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Raychem HWAT

Pentair Raychem HWAT System Installation And Operation Manual

HWAT System
INSTALLATION AND OPERATION MANUAL FOR HOT WATER TEMPERATURE MAINTENANCE SYSTEMS FOR THERMALLY INSULATED PIPES
THERMAL MANAGEMENT SOLUTIONS WWW.THERMAL.PENTAIR.COM
ii
Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD
Raychem HWAT Systems must be installed correctly to ensure proper operation and to prevent shock and fire. Read these important warnings and carefully follow all the installation instructions.
• To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Pentair Thermal Management requirements, agency certifi­cations, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit breakers.
• Approvals and performance are based on the use of Pentair Thermal Management parts only. Do not sub­stitute parts or use vinyl electrical tape.
• Bus wires will short if they contact each other. Keep bus wires separated.
• Connection kits and heating cable ends must be kept dry before and during installation.
• The black heating cable core is conductive and can short. They must be properly insulated and kept dry.
• Damaged bus wires can overheat or short. Do not break bus wire strands when preparing the cable for connection.
• Damaged heating cable can cause electrical arc­ing or fire. Do not use metal attachments such as pipe straps or tie wire. Use only Pentair Thermal Management approved tapes and cable ties to secure the cable to the pipe.
• Do not attempt to repair or energize damaged cable. Remove damaged cable at once and replace with a new length using the Raychem RayClic-S splice kit. Replace damaged connection kits.
• Use only fire-resistant insulation which is compatible with the application and the maximum exposure temperature of the system to be traced.
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Table of Contents
1
General Information 1
1.1 Use of the Manual 1
1.2 Safety Guidelines 2
1.3 Typical HWAT System 2
1.4 Electrical Codes 3
1.5 Approvals 3
1.6 Warranty 4
1.7 Trade Coordination 4
1.8 General Installation Notes 5
1.9 Tools Required 6
2
Heating Cable Verification and Selection 7
2.1 Heating Cable 7
3
Heating Cable Installation 8
3.1 Heating Cable Storage 8
3.2 Pre-Installation Checks 8
3.3 Installation 8
4
Heating Cable Components 14
4.1 General Connection Kit Information 14
5
Control and Monitoring 16
5.1 HWAT-ECO and ACCS-30 Controllers 16
6
Thermal Insulation 17
6.1 Insulating the System 17
6.2 Insulation Installation 17
7
Power Supply and Electrical Protection 20
7.1 Voltage Rating 20
7.2 Circuit Breaker Sizing 20
7.3 Electrical Loading 20
7.4 Ground-Fault Protection 21
8
Commissioning and Preventive Maintenance 22
8.1 Tests 22
8.2 Preventative Maintenance 24
9
Test Procedures 25
9.1 System Tests 25
9.2 Fault Location Tests 31
9.3 Cable and Connection Continuity
iv
10
Test Procedures 34
11
Troubleshooting Guide 38
1
1.1 Use of the Manual
This installation and operation manual is for Raychem HWAT Hot Water Temperature Maintenance systems installed on thermally insulated pipes only.
This manual details how to install and operate an HWAT system. The HWAT System includes the HWAT-R2 heating cables, RayClic connection kits, and the HWAT-ECO or ACS-30 controllers. It is important to review this manual and the following documents with the installing contractor:
• HWAT System Product Selection & Design Guide (H57538)
• HWAT-ECO Data Sheet (H57339)
• ACS-30 Mulitpoint Commercial heat-tracing Control System Data Sheet (H58261)
• HWAT Heating Cable Data Sheet (H57512)
• RayClic Connection System Data Sheet (H57545)
• HWAT-ECO Installation and Operation Manual (H57340)
• ACS-30 Programming Guide (H58692)
For additional information, contact:
Pentair Thermal Management
7433 Harwin Drive Houston, TX 77036 USA Tel: +1.800.545.6258 Tel: +1.650.216.1526 Fax: +1.800.527.5703 Fax: +1.650.474.7711 thermal.info@pentair.com
www.thermal.pentair.com
Important: For the Pentair Thermal Management warranty and agency approvals to apply, the instruc­tions that are included in this manual and product packages must be followed.
1
General Information1 General Information
2
1.2 Safety Guidelines
The safety and reliability of any heat-tracing system depends on the quality of the products selected, and on proper design, installation, and maintenance. Incorrect design, handling, installation, or mainte­nance of any of the system components can cause underheating or overheating of the pipe, or dam­age to the heating cable system, and may result in system failure, electric shock, or fire. The guide­lines and instructions contained in this guide are important. Follow them carefully to minimize these risks and to ensure that the HWAT System performs reliably.
Pay special attention to the following:
• Instructions marked
Important
• Warnings marked
WARNING
1.3 Typical HWAT System
A typical HWAT System is shown is Figure 1. The heating cable is cut to length in the field and is attached to the pipe with glass tape. A power con­nection kit connects the heating cable bus wires to power in a junction box. RayClic tees and splices accommodate pipe branches to connect two or three heating cables together. An end seal kit is used to terminate the end of the heating cable. A controller is used to set the maintain temperature and improve energy savings.
1
General Information
3
Splice
To power distribution panel
Note: Partial pipe insulation
shown here for clarity. All pipes must be fully insulated
End seal
Tee
Thermal
insulation
Heating cable
Pipe temperature sensor
Temperature sensor
Heating cable
Insulation
Glass tape
Power connection
Controller
To BMS
ETL
label
180°
Figure 1: Typical HWAT heating cable system
1.4 Electrical Codes
Section 427 of the National Electrical Code (NEC), and Part 1, Section 62 of the Canadian Electrical Code (CEC), in particular, govern the installation of electrical heat-tracing systems used on hot water pipes. All installations must be in compliance with this and any other applicable national or local codes.
1.5 Approvals
HWAT-R2 heating cable and RayClic connection kits, are UL Listed and CSA certified for use in non-haz­ardous locations. The HWAT-ECO controller is c-UL­us Listed and the ACS-30 controller is c-CSA-us cer­tified (ACS-UIT) and c-UL-us Listed (ACS-PCM2-5) to
1
General Information
4
US and Canadian standards for us in non-hazardous locations. Refer to the specific product data sheets for details.
1.6 Warranty
Pentair Thermal Management standard limited war­ranty applies to all products.
An extension of the limited warranty period to ten (10) years from the date of installation is available if a properly completed on-line warranty form is completed within (30) days from the date of installa­tion. The extension is valid for the HWAT-R2 heating
cable, RayClic connection kits and accessories, but not the HWAT-ECO or ACS-30 controllers. You can access the complete warranty on www.thermal.pentair.com.
1.7 Trade Coordination
Installation of an HWAT System can involve or impact the work of numerous trades. Therefore, effective and early coordination between trades is a critical aspect of all HWAT System Installations. The instal­lation of the heating cable and connections must be properly scheduled, along with the scheduling of the risers and insulation installation.
This guide will assist the installer throughout the installation process and must be reviewed by all affected trades before installation of the HWAT System begins. In a fast-track job, the HWAT System must be considered a critical path item: the pipe, heating cable, insulation, and wallboard must all be installed in the proper order, since the heating cable cannot be installed later. If, for example, the walls go up before the heating cable commissioning tests have been completed, it may be necessary to remove the walls in order to repair a damaged or improperly installed system.
Ensuring that the installation of the HWAT System is included in the overall construction schedule will help ensure a successful and trouble-free installation.
1
General Information
5
1.8 General Installation Notes
Read and observe the instructions in this guide to insure that the HWAT System is installed successfully.
• Accidental damage to the system can be minimized during construction by installing thermal insulation on the pipe immediately after the pipe has been traced and the heating cable has been tested.
• Read all installation documentation to familiarize yourself with the system components.
• Read and follow all warnings and recommenda­tions. All involved trades should review this entire guide and assess the recommendations applicable to their scope of work.
• All heat-traced pipes and equipment must be ther­mally insulated. Insulation is an important part of the HWAT System. For an effective system, the fiberglass insulation must be a specific thickness for each specific pipe size as detailed in Table 2 on page17.
• Do not install the HWAT System below the mini­mum installation temperature.
– The minimum installation temperature for HWAT
heating cables is 0°F (–18°C)
– The minimum installation temperature for HWAT-
ECO is 40°F (5°C).
• Ensure that your water heater temperature is set at your desired pipe maintain temperature.
• Do not energize cable when it is coiled or on the reel.
• Never use metal tie wire or pipe straps to secure heating cables to pipes.
Important: Exceeding 185°F (85°C) for HWAT-R2 will decrease the power output of the heating cables over time.
1
General Information
6
1.9 Tools Required
For installing cable and connection kits:
• Utility knife
• Diagonal cutters
• Cable cutters
• Tape measure
• Screwdriver
• Heat gun or propane torch
For testing the heating cable:
• Megohmmeter 2500 Vdc
• Multimeter (voltage, resistance and capacitance)
1
General Information
7
2
Heating Cable Verification and
Selection
2.1 Heating Cable
The HWAT System includes HWAT-R2 heating cable designed to maintain the piping at specific tempera­ture settings with the use of the HWAT-ECO or ACS­30 controllers. Figure 2 shows the construction of the heating cable.
Nickel-plated copper bus wires
Self-regulating conductive core
Polymer-coated aluminum wrap
Tinned-copper braid
Modified polyolefin outer jacket
Modified polyolefin inner jacket
Figure 2: HWAT-R2 heating cable
The minimum control setpoint for HWAT-R2 is 105°F (40°C). The maximum control setpoint for HWAT-R2 is 140°F (60°C).
2 Heating Cable Verification and
Selection
8
3
Heating Cable Installation
3.1 Heating Cable Storage
• Store the heating cable in a clean, dry location. Temperature range: 0°F (–18°C) to 140°F (60°C).
• Protect the heating cable from mechanical damage.
3.2 Pre-Installation Checks
Check materials received:
• Review the heating cable design and compare the list of materials to the catalog numbers of the heating cables and connection kits received to confirm that the proper materials are on site. The heating cable type is printed on its jacket.
• The HWAT System is limited to 208 V or 240 V ser­vice when using the HWAT-ECO controller. When using the ACS-30 controller the voltage range is 208–277 V. Ensure that the service voltage avail­able is correct.
• Inspect the heating cable and connection kits to ensure there is no in-transit damage.
• Verify that the heating cable jackets are not dam­aged by conducting the insulation resistance test (refer to Section 9) on each reel of cable. Do not power the heating cable when it’s on the reel.
Check piping to be traced:
• Make sure all mechanical pipe testing (i.e. hydro­static testing/purging) is complete and the system has been cleared by the client for tracing.
• Walk the system and plan the routing of the heat­ing cable on the pipe.
• Inspect the piping and remove any burrs, rough surfaces or sharp edges.
3.3 Installation
• Pay out the heating cable, loosely stringing it along the pipe, making sure that the cable is always next to the pipe when crossing obstacles.
• Install HWAT heating cable in straight runs along the pipe. Spiraling the heating cable is not
necessary.
3 Heating Cable Installation
9
3
Heating Cable Installation
• If the cable is on the wrong side of an obstacle such as a crossing pipe or I-beam, you will need to reinstall it or cut and splice it.
• When installing the heating cable, the cable must not be compressed or pinched between two objects. Wall and floor penetrations and pipe hangers are particular areas of concern.
Figure 3: Protecting the heating cable in floor penetrations
• Run insulation through the pipe hanger ensuring that the pipe is not resting on the heater.
Figure 4: Pipe hanger with heating cable
• When making floor or wall penetrations, make sure the hole is large enough to accommodate the pipe and the thermal insulation. When sealing around pipes at floor penetrations, avoid damag­ing or cutting the heating cable, or pinching it between the pipe and the concrete.
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3
Heating Cable Installation
• The heating cable must not be embedded directly in the sealing material; the pipe should have ther­mal insulation over it (if allowed by local codes) or the heating cable should be run through the pen­etration in a tube or conduit. If the conduit must be sealed, use a pliable fire-resistant material (Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame­Safe) that can be removed if necessary.
Figure 5: Multiple pipe floor penetration
• On vertical piping groups, run the heating cable along the inside of the pipe close to other pipes so it will not be damaged if the pipe hits the side of the floor penetration. Run the heating cable over the outside of the pipe support. Do not clamp the heating cable to the pipe with the pipe support.
• In high-rise construction it may be necessary to install the HWAT System 10 or 12 floors at a time to fit into the construction schedule. If so, the end of the heating cable should be sealed with a RayClic-E end seal and placed in an accessible location. This allows testing of one part of the heating cable at a time, and allows splicing it to another section when the system is complete.
Paying out the cable:
• Use a reel holder that pays out smoothly with little tension. If the heating cable snags, stop pulling.
• Keep the heating cable strung loosely but close to the pipe being traced to avoid interference with supports and equipment.
• Meter marks on the heating cable can be used to determine cable length.
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3
Heating Cable Installation
• Protect all heating cable ends from moisture, con­tamination and mechanical damage.
Figure 6: HWAT cable layout
When paying out the heating cable, AVOID:
• Sharp edges
• Excessive pulling force or jerking
• Kinking and crushing
• Walking on it, or running over it with equipment
WARNING: Fire and shock hazard. Do not install damaged cable. Connection kits and cable ends must be kept dry before and during installation.
Positioning heating cables
If possible, position the heating cable on the lower section of the pipe, at the 4 or 8 o’clock positions, as shown below, to protect it from damage.
Figure 7: Cable positioning
12
3
Heating Cable Installation
Attaching the heating cable
Starting from the end opposite the reel, tape the heating cable to the pipe every 2 feet. Work back to the reel. Leave extra heating cable at the power con­nection, at all sides of splices and tees to allow for future servicing. See Table 1 on page15.
• Install heating cable connection kits immediately after attaching the heating cable. If immediate installation is not possible, protect the heating cable ends from moisture.
Bending the cable
When positioning the heating cable on the pipe, do not bend tighter than 1/2” radius. The heating cable does not bend easily in the flat plane. Do not force such a bend, as the heating cable will be damaged.
1/2"
Figure 8: Bending technique
Crossing the cable
HWAT heating cables are self-regulating and may be overlapped whenever necessary without overheating or burning out.
Cutting the cable
Cut the heating cable to the desired length after it is attached to the pipe. HWAT can be cut to length without affecting the heat output per foot.
Attachment tapes
To ensure that the heating cable is in full contact with the pipe, use tape to attach the heating cable to the pipe every 2 ft (.6 m). Use Raychem GT-66 attachment tape. One roll will handle approximately 50 ft (15 m) of cable.
13
3
Heating Cable Installation
Figure 9: Attaching the heating cable
To ensure sufficient heat transfer AT-180 aluminum tape must be used to install the heating cable on plastic pipes as shown in Figure 10.
WARNING: Do not use metal attachments such as pipe straps or tie wire. Do not use vinyl-based electrical or duct tape. Use only Pentair Thermal Management approved tapes.
Raychem HWAT heating cable
Continuous AT-180 alluminum tape over heating cable
Rigid plastic pipe
Thermal insulation
Figure 10: Installed on plastic pipe with aluminum tape
Raychem GT-66 glass tape
2 ft.
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4
Heating Cable Components
4.1 General Connection Kit Information
Raychem RayClic connection kits must be used with HWAT-R2 heating cable. A complete circuit requires a power connection and an end seal. Splices and tees and other connection kits are used as needed. Use the HWAT System Design Guide (H57510) to select appropriate connection kits. Installation instructions are included with every connection kit. Steps for preparing the heating cable and installing connection kits must be followed. HWAT connection kit locations should be noted on “As Built” drawings. Connection kit locations should be marked on the outside of the insulation cladding with the labels provided in the kits.
RayClic-PT
powered
tee
RayClic-PC
powered connection
RayClic-S
splice
RayClic-X
cross tee
RayClic-T
tee
RayClic-PS
powered
splice
RayClic-LE
lighted end seal
RayClic-E
end seal
Alternate
lighted end seal
Alternate
connection kits
HWAT heating cable
Figure 11: RayClic connection system
Connection Kit Installation
• When practical, mount the connection kits on top of the pipe. All heating cable connections must be mounted above grade level.
• Leave excess cable to serve as a service loop at all connection kits (power, splice, cross or tee) for future maintenance, as detailed in Table 1. The additional heating cable will easily pay for itself in time savings if it becomes necessary to check or replace a connection kit after installation. Splices and tees should have a service loop on each of the heating cables entering the connection kit.
4 Heating Cable Components
15
4
Heating Cable Components
TABLE 1: SERVICE LOOPS FOR EACH CONNECTION KIT
RayClic-PC 1 2.0 ft (0.6 m) 2 ft (0.6 m) RayClic-S 2 1.0 ft (0.3 m) 2 ft (0.6 m) RayClic-T 3 1.0 ft (0.3 m) 3 ft (0.9 m) RayClic-X 4 1.0 ft (0.3 m) 4 ft (1.2 m) RayClic-PS 2 1.5 ft (0.5 m) 3 ft (0.9 m) RayClic-PT 3 1.3 ft (0.4 m) 4 ft (1.2 m) RayClic-E 1 NA NA RayClic-LE 1 2.0 ft (0.6 m) 2.0 ft (0.6m)
Connection # of cable Cable length/ Total cable length kit name connections/kit connection (Service loop)
• All power connection kits must be installed in accessible locations. Access to splices, tee kits and end seals is recommended for future modifi­cation or maintenance but is not required.
• Locate junction boxes for easy access but not where they may be exposed to mechanical abuse.
• Heating cables must be installed over, not under, pipe straps used to secure components.
WARNING: The black heating cable core is elec­trically conductive and can short. It must be proper­ly insulated and kept dry. Damaged bus wires can overheat or short.
WARNING: Fire and shock hazard. Raychem brand specified components must be used. Do not substitute parts or use vinyl electrical tape.
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5
Control and Monitoring
5.1 HWAT-ECO and ACS-30 Controllers
The Raychem HWAT-ECO controller is designed for use only with HWAT-R2 heating cables and must be used to ensure proper water temperature.
Refer to the HWAT-ECO Installation and Operation Manual (H57340) for the installation and operation instructions of the controller.
Figure 12: HWAT-ECO controller
The ACS-30 Control System is also approved for use with HWAT-R2 heating cable. Refer to the ACS-30 Programming Guide (H58692) for the installation and operating instructions of the control system.
Heat-tracing system
ACCS-UIT2
(Optional)
RMM2
COMMON ALARM
POWER CONTROL
MODULE ACCS-PCM-5
COMMON ALARM
POWER CONTROL
MODULE ACCS-PCM-5
ACCS-PCM2-5 ACCS-PCM2-5
Figure 13: ACS-30 Control System
5 Control and Monitoring
17
6
Thermal Insulation
6.1 Insulating the System
Pipes must be insulated with the correct thermal insulation to maintain the desired pipe tempera­tures. For pipes 1 1/4 inches and smaller, use insu­lation that is oversized by 1/4 inch to allow room for insulating over the heating cables. The thermal insulation schedule is shown in Table 2.
TABLE 2: FIBERGLASS INSULATION SCHEDULE
1/2 3/4 1/2 3/4 1 1 1 1 1/4 1 1 1/4 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 2 2 2 2 1/2 2 1/2 2 1/2 3 3 3
Copper pipe IPS insulation Insulation size (in) size (in) thickness (in)
Important: For pipes 3 inches and larger, the thickness of insulation can be equal to the pipe diam­eter with one run of heating cable or 1/3 the pipe diameter with two runs of heating cable.
6.2 Insulation Installation
• Before insulating the pipe, visually inspect the
heating cable and connection kits to ensure they are properly installed and there are no signs of damage. Damaged cable or connection kits must be replaced.
• Check that the insulation type and thickness com-
plies with the insulation schedule detailed in Table
2.
• Insulate the pipes immediately after the heating
cable is installed and has passed all tests to mini­mize damage to the cable.
• Insulate the pipe at floor and wall penetrations.
Failure to do so will cause cold spots in the water system and could lead to damage to the heating cable. If local codes do not allow this, the heating cable should be run through a conduit or channel before the firestop is installed. Use a fire-resistant
6 Thermal Insulation
18
6
Thermal Insulation
sealing compound such as Dow Corning Fire Stop, 3M Fire Barrier, or T&B Flame-Safe.
• Do not use staples to close the insulation. Use tape or the adhesive-lined edge of the insulation to ensure that the seam remains sealed. Staples can damage the HWAT heating cable.
Figure 14: Sealing the insulation seam
• When installing splice, tee and end seal kits under­neath the thermal insulation, mark the location of splices, tees, and end seals on the outside of the insulation, with labels provided in the kits, while installing the insulation. Use large diameter insu­lation or sheets to cover splices, tees, or service loops.
Figure 15: Installing Connection kits above insulation.
• All power connection kits must be mounted above the thermal insulation.
19
6
Thermal Insulation
• Splice and Tee connection kits may be installed above the insulation using the optional SB-04 mounting bracket. The pipe and heating cable ser­vice loops must be fully insulated as shown above.
Figure 16: Installing connection kits below insulation.
• Make sure that all heat-traced piping, fittings, wall penetrations, and branch piping are insulated. Correct temperature maintenance requires proper­ly installed and dry thermal insulation. Uninsulated sections of pipe can result in cold spots.
• After installing insulation, electrical codes require that you install “Electric Traced” labels along the piping at suitable intervals (10-foot intervals rec­ommended) on alternate sides.
WARNING: Use only fire-resistant insulation,
such as fiberglass.
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7
Power Supply and Electrical
Protection
7.1 Voltage Rating
Verify that the supply voltage is either 208 or 240 volts as specified by the HWAT System design.
7.2 Circuit Breaker Sizing
Circuit breakers must be sized using the cable lengths shown in Table 3. Do not exceed the maxi­mum circuit length shown for each breaker size. When using the HWAT-ECO controller install circuit breakers that incorporate 30-mA ground-fault circuit protection, or provide equivalent levels of ground­fault protection. Ground-fault protection is integrat­ed into the ACS-30 control system so no additional protection is required.
TABLE 3: MAXIMUM CIRCUIT LENGTH IN FEET METERS
15 Amp 250 (75) 20 Amp 330 (100) 30 Amp 500 (150)
Breaker Size HWAT-R2
7.3 Electrical Loading
Over-current devices are selected according to the heating cable type, supply voltage, and circuit length to allow for start-up. The design specifies the size and type of over-current device. Piping systems are seldom installed exactly as the drawings show. If changes are made, make sure that all circuit lengths comply with Table 3.
7 Power Supply and Electrical
Protection
21
7
Power Supply and Electrical
Protection
7.4 Ground-Fault Protection
If the heating cable is improperly installed, or physi­cally damaged to the point that water contacts the bus wires, sustained arcing or fire could result. If arcing does occur, the fault current may be too low to trip conventional circuit breakers. Pentair Thermal Management, the U.S. National Electrical Code, and the Canadian Electrical Code require both ground-fault protection of equipment and a ground­ed metallic covering on all heating cables. All HWAT heating cables meet the metallic covering require­ments. Ground-fault protection must be provided by the installer.
WARNING: To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Pentair Thermal Management requirements, agency certifications, and national electrical codes, ground­fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit breakers.
WARNING: Disconnect all power before making connections to the heating cable.
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8
Commissioning and Preventive
Maintenance
Pentair Thermal Management requires a series of commissioning tests be performed on the HWAT System. These tests are also recommended at regu­lar intervals for preventive maintenance. Results must be recorded and maintained for the life of the system, utilizing the “Installation and Inspection Record” (refer to Section 11). Submit this manual with initial commissioning test results to the owner.
Ensure that your water heater and mixing valve temperature are set at your desired pipe maintain temperature.
Important: Exceeding185°F (85°C) for HWAT-R2 will decrease the power output of the heating cables over time.
8.1 Tests
A brief description of each test is found below. Detailed test procedures are found in Section 9.
Visual inspection
Visually inspect the pipe, insulation, and connec­tions to the heating cable for physical damage. Check that no moisture is present, electrical con­nections are tight and grounded, insulation is dry and sealed, and control and monitoring systems are operational and properly set. Damaged heating cable must be replaced. Once the heating cable is installed any repairs to pipes should be done very carefully. The heater must be shielded from exces­sive heat. Temperatures greater than 185°F will permanently damage the affected section of heater. Damage due to excessive external heat may or may not effect the operation of the entire circuit. A torch must not be used on the pipe, pipe hangers, or riser clamps after the heating cable has been installed on the pipe because this can cause permanent dam­age to the heating cable (even if it does not appear to be burned). Use a saw, not a torch, to cut riser clamps. If use of a torch is unavoidable, cut the fiberglass tape that holds the HWAT cable to the pipe on either side of the area to be heated, and pull the cable away from the pipe. Make sure you do not cut the HWAT cable. Shield the cable from the flame.
8 Commissioning and Preventive
Maintenance
23
8
Commissioning and Preventive
Maintenance
Charred or damaged cable must be replaced to avoid the risk of arcing or fire.
Figure 17: Shielding the cable from the flame
Circuit length verification (capacitance test)
The installed circuit length is verified through a capacitance measurement of the HWAT heating cable. Compare the calculated installed length against the system design. If the calculated length is shorter than the system design, confirm all con­nections are secure and the grounding braid is continuous.
Insulation Resistance
Insulation Resistance (IR) testing is used to verify the integrity of the heating cable inner and outer jackets. IR testing is analogous to pressure testing a pipe and detects if a hole exists in the jacket.
Power check
The power check is used to verify that the system is generating the correct power output. This test can be used in commissioning to confirm that the circuit is functioning correctly. For on-going maintenance, compare the power output to previous readings.
The heating cable power output per foot is calculated by dividing the total wattage by the total length of a circuit. The current, voltage, operation temperature and length must be known. Circuit length can be determined from “as built” drawings, meter marks on the cable or with the capacitance test. The watts per foot can be compared to the heating cable out-
24
8
Commissioning and Preventive
Maintenance
put in Section 9 for an indication of heating cable performance:
Ground-fault test
Test all ground-fault breakers per manufacturer’s instructions.
Cable and Connection Continuity
Cable and connection continuity test verifies all the electrical connections are made properly. Pentair recommends conducing this test as the cable is installed to identify any potential problems imme­diately. This test can also be conducted after the entire cable run is installed but before end seals are applied.
8.2 Preventative Maintenance
Recommended maintenance for HWAT Systems consists of performing the system tests for commis­sioning, and on a regular basis. Procedures for these tests are described in Section 9. Systems should be checked each year. If the HWAT System fails any of the tests, refer to Section 10 for trouble shooting assistance. Make the necessary repairs and replace any damaged cable immediately. De-energize all cir­cuits that may be affected by maintenance. Protect the heating cable from mechanical or thermal dam­age during maintenance work.
Maintenance records
The “Installation and Inspection Record,” (refer to Section 11) should be filled out during all mainte­nance and repairwork and kept for future reference.
Repairs
Use only HWAT heating cable, HWAT-ECO or ACS-30 controller, and RayClic connection kits when replac­ing any damaged heating cable system. Repair the thermal insulation to original condition or replace with new insulation, if damaged. Retest the system after all repairs or replacements.
WARNING: Damage to cables or components can cause sustained electrical arcing or fire. Do not attempt to repair damaged heating cable. Do not energize cables that have been damaged by fire. Replace damaged cable at once by removing the entire damaged section and splicing in a new length using the appropriate RayClic splice kits.
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9
Test Procedures
9.1 System Tests
The following tests must be done after installing the RayClic connection kits, but before the thermal insulation is applied to the pipe:
1. Visual inspection
2. Insulation resistance test
After the thermal insulation has been installed on the pipe, the following tests must be performed:
1. Visual inspection
2. Insulation resistance test
3. Circuit length verification (capacitance test)
4. Power test
5. Temperature test
All test procedures are described in this manual. It is the installer’s responsibility to perform these tests or have an electrician perform them. Record the results in the Installation and Inspection Record in Section 11.
1. Visual inspection test
• Check inside all power, splice and tee kits for proper installation, overheating, corrosion, mois­ture, or loose connections.
• Check the electrical connections to ensure that ground and bus wires are insulated over their full length.
• Check for damaged, missing or wet thermal insulation.
• Check that end seals, splices, and tees are prop­erly labeled on insulation cladding.
• Check HWAT-ECO or ACS-30 controller for proper setpoint and operation. Refer to the HWAT-ECO Installation and Operation Manual or ACS-30 Programming Guide for details.
2. Insulation Resistance test
Frequency
Insulation resistance testing is required during the installation process, and as part of regularly sched­uled maintenance, as follows:
9 Test Procedures
26
9
Test Procedures
• Before installing the cable
• Before installing components
• Before installing the thermal insulation
• After installing the thermal insulation
• Prior to initial start-up (commissioning)
• As part of the regular system inspection
• After any maintenance or repair work
Procedure
Insulation resistance testing (using a megohm­meter) should be conducted at three voltages; 500, 1000, and 2500 Vdc. Potential problems may not be detected if testing is done only at 500 and 1000 volts. First measure the resistance between the heating cable bus wires and the braid (Test A), then measure the insulation resistance between the braid and the metal pipe (Test B). Do not allow test leads to touch junction box, which can cause inaccurate readings.
Important: System tests and regular maintenance procedures require that insulation resistance testing be performed. Test directly from the HWAT-ECO, ACS­30 or the junction box closest to the RayClic-PC.
WARNING: Fire hazard in hazardous locations. Insulation resistance test can produce sparks. Be sure there are no flammable vapors in the area before performing this test.
Insulation resistance criteria
A clean, dry, properly installed circuit should measure thousands of megohms, regardless of the heating cable length or measuring voltage (500–2500Vdc). The following criteria are provided to assist in determining the acceptability of an installa­tion where optimum conditions may not apply.
• All insulation resistance values should be greater
than 1000 megohms. If the reading is lower, con­sult Section 10, Troubleshooting Guide.
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