix
End Cap
Buss Wire
Heat Generating Matrix
Thermostat
Contactor
Thermostat
I. Self-Regulating
L2
Power Supply
L1
L2 L1
Control
Circuit
Power
Supply
Heat Resistance Wire
End Cap
16
End Cap
Buss Wire
Heat Resistance Wire
Thermostat
Contactor
Buss Wire
Thermostat
II. Constant Wattage
L2
Power Supply
L1
L2 L1
Control
Circuit
Power
Supply
Page 17
End Cap
Cold Lead
OR
Heat Resistance Wire
Thermostat
L2
Power Supply
L1
Heat Resistance Wire
End Cap
Contactor
L2
Power
Supply
L1
Control
Circuit
L2
L1
Thermostat
III. Mineral Insulated / Series Long Line
Installation Testing
To identify potential damage, installation testing should be completed at the following times:
• Prior to installing the heating cable
• Prior to installing the connection kits
• Prior to insulating the pipe
• After insulating the pipe
• Prior to energizing the cable
• During periodic system check-ups
• After maintenance/repair work
As part of the installation testing, complete the following steps:
1. Visually inspect the heater cable and temperature con­trols for signs of mechanical damage. If damage is seen, either replace the complete heater cable, or cut out the damaged section and replace using the proper splice connection for the area and cable you are using.
Thermostat
2. Inspect all connections to be sure they are correctly as­sembled. Be sure each heater cable entry to a connection has a grommet and the compression plates and caps are properly tightened.
3. Determine the insulation resistance of the circuit using at least 1,000 VDC. It is strongly recommended that higher test voltages be used. Polymeric cables (SR, SLL, and CWM) should be tested at 2,500 VDC. Always perform this test at the power connection. See Table 4 for mini­mum insulation resistance readings. Any cable with an in­sulation resistance below the recommended value should be removed and factory should be contacted. See page 31 for a detailed explanation on how to conduct the insu­lation resistance test.
4. Check voltage at the end of circuit and record in the log on page 33. See page 31 for information on how to com­plete the end of circuit voltage test.
Table 4 – Minimum Insulation Resistance Readings
Delivery
Chromalox SRL 20 MΩ 20 MΩ 5 MΩ 5 MΩ
Chromalox SRP 20 MΩ 20 MΩ 5 MΩ 5 MΩ
Chromalox SRM/E 20 MΩ 20 MΩ 5 MΩ 5 MΩ
Chromalox CWM 20 MΩ 20 MΩ 5 MΩ 5 MΩ
Chromalox MI
Chromalox SLL 20 MΩ 20 MΩ 5 MΩ 5 MΩ
20 MΩ 20 MΩ 5 MΩ 5 MΩ
Installation
Pre-Insulation
17
Installation
Post-Insulation Maintenance
Page 18
Heating Cable Components
Connection Kits
Table 5 – U Series Connection Kits Overview
Catalog Number Description
NEMA 4X rated junction box designed to connect cables to customer supplied power wiring. This kit provides water-resistant cable entry for one
UPC
Power Connection
Box
UMC
Multiple Entry Power
Connection Box
UES
Above Insulation End
Seal Kit
cable, enclosure support, terminal block, and a water-resistant corrosion-resistant wiring enclo­sure with a 3/4” opening to accept a conduit hub (CCH-2 or equal)
NEMA 4X rated junction box designed to connect two or three cables. This kit provides water­resistant cable entry, enclosure support, terminal block, and a water-resistant, corrosion-resistant wiring enclosure. In addition to splicing or teeing cables, this model can be used to provide power connection to up to three cables from one con­nection kit.
NEMA 4X rated end seal designed to terminate cables. This kit provides water-resistant cable entry for one cable. It has a corrosion-resistant pipe support that brings the cable end outside of the insulation for easy access.
Installation
Manual
PJ495
PJ497
PJ496
UESL
End Seal Signal
Light Kit
USL
Power/End Seal
Signal Light Kit
SSK
Single Entry
Sealing Kit
NEMA 4X rated end seal designed to seal one cable and indicate power on with universal volt­age 120-277 LED indicator light. This model provides water-resistant cable entry, enclosure support, terminal block, and corrosion-resistant wiring enclosure. Available in red and green.
NEMA 4X rated end seal designed to power or seal one cable and indicate power on with uni­versal voltage 120-277 LED indicator light. This model provides water-resistant cable entry, enclosure support, terminal block, and corro­sion-resistant wiring enclosure.
This kit provides water-resistant cable entry for one cable. It has a corrosion-resistant pipe sup­port that brings the cable end outside of the insulation for easy connection to power.
PJ448
PJ937
PJ498
18
Page 19
Table 6 – U Long Line Series Connection Kits Overview
Catalog Number Description
NEMA 4X rated junction box designed to connect SLL heating cables to customer supplied power wir-
UPC LL
Power Connection
Kit
UMC LL
Multiple Entry Power
Connection Box
UES LL
End Seal
Connection Kit
ing. This kit provides water-resistant cable entry for one cable, enclosure support, crimp connections, cold leads, and a water-resistant corrosion-resistant wiring enclosure with an opening to accept a 3/4" conduit hub.
NEMA 4X rated junction box designed to connect two SLL heating cables to each other. This kit pro­vides water-resistant cable entry for one cable, enclosure support, crimp connections, and a water resistant corrosion-resistant wiring enclosure with an opening to accept a 3/4" conduit hub.
NEMA 4X rated junction box designed to terminate SLL heating cables outside of the insulation. This kit provides water-resistant cable entry for one cable, enclosure support, crimp connections, and a water­resistant corrosion resistant wiring enclosure with an opening to accept a 3/4" conduit hub.
Installation
Manual
PJ951
PJ949
PJ950
Table 7 – DL Series Connection Kits Overview
Catalog Number Description
RTES
End Seal Kit
RTPC
Power Connection
Kit
RTST
Slice & Tee Kit
NEMA 4X rated enclosure that provides waterproof cable entry for one (1) cable. The fitting has two (2) different mounting surfaces: one for pipes with a diameter of 3” or more, and one for smaller pipes
NEMA 4X rated junction box that provides water­proof cable entry for up to three (3) cables with an opening to accept a 3/4” conduit hub (Chromalox CCH-2 or equal).
NEMA 4X rated junction box that provides water­proof cable entry for two (2) cables for a splice or three (3) cables for a tee.
Installation
Manual
PJ450
PJ451
PJ452
19
Page 20
Table 8 – HL Series Connection Kit Overview
Catalog Number Description
HL-PC
Power Connection Box for Hazardous
Locations
Splice Kit for
Hazardous Locations
Tee Kit for Hazardous
Locations
HL-S
HL-T
Division 1 certified junction box and seal fitting. The kit is designed to connect self­regulating cables to customer supplied power wiring. The pipe stand-off and seal fitting combination provides a water resis­tant and explosion proof seal. The junction box has a 3/4" opening with top or side entry for the power connection.
Division 1 certified junction box and seal fittings. The kit is designed to splice two self-regulating cables. The cable entry fit­ting and seal fitting combination provides a water-resistant and explosion proof seal.
Division 1 certified junction box and seal fittings. The kit is designed to splice three self-regulating cables. The cable entry fit­ting and seal fitting combination provides a water-resistant and explosion proof seal.
Installation
Manual
PJ912
PJ920
PJ921
HL-ES
End Seal for
Hazardous Locations
Division 1 certified junction box and seal fitting. The kit is designed to terminate a run of self-regulating cable. The pipe stand-off and seal fitting combination pro­vides a water resistant and explosion proof seal.
PJ918
20
Page 21
Table 9 – MI Series Connection Kit Overview
Catalog Number Description
JB-7-4
MI Cable Power
Connection Kit
JB-7-MB
MI Cable Pipe
Mounting Bracket
SSW-100
Stainless Steel Tie
Wire
SSP-1
Stainless Steel
Spacer Strip
Installation
Manual
NEMA 7 cast aluminum junction box for miner­al insulated cable.
N/A
Pipe mounting bracket to be used with the JB-7-4 power connection kit.
N/A
Stainless steel tie wire, 100ft roll.
N/A
Stainless steel spacer strip with 1” spaced tabs, 50ft roll.
N/A
HTC
Heat Transfer
Cement
Heat transfer cement available in 1 and 5 gal­lon pails.
N/A
21
Page 22
Accessories
Table 10 – Accessories Overview
Catalog Number Description
180 ft roll of aluminum foil installation tape.
AT- 1
Aluminum Tape
FT-3
Fiberglass Tape
2-mil thickness with high tensile strength; 2-1/2” wide. 200°F (93°C) rating. Minimum application temperatures 40°F (5°C).
66 ft roll of glass cloth installation tape. 3/8” wide. 500°F (260°C) rating. Strap at one-foot intervals. Minimum application temperature 40°F (5°C).
Installation
Manual
N/A
N/A
PS
Stainless Steel Pipe
Straps
CL-1
Caution Labels
SSP-1
Stainless Steel
Spacer Strip
SSW-100
Stainless Steel Tie
Wire
HTC
Heat Transfer
Cement
One (1) pipe strap used to attach kits to pipe. Available for pipe sizes 1/2” to 3/4”, 1” to 3-1/2”, 2-1/2” to 9”, and 9” to 19.5”.
Pack of five (5) weather resistant electric heat tracing caution labels.
Stainless steel spacer strip with 1” spaced tabs, 50ft roll.
Stainless steel tie wire, 100ft roll.
Heat transfer cement available in 1 and 5 gal­lon pails.
N/A
N/A
N/A
N/A
N/A
22
Page 23
Control Systems
Ambient Sensing
The ambient sensing control systems activate the heating cable when the ambient temperature falls below the thermostat set point. It is important that these devices are installed above ground at the pipe segment that is subject to the lowest tempera­tures and fastest wind speeds. The device should be placed out of direct sunlight.
Table 11 – Sensors
Installation
Manual
N/A
Installation
Manual
-
N/A
Table 12 – Thermostats
Catalog Number Description
Measures the ambient air temperature to prevent
GIC-AMB
Ambient Heat Trace
Sensor
Catalog Number Description
B-100
Freeze Protection
Thermostat
freeze-up of process piping that is carrying prod­ucts whose temperature must be kept above freezing. The RTD sensor element is made up with a Copper sheath and can be installed direct­ly to a controller or junction box using the 1/2”
NPT conduit fitting.
The B100 direct mount thermostats feature liquid­filled thermal assemblies and sense air tempera tures from 15 to 140°F. The thermostats are epoxy coated to seal from moisture and contaminants in compliance with NEMA 4X requirements.
THL
Freeze Protection
Thermostat
TXL
Freeze Protection
Thermostats
Table 13 – Thermostats with Power Connection
Catalog Number Description
UAS
Ambient Sensing
Thermostat and
Power Connection
Kit
RTA S
Ambient Sensing
Thermostat and
Power Connection
Kit
The THL direct mount thermostats feature liquid­filled thermal assemblies and sense air tempera­tures from 15 to 140˚F. The thermostats are epoxy coated to seal from moisture and con­taminants in compliance with NEMA 4X require­ments.
The TXL direct mount thermostats feature liquid­filled thermal assemblies and sense air tempera tures from 15 to 140˚F. The thermostats are epoxy coated to seal from moisture and contaminants in compliance with NEMA 4X requirements.
NEMA 4X rated junction box designed to connect a single cable run to power and control cable out put via ambient air temperature in non-hazardous areas. This kit provides water-resistant cable entry with a 3/4” opening to accept a conduit hub (CCH-2 or equal). Temperature set point 0° to 225°F (-81°C to 107°C) with 10°F scale divisions.
-
-
NEMA 4X rated junction box with ambient sens-ing thermostat. Provides temperature control and termination for one (1) cable. One (1) addi-tional cable can be connected upon purchase of additional grommet.
N/A
N/A
Installation
Manual
PJ943
PJ453
RTAS-EP
Ambient Sensing
Thermostat and
Power Connection
Kit
Modified version of the RTAS which utilizes a hermetically sealed switch. Class I, Division 2 approved.
23
PJ972
Page 24
Line Sensing
The line sensing control systems activate the heating cable when the pipe temperature drops below the desired setpoint. The sensor must be secured to the pipe with aluminum tape and the insulation must be sealed where the capillary comes through. The device should be mounted above ground in an area without heavy pedestrian or equipment traffic. To avoid thermal in­terference with the sensor, it is important that the sensor is installed at 90 degrees from the nearest heating cable or centered equally between cables if more than one heating cable is used. The sensor should ideally be installed at the end of the circuit but can be installed at any location that is at least 3 feet away from any heat sinks. See installation detail AD19.
Table 14 – Sensors
Catalog Number Description
The RBF sensor measures the surface tempera­ture of process piping that is carrying products whose temperatures must be controlled to pre-
RBF
Heat Trace or Pipe
Sensor
RBF-HT
RTD Heat
Trace Sensor
vent freeze-up, or to maintain a viscosity level so that the inner medium will flow. The Thermocouple or RTD Sensor Element is made up with a 316SS sheath and has a stainless-steel mounting pad.
The RBF-HT sensor measures the surface tempera­ture of process piping that is carrying products whose temperature must be controlled. The RTD sensor element is made up with a 316 SS sheath and can be installed directly to a controller or junc­tion box using the 1/2” conduit fitting.
Installation
Manual
N/A
N/A
Table 15 – Thermostats
Catalog Number Description
The E100 remote mount thermostats utilize a stain-
E-100
Line Sensing
Thermostat
THR
Line Sensing
Thermostat
TXR
Line Sensing
Thermostats
less-steel bulb and capillary design to accurately sense temperature at key points along a pipe. The thermostats are epoxy coated to seal from moisture and contaminants in compliance with NEMA 4X requirements.
The THR remote mount thermostats utilize a stain­less-steel bulb and capillary design to accurately sense temperature at key points along a pipe. The thermostats are epoxy coated to seal from moisture and contaminants in compliance with NEMA 4X requirements.
The TXR remote mount thermostats utilize a stain­less-steel bulb and capillary design to accurately sense temperature at key points along a pipe. The thermostats are epoxy coated to seal from moisture and contaminants in compliance with NEMA 4X requirements.
Installation
Manual
N/A
N/A
N/A
24
Page 25
Table 16 – Thermostats with Power Connection
Catalog Number Description
NEMA 4X rated junction box designed to connect a
UBC
Line Sensing
Thermostat and
Power Connection
Kit
RTBC
Line Sensing
Thermostat and
Power Connection
Kit
single cable run to power and control cable output via pipe temperature in non-hazardous areas. This kit provides water-resistant cable entry with a 3/4” opening to accept a conduit hub (CCH-2 or equal). Temperature set point 0° to 400°F (-81°C to 200°C) with 10°F scale divisions.
NEMA 4X rated junction box with line sensing ther­mostat; 8” stainless steel capillary. Provides tem­perature control and termination for one (1) cable.
Modified version of the RTBC which utilizes a
RTBC-EP
Line Sensing
hermetically sealed switch. Class I, Division 2 approved.
Thermostat and
Power Connection
Kit
Installation
Manual
PJ942
PJ454
PJ973
25
Page 26
Table 17 – Controllers
Catalog Number Description
Microprocessor-based system with SSR power control, full monitoring, and alarms. Single or
ITC1 & ITC2
Digital Heat Trace
dual point control. NEMA 4X Fiberglass and stainless steel options available.
Controller
1 & 2 Circuits
Installation
Manual
PK509
ITAS 2-48 ITLS 2-48
Heat Tracing
Control Panel
ITASC1D2 2-48 ITLSC1D2 2-48
Heat Tracing
Control Panel
FPAS(M)
Freeze Protection
Ambient Sensing
(Monitoring) Series
FPLS(M)
Freeze Protection
Line Sensing
(Monitoring) Series
Microprocessor-based control/monitoring and power management system for ambient sensing, line sensing or a combination of both. Capacity of 2-48 circuits but can be increased to 72 cir­cuits with extension panels, ITAS-EXT 2-48 and ITLS-EXT 2-48. User-friendly touch screen HMI. NEMA 4/4X options available.
Microprocessor-based control/monitoring and power management system for ambient sensing, line sensing or a combination of both. Capacity of 2-48 circuits but can be increased to 72 cir­cuits with extension panels, ITASC1D2-EXT 2-48 and ITLSC1D2-EXT 2-48. User-friendly touch screen HMI. NEMA 4/4X options available.
The FPAS series controls multiple heat trace cir­cuits via an ambient sensing external thermostat, external electronic controller or via an ambient sensing, door mounted 6040 DIN controller. Chromalox recommended controllers include: RTAS, RTAS-EP, B100, E100 or the 6040 DIN controller. NEMA 4/4X options available.
The FPLS series controls each heat trace line with individual Chromalox RTBC, RTBC-EP, E-100 or E121 line sensing controls. Each circuit should be controlled by an individual sensor/ controller. Depending on the application, control­lers can switch more than one circuit. NEMA 4/4X options available.
PK497
PK497
PK557
PK557
RSP
IntelliTrace Remote
Sensor Panel
DTS-HAZ
Heat Trace Digital
Thermostat
NEMA 4 Painted Steel, NEMA 4X Fiberglass or NEMA 4X 305SS enclosure. Fully integrated package that consolidates up to 252 temperature sensor signals in a single enclosure. Works seamlessly with the Chromalox IntelliTrace ITLS/ ITAS heat trace control panels.
The DTS-HAZ digital thermostat is a NEMA 4X rated power connection kit and microprocessor­based temperature control. It is used for freeze protection or process temperature maintenance of pipes or tanks protected by heat tracing prod­ucts.
26
PK497
PJ944
Page 27
Table 18 – Controllers Comparison
ITC DTS-HAZ ITAS ITLS ITASC1D2 ITLSC1D2 FPAS FPASM FPLS FPLSM
Controls
Ambient sensing
• • • • • •
Line sensing • • • • • •
PASC • • • • •
Monitoring
Ambient temperature
Pipe temperature
• • • • • • • •
• • • • • • • •
Ground fault • • • • • • •
Current • • •
Location
Local • • • • • • • • • •
Remote • • • • • • •
Hazardous • • •* •* • • •* •* •* •*
Communications
Local display • • • • • •
Remote display
Network to DCS
• • • • • •
• • • • • • •* •*
General
Number of circuits
Sensor Mapping
1-2 1 2-72 2-72 2-72 2-72 6-42 6-42 6-42 6-42
• • • •
BACnet •** •* •* •* •*
Number of circuits
110-
277
110-277 120-480 120-480 120-480 120-480
120-
480
120-480 120-480
cUL/UL,
Aprovals
cUL/
UL, CE
CE,ATEX,
IECEX
cUL/
UL, CE
cUL/
UL, CE
cUL/UL, CE cUL/UL, CE
cUL/
UL, CE
cUL/
UL, CE
cUL/
UL, CE
cUL/
UL, CE
Zone 2
*Not a standard offering. **Not included in standard offering and only available for single circuit use.
120-
480
27
Page 28
Thermal Insulation
An installed heating circuit should be thermally insulated im­mediately to provide protection from damage from ongoing work. Things to remember about insulating:
• Insulate the equipment being heat traced as soon as pos­sible after the heating cable is installed. This will protect the cable from possible physical damage.
• The type and thickness of thermal insulation specified on the design drawing must be used. If you use another type or thickness, the heater cable type or amount may have to be changed.
• Never install wet insulation. Both the piping and the insu­lation must be dry when thermally insulating a circuit. Wet insulation may cause start-up or operational problems.
• Properly weatherproof the thermal insulation. All places where valve stems, conduits, pipe supports, connection housing, thermal capillary tubes, etc. extend outside the insulation jacketing must be sealed with a suitable com­pound to keep water out.
• Insulate valves fully up to, and including, the packing gland.
• Heat trace and fully insulate the face of all non-diaphragm pressure instruments.
Commission Testing
• Insulation must be covered by a weatherproof barrier, such as an aluminum jacket.
• If you are using metal jacketing and sheet metal screws, be sure the screws are not long enough to penetrate the thermal insulation and damage the heater cable.
• Again, perform the megger test on the circuit immediately after the thermal insulation is installed to detect if any me­chanical damage may have occurred.
• When the insulation and the weatherproofing is complete, attach “Electric Traced” labels on the outside of the in­sulation. These should be installed where they are vis­ible from normal operations, usually on alternating sides about every 10 feet. It is also useful to mark the location of any connections buried under the insulation.
Additional requirements for rigid thermal insulations:
• In the standard single heater cable installation, rigid insu­lations do not need to be oversized. However, they should be carved so there is no gap in the insulation.
• In case of redundant or multiple heater cables, rigid insu­lations which are 0.500 inches oversized should be used.
1. Again, visually inspect the piping, insulation, and connec­tions for the heater cable to make sure no physical dam­age has occurred since the installation and start-up.
2. Megger the system again to determine if damage not readily visible has occurred.
3. Turn all branch circuit breakers to the OFF position.
For systems controlled by ambient sensing thermostats:
1. If the actual ambient temperature is higher than the de­sired thermostat setting, turn the thermostat setting up high enough to turn the system ON or (some models) turn the selector switch to the ON position.
2. Turn the main circuit breaker ON.
3. Turn the branch breakers ON one-by-one until all are on.
4. Allow system to run at least four hours in order to let all pipes reach steady-state.
5. Measure the amperage draw, ambient temperature and pipe temperature for each circuit and record in the in­stallation log. This information may be needed for future maintenance and troubleshooting.
6. When the system is completely checked out, reset the thermostat to the proper temperature.
For systems controlled by line sens­ing thermostats:
1. Set the thermostat to the desired control temperature.
2. Turn the main circuit breaker ON.
3. Turn ON the branch circuit breakers controlled by the thermostat.
4. Allow the pipe temperatures to be raised to the control point. This may take up to four hours for most circuits (large full pipes may take longer).
5. Measure the amperage draw, ambient temperature, and pipe temperature for each circuit and record in the in­stallation log. This information may be needed for future maintenance and troubleshooting
For redundant systems:
Follow the procedure above for the type of control system you have, but commission the systems one at a time. Start up the primary system, qualify it and shut it down. Then start up the backup system, qualify it and shut it down
28
Page 29
Specifications
Table 19 – CWM Cable Maximum Maintenance Temperatures
Temperatures (˚F)
Output (W/Ft.) 3 4 6 6.7 8 9 10.1 10.6 12
w/o AT-1 Tape 340 325 293 282 262 246 229 222 200
w AT-1 Tape 350 344 332 328 320 314 307 304 296
Table 20 – SRL Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
Cable
Rating
SRL3-1
10A 15A 20A 25A 30A 40A 10A 15A 20A 25A 30A 40A 10A 15A 20A 25A 30A 40A
205
SRL3-2 400 600 660 NR NR NR 275 415 555 660 NR NR 245 370 495 600 660 NR SRL5-1 125 185 250 270 NR NR 90 135 180 225 270 NR 80 120 160 205 245 270 SRL5-2 250 375 505 540 NR NR 180 270 360 450 540 NR 160 245 325 405 490 540 SRL8-1 100 150 200 215 NR NR 70 110 145 180 215 NR 65 100 130 165 200 210 SRL8-2 185 285 375 420 NR NR 135 200 265 335 395 420 120 175 235 300 350 420 SRL10-1 60 95 130 160 180 NR 50 80 105 130 155 180 45 70 95 120 140 180 SRL10-2 100 160 210 260 315 360 80 125 170 210 255 340 75 120 160 195 240 320
NR = Not Required. Maximum circuit length has been reached in a smaller breaker size. Note — Thermal magnetic circuit breakers are recommended since magnetic circuit breakers could “nuisance trip” at low temperature.
50˚F Start-up (Ft.) 0˚F Start-up (Ft.) -20˚F Start-up (Ft.)
305 360 NR NR NR 135 200 270 330 360 NR 120 185 245 300 360 NR
Table 21 – SRP Circuit Breaker Selection
Cable
Rating
SRP5-1 145 195 295 390 490 110 145 215 295 360 70 90 135 180 225
SRP5-2 295 385 580 750 750 220 290 430 580 720 135 180 270 360 450
SRP10-1 100 135 200 270 330 70 95 145 190 240 65 85 130 175 215
SRP10-2 200 270 400 530 665 145 190 290 380 480 130 175 260 350 440
SRP15-1 75 100 150 200 250 60 80 120 160 200 55 70 110 145 180
SRP15-2 150 195 295 390 500 120 160 235 320 400 110 145 220 290 360
Table 22 – SRM/E Circuit Breaker Selection (Max. Circuit Lengths in Ft.)
Cable
Rating
SRM/E 5-1 180 240 360 375 NR 165 220 330 375 NR 155 210 310 375 NR
SRM/E 5-2 360 480 720 750 NR 325 430 645 750 NR 310 415 620 750 NR
SRM/E 8-1 145 190 285 325 NR 135 175 265 325 NR 130 165 250 325 NR
SRM/E 8-2 285 380 575 650 NR 255 345 520 650 NR 245 335 490 650 NR
SRM/E 10-1 95 125 190 250 NR 90 110 175 250 NR 85 100 170 245 250
SRM/E 10-2 190 255 385 490 NR 165 225 345 490 NR 155 215 330 470 490 SRM/E 15-1 70 95 145 190 210 65 85 125 165 210 60 80 120 150 210 SRM/E 15-2 145 190 290 385 420 120 175 270 360 420 115 165 260 340 420 SRM/E 20-1 60 75 115 155 160 50 65 105 140 160 45 65 100 135 160 SRM/E 20-2 115 155 230 305 350 100 135 200 270 350 90 130 195 255 335
NR = Not Required. Maximum circuit length has been reached in a smaller breaker size. Note — Thermal magnetic circuit breakers are recommended since magnetic circuit breakers could “nuisance trip” at low temperature.
50°F Start-Up (Ft.) 0°F Start-Up (Ft.) -20°F Start-Up (Ft.)
15A 20A 30A 40A 50A 15A 20A 30A 40A 50A 15A 20A 30A 40A 50A
50°F Start-Up (Ft.) 0°F Start-Up (Ft.) -20°F Start-Up (Ft.)
15A 20A 30A 40A 50A 15A 20A 30A 40A 50A 15A 20A 30A 40A 50A
29
Page 30
Table 23 CWM Specifications
Cable Length (ft.)
0.00
2.00
6.00
8.00
10.00
4.00
0
200
400
600
800
1000
1200
1400
1600
SLL45
SLL28
SLL18
SLL10
12.00
W/Ft.
Cable Length (ft.)
0.00
2.00
6.00
8.00
10.00
4.00
0
500
1000
1500
2000
2500
3000
4000
14.00
16.00
SLL45
SLL28
SLL18
SLL10
W/Ft.
12.00
3500
Cable Length (ft.)
0.00
2.00
6.00
8.00
10.00
4.00
0
1000
2000
3000
4000
5000
6000
7000
14.00
16.00
SLL45
SLL28
SLL18
SLL10
W/Ft.
12.00
Cable Length (ft.)
0.00
2.00
6.00
8.00
10.00
4.00
0
1000
2000
3000
4000
5000
6000
7000
14.00
16.00
8000
SLL45
SLL28
SLL18
SLL10
W/Ft.
12.00
Model
Circuit Load
(Amps / Ft.)
Max Circuit Length (Ft.)
CWM 4-1CT 0.033 350
CWM 8-1CT 0.067 240
CWM 12-1CT 0.100 200
CWM 4-2CT 0.017 700
CWM 8-2CT 0.033 480
CWM 12-2CT 0.050 400
CWM 12-4CT 0.025 780
Table 24 – SLL Specifications
Nominal Output Ratings on Metal Pipe - 120 VAC Nominal Output Ratings on Metal Pipe - 240 VAC
Nominal Output Ratings on Metal Pipe - 480 VAC Nominal Output Ratings on Metal Pipe - 600 VAC
NR = Not Required. Maximum circuit length has been reached in a smaller breaker size.
Note — Thermal magnetic circuit breakers are recommended since magnetic circuit breakers could “nuisance trip” at low temperature
Table 25 – Commercial Heating Device Installation Type
Intallation
Type Type Definition Examples of Type Cable Type
Hot water lines Freeze protection
A
Insulated Surfaces (Including Pipe)
Sprinkler systems Grease lines
Pre-insulated pipe Fuel oil lines
Below grade trace heating
30
SRL, SRP,
SRM/E
CWM, MI
.
Page 31
Troubleshooting
Table 26 – Troubleshooting Guide
Observed Problem Potential Causes Corrective Actions
Reinstall thermostat on an appropriate pipe seg­ment. Ensure thermocouple is fully contacting the pipe.
Remove damaged or wet insulation and install new, dry insulation. Ensure new insulation is weatherproofed.
Additional heating cable can be added, as long as the proper connection kits are used, and the new heating cable length does not exceed the maximum circuit length.
Contact a Chromalox representative and modify design as needed.
Apply voltage as specied. Check/repair electrical
supply lines.
Replace damaged cable. Check pipe temperature and cable power output.
Ensure length and heat trace path matches draw­ings.
Connect all splices and tees as per design speci-
cations.
Rewire to “Normally Closed” position
Lower pipe temperature if possible. Ensure correct heater selection and design. Contact a Chromalox representative and modify design if pipe temperature cannot be reduced.
Apply voltage as specied. Check/repair electrical
supply lines.
Replace damaged cable using the proper splice connection kits.
Ensure all connection kits are installed properly and inspect them for damage. Replace if neces­sary.
For uninsulated heating cable: Check the heating
cable for damage, especially around heat sinks. Replace damaged cable using the proper con­nection kits.
For insulated heating cable: Check the heating
cable for damage piecewise at each connection kit to determine the damaged segment.
The Locating Faults section on page 30 can be
used to estimate fault location.
Excessive moisture on heating cable core or bus
wires: Replace cable.
Moisture on connection kits: Retest after drying
out all components. Ensure all conduit entries are properly sealed during reinstallation.
Pipe temperature is too low
Power output is too low
Insulation resistance is low or inconsistent
Incorrect installation of thermostat/ther­mocouple
Damaged, missing, or wet insulation
Improper installation of heating cable on heat sinks
Error in thermal design
Incorrect voltage applied
Damaged heating cable
Incorrect circuit length due to uninstalled connections (splice/tee) or severed heat­ing cable
High-resistant connection due to improp­er installation of connection kits
Thermostat is wired in “Normally Open” position
The pipe temperature is too high
Incorrect voltage applied
Damaged heating cable
Shorted circuit
Moisture
Pipe temperature is too high Retest at ambient conditions
Test leads are in contact with junction box Retest after moving test leads
31
Page 32
Observed Problem Potential Causes Corrective Actions
Circuit breaker trips
Undersized circuit breaker Check design to ensure startup temperature,
Startup temperature is too low Start up when temperature is higher than -76˚F
Damaged heating cable Replace damaged cable using the proper con-
Bus wires touching and shorting out Check for proper termination at end seal. Note
Moisture Excessive moisture on heating cable core or bus
Undersized GFPD
current loads, and maximum circuit length are not exceeded, and that the power wire size is com­patible with the circuit breaker. Replace circuit breaker if necessary.
(-60˚C).
nection kits.
that the heating cable could be permanently dam­aged and may need to be replaced.
wires: Replace cable.
Moisture on connection kits: Retest after drying
out all components. Ensure all conduit entries are properly sealed during reinstallation.
Replace with appropriately sized GFPD.
Test Procedures
wire. To determine a low resistance ground fault, the resis­tance reading is taken between the bus wires and the braid
When testing any Chromalox heat trace product, al­ways utilize the proper protective equipment and be sure to comply with all applicable safety guidelines.
Before testing any Chromalox heat trace products, ensure that all test equipment is working as intend­ed and has been properly calibrated.
Only trained and qualified personnel should admin­ister the test.
Locating Faults
The three most common test methods for finding the approx­imate location of a fault in a heating cable are:
• Ratio test
• Conductance test
• Capacitance test
with one lead on bus wire and one on the braid. Example: There is a bus wire short at an unknown point on
a 100ft cable. The resistance reading between the bus wires is 6Ω from the front end of the cable and 14Ω from the back end.
The bus wire short is approximated to be 30ft (30% of 100ft) from the front end of the cable.
Conductance Test
The conductance test can be used to find the fault location of a severed heating cable. A standard ohmmeter is used to take resistance readings between the bus wires from both the front (F) and back (B) end of the cable. The fault location (L) as a percentage of cable length measured from the front end can be approximated by:
Ratio Test
The ratio test can be used to approximate the fault location of a bus wire short or a fault from bus wire to ground braid. A standard ohmmeter is used to take resistance readings from both the front (F) and back (B) end of the cable. The fault lo­cation (L) as a percentage of cable length measured from the front end can be approximated by:
To determine a bus wire short, the resistance reading is taken between the bus wires with one lead placed on each bus
Example: A 100 ft long heating cable is severed at an un­known point. The bus-to-bus resistant reading is 10.0Ω from the front end and 2.5Ω from the back end.
The cable is estimated to be severed at around 20ft (20% of 100ft) from the front of the cable.
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Capacitance Test
The capacitance test can be used to estimate the length of an intact heating cable or the fault location of a severed cable that has passed the insulation resistance testing. A capaci­tance reading is taken between the bus wires and the braid at the end with the power connection. The bus wires should be twisted together and connected to the positive lead, and the braid should be connected to the negative lead. The fault lo­cation can be found by multiplying the recorded capacitance with the capacitance factor found in Table 25.
Table 27 – Capacitance Factors
Example: A heating cable with a capacitance factor of 7 ft/ nF is severed at an unknown point. The capacitance reading between the bus wires and the braid is 12 nF.
The cable is estimated to be severed at around 84ft from the power connection.
Part
Number Description
Capacitance Factor
(ft/nF)
SRL3-1CR/CT 3 W / FT @ 50˚F - 120V 5.5
SRL3-2CR/CT 3 W / FT @ 50˚F - 208-277V 5.9
SRL5-1CR/CT 5 W / FT @50˚F - 120V 6.0
SRL5-2CR/CT 5 W / FT @ 50˚F - 208-277V 5.4
SRL8-1CR/CT 8 W / FT @ 50˚F - 120V 5.5
SRL8-2CR/CT 8 W / FT @ 50˚F - 208-277V 5.5
SRL10-1CR/CT 10 W / FT @ 50˚F - 120V 5.1
SRL10-2CR/CT 10 W / FT @ 50˚F - 208-277V 5.3
SRM/E5-1CT 5 W / FT @50˚F - 120V 7.5
SRM/E5-2CT 5 W / FT @ 50˚F - 208-277V 7.2
SRM/E8-1CT 8 W / FT @ 50˚F - 120V 7.5
SRM/E8-2CT 8 W / FT @ 50˚F - 208-277V 7.6
SRM/E10-1CT 10 W / FT @ 50˚F - 120V 7.4
SRM/E10-2CT 10 W / FT @ 50˚F - 208-277V 7.4
SRM/E15-1CT 15 W / FT @ 50˚F - 120V 7.9
SRM/E15-2CT 15 W / FT @ 50˚F - 208-277V 7.5
SRM/E20-1CT 20W / FT @ 50˚F - 120V 7.5
SRM/E20-2CT 20 W / FT @ 50˚F - 208-277V 7.2
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Insulation Resistance (Megger) Test
The insulation resistance test detects potential damage that could result in the cable shorting out. A megohmmeter is used to measure the insulation resistance between the conductive core and the grounding braid, and the reading is compared to the allowable minimum resistance reading (See Table 4). The megohmmeter should be a minimum of 1000 Vdc, but the use of 2500 Vdc is preferred. If possible, the meter should be battery-operated, though digital or analog meters can also be used.
1. De-energize the circuit.
2. Open the cover on the power termination kit.
3. Disconnect the bus wires and braid from the terminals.
4. Set the test voltage to 0 Vdc.
5. Connect the negative lead to the ground braid and the positive lead to the bus wires.
6. Turn on the megohmmeter and perform insulation resis­tance test for one minute, until the needle on the meter stops moving.
7. Check the reading and ensure it is above the allowable minimum resistance reading.
8. Record the tested value in the log.
9. Turn off the megohmmeter and discharge it with an ap­propriate grounding rod (if the meter does not self-dis­charge).
10. Reconnect the wires and close the power termination kit.
5. Energize the circuit.
6. Allow the circuit to run for at least 20 minutes.
7. Take the current reading and record in the log.
8. De-energize the circuit.
9. Disconnect and turn off the meter.
10. Reconnect the bus wires and close the termination kit.
To determine the thermal output, complete the calculation below:
Thermal output = (Current Reading / Circuit Length) x Voltage
Compare the result to the charted output temperature in the “Chromalox Design Guide for Heat Tracing Products”.
For additional information about this test, please watch the “Stabilized Current Test” video in the Chromalox video library:
https://www.chromalox.com/en/Resources-and-Support/ Technical-Resources/Video-Library/Video-Library
End of Current Voltage Test
This test determines the voltage at the end of the line, which verifies the proper voltage. To perform the test, a standard multimeter with auto-range up to 600V is required. If pos­sible, the meter should be battery-operated, though digital or analog meters can also be used.
For additional information about this test, please watch the “Heat Trace Megger Testing Procedure” video in the Chro­malox video library:
https://www.chromalox.com/en/Resources-and-Support/ Technical-Resources/Video-Library/Video-Library
Stabilized Current Test
The stabilized current test determines the cable current at full voltage. It ensures that the cable power output is correct for design and that it is stable. To perform this test, a stan­dard multimeter with an Amp clamp or an all-in-one unit is required. Ensure the meter has an auto-range up to 100A. If possible, the meter should be battery-operated, though digi­tal or analog meters can also be used.
1. De-energize the circuit.
2. Open the cover on the power termination kit.
3. Disconnect the bus wires from the terminals.
4. Clamp the meter onto one bus wire.
Maintenance
Recommended maintenance for Chromalox heat tracing sys­tems consists of performing the steps involved in the com­mission testing on a regular basis. For those systems con­trolled by line sensing thermostats, Chromalox recommends checking the system at least twice per year. Systems con­trolled by an ambient-sensing thermostat should be checked when the season requiring their use is approaching.
1. De-energize the circuit.
2. Remove the end cap.
3. Expose the bus wires.
4. Connect one test lead to each bus wire and energize the circuit
5. Read the resulting voltage and compare it to the desired value.
6. Record the reading in the test log.
7. De-energize the circuit.
8. Disconnect and turn off the multimeter.
9. Reconnect the end cap.
For additional information about this test, please watch the “End of Current Voltage Test” video in the Chromalox video library:
https://www.chromalox.com/en/Resources-and-Support/ Technical-Resources/Video-Library/Video-Library
Repair or replace all damaged heater cable, connections, thermal insulation and weatherproofing using only Chromal­ox connections and methods before testing the system.
Record all repairs made and measurements taken in the in­stallation and maintenance log.
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Installation and Maintenance Log
Reference Information
Circuit Number
Circuit Breaker Number
Drawing Number
Circuit Length
Heat Tracing Visual Checks
No Signs of Moisture, Corrosion or Damage
Proper Electrical Connection
Proper Grounding of the Braid
Heat Tracing Electrical Checks
Megger Test (500 VDC) (Bypass Controls)
Amperage Draw Test Compare to design Amperage Draw
Voltage at end of Circuit*
Accessories/Control Checks
Temperature Control Properly Set
Initial
Date
Initial
Date
Initial
Date
Meg Ohms
Date
Amperage
Amp. Temp
Date
Voltage
Date
Setpoint
Date
Sensors Protected and Undamaged
All Enclosures and Kits Closed and Sealed
Thermal Insulation Checks
Location of Kits Visible on Outside of Insulation
Insulation is Complete, Dry and Weatherproof
* This test must be performed at installation or at any time the cable is cut or damaged in any way.
Initial
Date
Initial
Date
Initial
Date
Initial
Date
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Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
Chromalox, Inc.
1347 Heil Quaker Boulevard
Lavergne, TN 37086
(615) 793-3900
www.chromalox.com
© 2021 Chromalox, Inc.
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