Danfoss PX Pipe Trace Heating System Installation guide
Installation Instruction
Danfoss PX Pipe Trace Heating System
Installation Instruction
Danfoss PX Pipe Trace Heating System
Table of contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Certifications / Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6 System design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 Power connection components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8 End-termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 Trace heater installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maximum heating circuit length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required tools / equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unrolling the trace heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation on pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation on functional elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Tests and putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Measurement of the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Acceptance test and acceptance test report. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Visual and functional inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Personnel training courses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Repairwork on piping or thermal insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
15 Acceptance report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
16 Limited product warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
17 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
18 Sécurité et avertissements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Installation Instruction
Danfoss PX Pipe Trace Heating System
1 Overview
This manual introduces the installation and operation of trace heating circuits using the following
self-regulating trace heaters:
• Danfoss PX Pipe Trace Heating System
The self-regulating trace heater features a temperature-dependent resistive element between two parallel copper conductors, that regulates and limits the heat output of the trace heater according to the
ambient temperature. If the ambient temperature rises, the power output of the trace heater is reduced. This self-regulating property prevents overheating which would cause damage to the trace heater.
Even crossing or overlapping with other trace heaters (or other portions of the same trace heater) are
possible.
The heating system is set up as a fixed equipment heating system for pipes in ordinary areas. Thanks to
the parallel design the trace heater can be cut and installed to any required length as specified in table
on page 7.
Multiple options for connection, splicing and end-termination of the heating circuit are available to
meet the individual requirements on site. A large variety of accessories allows for easy customization
and extensibility.
2 Safety
For safe installation and operation of the Danfoss PX Pipe Trace Heating System, all technical requirements and instructions given in this manual must be followed.
WARNING:
Risk of fire or electrical shock. Follow these guidelines to avoid personal injury or material damage.
• All electrical systems and installations must comply with Danfoss requirements and be installed in
accordance with the relevant electrical codes and any other applicable national and local codes.
• The US and Canadian electrical codes require ground fault protection to be provided for all trace
heating circuits.
• Install the trace heater circuit carefully.
• Use the trace heater in accordance with the intended purpose and strictly comply with the operational data specified in section Technical Data.
• The bending radius of the trace heater must be at least 1” (25 mm). Do not bend on the narrow axis.
• To avoid short circuits, do not connect the trace heater bus wires together.
• Keep all components and the trace heaters dry before and during installation
• Each heating circuit must be marked with electrical warning labels (see section Accessories).
• Keep these instructions for future reference. If applicable, leave them with the end user.
• De-energize before installation or servicing.
• Use only original Danfoss accessories.
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Danfoss PX Pipe Trace Heating System
3 Certifications / Approvals
Self-regulating trace heater Danfoss PX.
4 Technical data
Ambient temperature range -67 °F to +185 °F / -55 °C to +85 °C
Operation temperatures -40 °F to +149 °F /-40 °C to +65 °C
Voltage 110 to 120 VAC / 208 to 254 VAC
Heat output 3 to 10 W/ft / 10 to 33.6 W/m
Resistance Grounding braid: < 18.2 Ω/km
Dimensions
polyolefin outer jacket 0.46” x 0.23” (11.6 x 5.8 mm)
Minimum bending radius 1” (25 mm)
Do not bend in an upright position.
5 Personnel requirements
The personnel executing installation and maintenance tasks must have acquired the skills and specialized knowledge relating to the types of protection and types of devices concerned. At least, the
personnel must have:
• a general understanding of the relevant electrical engineering
• a basic knowledge of quality assurance, including the principles of auditing documentation, traceability of measurements and calibration of measurement instruments.
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Danfoss PX Pipe Trace Heating System
6 System design
A heating circuit with self-regulating trace heaters usually consists of:
• Power supply cable connection;
• End-termination.
The following pages list all compatible components for the PX heating system. The respective installation instructions are included in the scope of delivery.
7 Power connection components
The following components can be used for power connection with the PX Pipe Trace Heating System:
Power connection kit
Cable to Junction Box with
½” NPT cable gland
For connection of selfregulating trace heaters in
a junction box. Electrical
insulation is ensured by heat
shrink tubes.
Junction is not included.
Includes end-temination.
Catalog No.: 088L0023
8 End-termination
The following components can be used for end-termination with the PX Pipe Trace Heating System.
End-termination
Connecto NA B-E Silicone end
seal for insulation of the end
of the trace heater.
Includes 5 x endcap and 2 x
Silicone adhesive.
End-termination
Heat shrinkable end cap for
insulation of the end of the
trace heater.
Includes 5 kits.
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Catalog No.: 088L0767
Catalog No.: 088L1457
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Danfoss PX Pipe Trace Heating System
9 Accessories
The following original Danfoss accessories are available for the PX Pipe Trace Heating System.
Aluminium adhesive tape
application under trace
heaters for better heat
distribution.
Electrical warning label
Warning label for trace heater
circuits
Catalog No.: 088L0409
Catalog No.: 088L0412
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Installation Instruction
Danfoss PX Pipe Trace Heating System
10 Trace heater installation
Preparation
Before installing any electric trace heating, the person installing must check if the trace heating has
been designed and planned correctly. It is particularly essential to verify the following points:
• complete project planning documentation, operating instructions and installation instructions.
• correct selection of the trace heater and accessories with respect to:
· calculation of heat losses;
· max. permissible operating temperature;
· max. permissible ambient temperature;
· temperature class;
· heating circuit length.
Before installing, make sure that all piping and equipment is properly installed and pressure tested.
Maximum heating circuit length
The following table shows the maximum circuit lengths in m (ft) for the different trace heater types
with standard circuit breaker amperages. Breaker sizing should be based on the National Electrical
Code, Canadian Electrical Code or any other local or applicable code.
NOTICE: If the required trace heater length exceeds the maximum heating circuit length you must
install multiple heating circuits.
Power output
Trace
heater type
PX-F3 (3 W/ft)
PX-F5 (5 W/ft)
PX-F8 (8 W/ft)
PX-F10 (10 W/ft)
Start-up
temp.
°F (°C)
+50 (+10) 312 (95) 312 (95) 312 (95) 591 (180) 591 (180) 591 (180) 673 (205) 673 (205) 673 (205)
0 (-18) 295 (90) 312 (95) 312 (95) 551 (168) 591 (180) 591 (180) 597 (182) 640 (195) 640 (195)
-20 (-29) 246 (75) 312 (95) 312 (95) 476 (145) 591 (180) 591 (180) 505 (154) 623 (190) 640 (195)
-40 (-40) 240 (73) 312 (95) 312 (95) 420 (128) 558 (170) 591 (180) 479 (146) 623 (190) 640 (195)
+50 (+10) 262 (80) 262 (80) 262 (80) 486 (148) 492 (150) 492 (150) 525 (160) 525 (160) 525 (160)
0 (-18) 197 (60) 262 (80) 262 (80) 394 (120) 492 (150) 492 (150) 394 (120) 525 (160) 525 (160)
-20 (-29) 161 (49) 262 (80) 262 (80) 328 (100) 443 (135) 476 (145) 328 (100) 525 (160) 525 (160)
-40 (-40) 157 (48) 256 (78) 262 (80) 312 (95) 394 (120) 476 (145) 315 (96) 512 (156) 525 (160)
+50 (+10) 190 (58) 207 (63) 207 (63) 344 (105) 377 (115) 377 (115) 381 (116) 413 (126) 413 (126)
0 (-18) 125 (38) 184 (56) 207 (63) 246 (75) 312 (95) 344 (105) 246 (75) 374 (114) 413 (126)
-20 (-29) 105 (32) 177 (54) 207 (63) 203 (62) 289 (88) 322 (98) 210 (64) 348 (106) 404 (123)
-40 (-40) 98 (30) 164 (50) 207 (63) 190 (58) 272 (83) 302 (92) 197 (60) 328 (100) 387 (118)
+50 (+10) 148 (45) 167 (51) 180 (55) 262 (80) 312 (95) 312 (95) 295 (90) 335 (102) 361 (110)
0 (-18) 98 (30) 138 (42) 148 (45) 190 (58) 256 (78) 295 (90) 197 (60) 276 (84) 295 (90)
-20 (-29) 85 (26) 125 (38) 131 (40) 164 (50) 230 (70) 269 (82) 171 (52) 236 (72) 262 (80)
-40 (-40) 72 (22) 115 (35) 118 (36) 131 (40) 180 (55) 230 (70) 131 (40) 197 (60) 230 (70)
Operating Voltage: 120 Vac Operating Voltage: 208 Vac Operating Voltage: 240 Vac
20 A 30 A 40 A 20 A 30 A 40 A 20 A 30 A 40 A
Maximum heating circuit length in ft. (m)
NOTICE: Automatic circuit breaker has to be “C” tripping characteristic.
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Installation Instruction
Required tools / equipment
The following tools are required for installation of the PX Pipe Trace Heating System:
• Wire cutters
• 2 adjustable wrenches (up to 1” (25 mm)); for installation of an insulation bushing only)
Unrolling the trace heater
WARNING:
Risk of short cuts and/or material damage. Keep the trace heater ends dry before and during installation. Observe the trace heater’s installation instructions.
Danfoss PX Pipe Trace Heating System
1
Unroll the required trace heater in a straight line and cut to the correct length. Cut off the trace
heater ensuring a straight cut.
Do not bend or pinch the trace heater, or pull it over sharp edges.
Installation on pipes
This step is necessary for plastic pipes only since plastic pipes conduct heat less efficiently than
metal pipes do. For metal pipes continue with step 4.
Place aluminium tape where the trace heater will be attached for better heat distribution.
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