Nelson Installation and Maintenance Instructions: GA-1765, Nelson Heat Trace Self-Regulating Heater Cable Manuals & Guides
Installation &
Maintenance
S E L F - R E G U L A T I N G
HEATER CABLE
CONTENTS
CONTENTS .......................................................................................................................... 2
GENERAL INFORMATION ................................................................................................... 4
How Heating Systems Work................................................................................................................ 4
PRODUCT SELECTION ....................................................................................................... 4
RECEIPT & STORAGE ........................................................................................................ 4
Receipt ................................................................................................................................................ 4
Storage ................................................................................................................................................ 4
Withdrawal from Storage ..................................................................................................................... 4
CONDITIONS OF SAFE USE ............................................................................................... 5
INSTALLATION .................................................................................................................... 7
Scheduling ........................................................................................................................................... 7
Pre-Installation Check ......................................................................................................................... 7
Heater Handling................................................................................................................................... 7
Heater Cable Location ......................................................................................................................... 8
Straight Tracing ................................................................................................................................... 8
Spiraling ............................................................................................................................................... 8
Attachment .......................................................................................................................................... 9
Cutting the Heater Cable ..................................................................................................................... 9
Installation Details ............................................................................................................................... 9
SYSTEM COMPONENTS ................................................................................................... 12
Accessories ....................................................................................................................................... 12
THERMAL INSULATION .................................................................................................... 13
Pre-Installation Checks ..................................................................................................................... 13
Installation ......................................................................................................................................... 13
Marking .............................................................................................................................................. 13
THERMOSTATS & SENSORS ........................................................................................... 14
ELECTRICAL REQUIREMENTS ........................................................................................ 14
Voltage Rating ................................................................................................................................... 14
Electrical Loading .............................................................................................................................. 14
Protection Requirements for Branch Circuits .................................................................................... 14
Waterproofing .................................................................................................................................... 15
Testing ............................................................................................................................................... 15
Procedure .......................................................................................................................................... 16
START-UP .......................................................................................................................... 19
Heat-up Time ..................................................................................................................................... 19
Diversity Factor ................................................................................................................................. 19
OPERATION & MAINTENANCE ......................................................................................... 19
TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
GA-1765 Rev. 9
Sheet 2 of 22
August 2016
System Design, Installation & Documentation .................................................................................. 19
Preventive Maintenance ................................................................................................................... 19
Visual Inspections ............................................................................................................................. 19
Frequency ......................................................................................................................................... 19
Personnel Training ............................................................................................................................ 19
Maintenance ..................................................................................................................................... 20
Piping Repairs ................................................................................................................................... 20
DAMAGED PRODUCTS ..................................................................................................... 20
TROUBLESHOOTING ........................................................................................................ 21
TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
GA-1765 Rev. 9
Sheet 3 of 22
August 2016
Insulation
Heater Cable
Pipe
Figure 1
GENERAL INFORMATION
The Installation and Maintenance Manual is intended for use with Nelson Heat Trace self-regulating heating
cable and component system on insulated pipes and vessels only. These instructions are suitable for use with
the heating cables and components listed on sheets 5, 6 and 13. For applications not specifically addressed,
please contact your local representative.
How Heating Systems Work
An electric heating cable system uses the heater cable to replace the heat that is lost through the thermal
insulation system. Replacing the lost heat allows the pipe and product inside the pipe to be kept at a constant
temperature. This will keep water from freezing and bursting a pipe, or a liquid from setting up and plugging the
pipe. Simple systems may turn the entire system on with a contactor or switch, while others will use a thermostat
or controller with each heater cable to regulate the temperature.
PRODUCT SELECTION
Check and verify that the proper heater cables are being installed on each pipe and vessel. If no
design/installation documents exist, check Nelson Heat Trace Design & Selection Guides to determine the
proper equipment for the application.
RECEIPT & STORAGE
Receipt
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 of
cable are recommended.
If design documents (line lists or per circuit bills of material) exist, check the received material against the
lists 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. Lot
number coding is printed on the heating core of HLT and QLT cables, and on the first electrical jacket of all
other cables. The last 2 digits designate the year of manufacture and the preceding digits represent the
sequential lot numbering format. Example: 35407 would represent lot number 354 manufactured in 2007. Lot
numbers are repeated every 30.5cm (12.0”). Lot numbers can also be located on each shipping spool
identification label.
Storage
Cable and system components should be stored in a clean, dry area. The equipment should be protected from
mechanical damage during storage. The storage temperature range is -40°C to +60°C (-40°F to +140°F).
Withdrawal from Storage
It is recommended that a check out record be kept (in conjunction with the receipt records) on equipment as it is
removed from storage. This will serve to identify material shortages before they happen as project additions
often cause the use of material for other than designated piping.
GA-1765 Rev. 9
Sheet 4 of 22
August 2016
TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
Compliance with Safety Requirements has been assured by compliance with:
NEC® 2014; NFPA 70: National Electrical Code®, International Electrical Code Series
IEEE Std 515™-2011 Standard for the Testing, Design, Installation, and Maintenance of Electrical Resistance
Heat Tracing for Industrial Applications
IEEE Std 515.1™-2012 Standard for the Testing, Design, Installation, and Maintenance of Electrical Resistance
Heat Tracing for Commercial Applications
UL
Certificate No.
Coding
LT: E49805
Class I, Division 2, Group ABCD.
Class II, Division 2, Group FG. Class III
Class I, Zone 1 and 2, Group IIC
QLT: E49805
Class I, Division 2, Group ABCD.
Class II, Division 2, Group FG. Class III
Class I, Zone 1 and 2, Group IIC
HLT: E49805
Class I, Division 2, Group ABCD.
Class II, Division 2, Group FG. Class III
Class I, Zone 1 and 2, Group IIC
XLT: E49805
Class I, Division 2, Group ABCD.
Class II, Division 2, Group FG. Class III
D1-LT: E49805
Class I, Division 1, Group BCD.
Class II, Division 1 Group EFG. Class III
D1-HLT: E49805
Class I, Division 1, Group BCD.
Class II, Division 1 Group EFG. Class III
D1-XLT: E49805
Class I, Division 1, Group BCD.
Class II, Division 1 Group EFG. Class III
FM
Certificate No.
Coding
LT: AM2A4.AF
Class I, Division 2, Group BCD.
Class II, Division 2, Group G. Class III
Class I, Zone 1, Group IIC
HLT: AM2A4.AF
Class I, Division 2, Group BCD.
Class II, Division 2, Group G. Class III
Class I, Zone 1, Group IIC
D1-LT: 3004655
Class I, Division 1, Group BCD
Class I, Zone 1, Group IIB
D1-HLT: 3004655
Class I, Division 1, Group BCD.
Class I, Zone 1, Group IIB
CSA
Certificate No.
Coding
LT: LR 42104
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 T6** (T5**).
HLT: LR 42104
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.
XLT: LR 42104
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.
LLT: LR 42104
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)
CONDITIONS OF SAFE USE
Ordinary Locations:
For ordinary location approvals, please refer to marking on respective product or contact manufacturer.
Hazardous Locations:
TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
GA-1765 Rev. 9
Sheet 5 of 22
August 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 60079-31:2014
IECEx: IEC 60079-0:2011, IEC 60079-30-1:2007, IEC 60079-31:2013
KEMA
Certificate No.
Coding
LT / UT-1: KEMA 07ATEX0124
II 2 G Ex e IIC T6** Gb (LT3, LT23, LT5, LT25)
II 2 D Ex tb IIIC T 80ºC Db
II 2 G Ex e IIC T5** Gb (LT8, LT28, LT10, LT210, UT-1)
II 2 D Ex tb IIIC T 95ºC Db
QLT: KEMA 07ATEX0124
II 2 G Ex e IIC T3 Gb
II 2 D Ex tb IIIC T 195ºC Db
HLT: KEMA 07ATEX0124
II 2 G Ex e IIC T3 Gb
II 2 D Ex tb IIIC T 195ºC Db
XLT: KEMA 07ATEX0124
II 2 G Ex e IIC T3 Gb
II 2 D Ex tb IIIC T 195ºC Db
LLT: DEKRA 15ATEX0064
II 2 G Ex e IIC T5 Gb
II 2 D Ex IIIC T 95ºC Db
UT-2: DEKRA 15ATEX0064
II 2 G Ex e IIC T5 Gb
II 2 D Ex IIIC T 95ºC Db
IECEx
Certificate No.
Coding
LT / UT-1: IECEx KEM 07.0041
Ex e IIC T6** Gb (LT3, LT23, LT5, LT25)
Ex tb IIIC T 80ºC Db
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 T 195ºC Db
LLT: IECEx DEK15.0032
Ex e IIC T5 Gb
Ex tb IIIC T 95ºC Db
UT-2: IECEx DEK15.0032
Ex e IIC T5 Gb
Ex tb IIIC T 95ºC Db
Electrical Data:
Product
Rated Voltage
Maximum Overcurrent
Protection
Maximum Steady-State
Current
LT, QLT, HLT, D1-LT, D1-HLT
100V, 110V, 120V
40 Amps
18 Amps
LT2, QLT2, HLT2, UT-1, D1-LT2,
D1-HLT2
200V, 208V, 220V, 230V, 240V, 277V
40 Amps
18 Amps
XLT
100V, 110V, 120V
40 Amps
25 Amps
XLT2
200V, 208V, 220V, 230V, 240V, 277V
40 Amps
25 Amps
LLT / UT-2
200V, 208V, 220V, 230V, 240V, 277V
60 Amps
38 Amps
Specifications:
LT / UT-1
QLT
HLT
D1-LT
D1-HLT
LLT / UT-2
XLT
Maximum Maintain Temperature
65ºC
(150ºF)
121ºC
(250ºF)
121ºC
(250ºF)
65ºC
(150ºF)
121ºC
(250ºF)
65ºC
(150ºF)
121ºC
(250ºF)
Maximum Continuous Exposure Temperature
(continuous power on)
65ºC
(150ºF)
121ºC
(250ºF)
121ºC
(250ºF)
65ºC
(150ºF)
121ºC
(250ºF)
65ºC
(150ºF)
150ºC
(300ºF)
Maximum Intermittent Exposure Temperature
(1000 hours cumulative exposure)
85ºC
(185ºF)
121ºC
(250ºF)
215ºC
(420ºF)
85ºC
(185ºF)
215ºC
(420ºF)
85ºC
(185ºF)
232ºC
(450ºF)
Temperature Classification
(Cable wattage if applicable)
T6** (3, 5)
T5** (8, 10)
T3
T3
T6** (3, 5)
T5** (8, 10)
T3 (3 - 15)
T2C (18, 20)
T5
T3
Minimum Installation Temperature
-40ºC
(-40ºF)
-40ºC
(-40ºF)
-40ºC
(-40ºF)
-40ºC
(-40ºF)
-40ºC
(-40ºF)
-40ºC
(-40ºF)
-40ºC
(-40ºF)
Minimum Bend Radius at -40ºC (-40°F)
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)
0344 0344 0344 0344 0344
0344
** For more specific details on approvals, please refer to marking on respective product or contact manufacturer.
TULSA, OK 74101 TEL 918-627-5530 FAX 918-641-7336 www.nelsonheaters.com
GA-1765 Rev. 9
Sheet 6 of 22
August 2016
INSTALLATION
General Information
While there are many acceptable ways of installing Nelson Heat Trace electric heating equipment, certain
actions 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 a
voltage 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 wires
is 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 connections
should be sealed against moisture. This includes the use of proper cable sealing kits and the
moisture 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 when
installing self-regulating heater cables.
Do not expose heater cables to temperatures above their maximum ratings. Higher temperatures
can greatly shorten the life of a heater cable.
Immediately replace any damaged heater cable or components. Failure to replace any damaged
components (heater cable, components, or thermal insulation) will result in system failure.
Classified areas (explosive dust or gases) require the use of special electrical components. Any
area having explosive gases (such as chemical / petrochemical installations) or explosive dusts
(such as coal handling or granaries) require special cable, connection components and control
components that are approved for use in these areas. Installation of non-approved products can
result in fires or explosions.
Installation on plastic pipe requires special considerations in selections & installation. See the
Nelson 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).
Scheduling
The installation of the electric heat tracing requires coordination with the piping, insulation, electrical and
instrument 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 heater
cable installation.
Pre-Installation Check
Walk the piping system and plan the routing of the heater cable. This action is used to verify completion of all
instrumentation and mechanical work. All coatings (paint, etc.) and surfaces must be dry before attempting the
heater 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 other
equipment.
Leave an extra 30-46cm (12-18”) of heater cable at all power connections, tee splices and end seal connections to
facilitate ease of working with the connections.
Additional heater cable is required on valves, pipe supports and other equipment. See the installation detail
section 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.com
GA-1765 Rev. 9
Sheet 7 of 22
August 2016
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