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RaychemRaychem
™
ElectroMelt
System
D E S I G N GUIDED E S I G N GUIDE
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ElectroMelt System
Design Guide
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ElectroMelt System
Guide Design
Table of Contents
Introduction
ElectroMelt Products
ElectroMelt System Design
Design Steps
Overview 5
How to Use This Guide 5
How to Use the Installation and Operation Manual 5
System Description 5
Codes 5
Warranty 6
Raychem Self-Regulating Heating Cable Technology 6
Self-Regulating Heating Cable 7
Components 7
Accessories 7
Basic ElectroMelt System Design 9
Design for Standard Applications 9
Design for Nonstandard Applications 9
Step 1. Determine Heating Cable Spacing 10
Step 2. Lay out Heating Cable 10
Step 3. Determine Electrical Parameters 11
Installation and Testing 14
Supplemental Design Information
Project Submittal Data
Product Data Sheets
Factors Affecting Snow-Melting System Design 15
Performance Requirements 16
Anti-Icing Performance Requirements 16
Snow-Melting Performance Requirements 17
Electrical Performance Requirements 20
Submittal Data Form 23
Heating Cable 25
Power Connection and End Seal Kit, and Splice Kit 26
Expansion Joint Kit 27
Junction Box 28
Automatic Snow Controller 29
Ground-Fault Protection Device 30
Contactor 31
Ambient Sensing Thermostat 32
Accessories 33
Insulation Resistance Tester 34
Jacket Repair Kit 35
Condensed Specification Guide
Appendix A
3
37
Warranty; Suitability 39
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ElectroMelt System
Design Guide
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ElectroMelt System
Design Guide
Table of Contents
Overview
How to Use This Guide
How to Use the Installation
and Operation Manual
This guide presents Raychem's recommendations for designing and ElectroMelt
snow-melting and anti-icing system for use in concrete pavement. Do not use
the ElectroMelt system buried in asphalt.
WARNING: ElectroMelt heating cable and associated system components
are electrical devices that must be designed and installed properly.
Follow all design, installation, assembly, and test instructions to ensure
proper operation and to prevent shock or fire. Warnings are highlighted
with in the manual.
Following these recommendations will result in a reliable, energy-efficient system.
For information regarding other heat-tracing applications, contact your Raychem
representative.
The ElectroMelt System Design Guide provides instructions to all engineering
disciplines and trades involved in the design and installation of an Electro Melt
System. It provides design and performance data, electrical sizing information,
and heating-cable layout suggestions.
If, after reading this design guide, you still have questions concerning the design
of an ElectroMelt system, contact your Raychem representative. For instructions
on installing an ElectroMelt system be sure to read and follow the ElectroMelt
Installation and Operations Manual (H53392).
In addition to this design guide, electrical and mechanic design engineers
should also use the ElectroMelt Installation and Operations Manual as a general
reference document during the design of an ElectroMelt system. They should
use it during installation as well to coordinate the work of the trades involved.
During and after startup, they should use the manual to record important design
and test data.
System Description
Codes
Before design work begins, designers should review appropriate sections of the
manual with the Raychem representative. Design engineers will obtain design
details from the manual as well as trade coordination and testing requirements,
all of which should be addressed in the project specification to ensure a successful snow-melting or anti-icing system.
The general contractor or construction manager should arrange a meeting with
the other trades to discuss installation of the ElectroMelt system prior to the
system installation. At this meeting, each trade should be given the appropriate
section of the manual, and any questions regarding coordination and timing
should be addressed.
The ElectroMelt system performs snow-melting and anti-icing in concrete pavement.
The backbone of the system is the EM2-XR self-regulating heating cable. As the
illustration on the next page indicates, the cable's output is reduced automatically as
the pavement warms, so there is no possibility of failure due to overheating.
Elements of an ElectroMelt system include the EM2-XR heating cable, termination
and splice components, and accessories, such as a junction box, automatic controls,
ground-fault protection device, power contactor, and the tools necessary for a complete installation. This guide provides a data sheet for each element.
Installation of the ElectroMelt System is governed by Article 426 of the National
Electrical Code, which requires the use of a ground-fault protection device (GFPD).
Your installation must also comply with all applicable local codes and standards.
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Page 6
ElectroMelt System
Design Guide
Introduction
Warranty
The instructions in this guide and in the product packages must be followed.
The Raychem warranty will not apply in the event of damage caused by accident, misuse, neglect, alteration, or improper installation, repair, or testing. For
the complete warranty statement refer to Appendix A.
Raychem Self-Regulating
Heating-Cable Technology
At low temperature, there are many conducting paths, resulting in
high output and rapid pavement heat-up. Heat is generated only
when it is needed and precisely where it is needed.
At moderate temperature, there are fewer conducting paths
because the heating cable efficiently adjusts to weather conditions
by decreasing output-eliminating any possibility of concrete overheating.
At high temperature, there are fewer conducting paths and output is
correspondingly lower-conserving energy during operation.
6
Page 7
ElectroMelt System
Design Guide
ElectroMelt Products
Self-Regulating Heating Cable
Components
The ElectroMelt EM2-XR heating cable is embedded in concrete pavement to
melt snow and ice that might otherwise accumulate on the surface. The heating
cable responds to the local concrete temperature, increasing output when
concrete temperature drops and decreasing heat output when concrete temperature rises. The self-regulating heating cable cannot overheat and destroy itself,
even if overlapped in the concrete, and therefore does not require the use of
overlimit thermostats. For more detailed information on this cable, see page 25.
Description Catalog #
Self-regulating heating cable EM2-XR
Raychem provides all components necessary for system installation. They
are available from Raychem in the kits listed below.
Note: ElectroMelt components must be used in order to satisfy code, approval
agencies, and warranty requirements. Installation instructions included with the
kits must be followed. For more detailed information on these components, see
pages 26 and 27.
Description Catalog #
Power connection kit EMK-XP
(includes one end seal)
Splice kit EMK-XS
Expansion joint kit EMK-XEJ
Accessories
Raychem also provides the following accessories for the ElectroMelt system:
Description Catalog #
Junction box EMK-XJB
Automatic snow controller SD-CIT-1
Ground-fault protection device TraceGuard 277™
Contactor E104
Ambient sensing thermostat AMC-1A
Cable ties EMK-CT
Cable markers EMK-MARK
Crimping tool EMK-XT
Propane torch FH-2616A-1
Megohmeter EMK-MEG
Jacket repair kit EMK-XJR
For more detailed information on these accessories, see pages 28 to 35.
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Page 8
ElectroMelt System
Design Guide
Introduction
Snow Sensor and Controller
SD-CIT-1 (optional)
Power Connection and End Seal
EMK-XP
Heating Cable Splice
EMK-XS
Component Catalog # Usage Heating cable allowance
Power connection kit (includes end seal) EMK-XP One per circuit 3 feet
Splice kit EMK-XS As required 1 foot
Expansion joint kit EMK-XEJ One per expansion joint crossing 1½ feet
Cable ties EMK-CT One per foot of cable used —
Snow controller (optional) SD-CIT-1 One per system —
Expansion Joint Kit
EMK-XEJ
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Page 9
ElectroMelt System
Design Guide
Supplemental Design
Information
Basic ElectroMelt System Design
Design for Standard Applications
The power produced by ElectroMelt EM2-XR heating cable installed on 12-inch
centers is adequate for the majority of concrete-pavement snow-melting and
anti-icing systems. For this reason, the design steps in the next section and
information in other ElectroMelt literature are based on this spacing.
In addition, information in this guide and in other ElectroMelt literature is based
on the standard application of the EM2-XR heating cable in concrete pavement
poured on grade only.
ElectroMelt system literature includes the following:
• ElectroMelt System Brochure H53391
• ElectroMelt System Design Guide H53393
• ElectroMelt System Installation and Operation Manual H53392
The basic ElectroMelt system design for standard applications on grade is adequate for most snowfall and icing conditions, allowing no snow accumulation 97
percent of the time. The design keeps the pavement surface at or above freezing when the air above the pavement is a 5°F and the wind is steady at 10
miles per hour or less.
Because the design information in this guide applies only to standard concrete
pavement poured on grade, it should not be used for other applications.
Design Requirements and Assumptions
The design for standard applications is based on the following assumptions with
regard to the concrete and the heating cable:
Design for Nonstandard Applications
9
Concrete: Heating cable
• 4 to 6 inches thick • 12-inch cable spacing
• Placed on grade • Secured to reinforcing steel or mesh
• Standard density • Located 1 ½ to 2 inches below
finished surface
WARNING: Concrete cracks that extend to the depth of the cable may
damage the cable and create the risk of fire. Install the cable in pavement
or slabs that have been designed for long-term structural integrity.
Increased Power and Performance Requirements
Some applications and some locations require more snow-melting power or
more complete anti-icing protection than the standard 12-inch spacing provides.
For these cases, refer to the Supplemental Design Information section of this
guide for more detailed performance information and design data for nonstandard applications.
For nonstandard applications, contact your Raychem representative for assistance with your design. Using proprietary computer modeling based on a finite
difference program for nonstandard applications. Raychem can design the
appropriate system for a nonstandard application.
The following are some nonstandard applications:
• concrete thinner than 4 inches
• concrete thicker than 6 inches
• lightweight concrete
• concrete with pavers thicker than 1 ½ inches
• ramps and walkways with air below
• nonconcrete pavements
• concrete without reinforcing
• retrofitting of heating cable to existing pavement
Page 10
ElectroMelt System
Design Guide
Design Steps
Step 1.
Determine Heating-Cable Spacing
Step 2.
Lay Out Heating Cable
For most standard applications, ElectroMelt EM2-XR heating cable may be
installed on 12-inch centers. The design steps that follow are based on 12-inch
spacing.
Snowfall and icing conditions vary widely with location. For this reason, heating
cable installed on 12-inch centers may not provide adequate performance for
every location.
To determine correct heating-cable spacing for a particular location, consult the
Supplemental Design Information section of this guide.
For uniform heating, arrange the heating cable in a serpentine pattern that covers
the area. Space the cable on 12-inch centers or use alternate spacing determined
by consulting the Supplemental Design Information section of this guide.
Maintain the heating cable spacing in the design within 1 inch.
Use these symbols to indicate the heating cable and components:
Power Connection
End Seal
Splice
Do not route the heating cable closer than 4 inches to the edge of the pavement, drains, anchors, or other material in the concrete.
The water resulting from the melted snow or ice should run into a drain or off to
a safe area.
Arrange the heating cable so that both ends of the cable terminate in an aboveground, UL Listed or CSA Certified weatherproof junction box. The following are
guidelines for this procedure:
• Mount the heating-cable junction box above grade to prevent water entry
Use an EMK-XJB or equivalent UL Listed or CSA Certified weatherproof
junction box.
• Protect the heating cable from the pavement to the junction box by installing
heating cable inside individual 1-inch rigid metal conduits. Minimize the
length of the protective conduit. Do not penetrate building walls or floors with
the protective conduit or insulate the conduit.
• Extend the conduit approximately 6 inches into the concrete for support.
• Provide bushings on both ends of each conduit.
• Do not install more than one run of heating cable per conduit.
• Minimize the length of the conduit.
• Do not insulate the conduit.
• Do not penetrate building floors or walls with the conduit.
If possible avoid crossing expansion, crack-control, or other pavement joints.
Where crossing a joint is unavoidable, use the EMK-XEJ expansion joint kit to
protect the heating cable.
Use these symbols to indicate the location of the joints:
Expansion Joint
Crack-control joint
Expansion joint kit
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Page 11
ElectroMelt System
Design Guide
Design Steps
Calculate the total length of heating cable required as:
Total heating Heated area (ft²) x 12 end component
cable length Heated cable spacing (in.) allowancesª allowances
ªEnd allowance is the length of heating cable installed between the heated
area and the power connection junction box, measured in feet.
b
Component allowances measured in feet (see page 8).
=
Junction Box
EMK-XJB
+
+
b
Step 3.
Determine Electrical Parameters
6" (S/2)
6" (S/2)
This section will help you determine the electrical parameters for an ElectroMelt
system. To determine the demands an ElectroMelt system will place on your
electrical equipment, refer to "Electrical Performance Requirements" in the
Supplemental Design Information section of this guide.
Electrical Protection
The installation and design of the ElectroMelt System is governed by Article
426 of the National Electrical Code. Your installation must also comply with all
applicable local codes and standards. To comply with the National Electrical
Code, use a 30-mA ground-fault protection device (GFPD).
12" (S)
S = Heating cable spacing
1" Conduit
6"
11
Warning: To minimize the danger of fire from sustained electrical arcing
if the heating cable is damaged or improperly installed, use a ground-fault
protection device with a 30-mA trip level. Electrical fault currents may be
too small to trip conventional circuit breakers.
Voltage
Standard design information is provided for operation at 208 Vac. The allowable
range of voltage for EM2-XR is 208 to 277Vac. Using a voltage higher than
208 volts results in slightly higher surface temperatures and allows longer maximum circuit lengths as indicated in Tables 1 and 2.
Page 12
ElectroMelt System
Design Guide
Design Steps
Circuit Breaker Rating
Use thermal-magnetic circuit breakers rated no greater than 50 amperes for
overcurrent protection. Use the lowest rated circuit breaker compatible with the
circuit lengths to be used. Use Tables 1 or 2 below to determine maximum circuit length.
Table 1. Maximum Heating Cable Circuit Length for Startup at 0°F (in feet)
Circuit
breaker 208 V 220 V 240 V 277 V
50 amp 245* 250* 265* 300
40 amp 200* 200* 210* 240
30 amp 145 150 160 180
20 amp 100 100 110 120
15 amp 75 75 80 90
Heating cable operating voltage
Table 2. Maximum Heating Cable Circuit Length for Startup at 20°F (in feet)
Circuit
breaker 208 V 220 V 240 V 277 V
50 amp 265* 270* 285* 325
40 amp 210* 215* 230* 260
30 amp 160 165 170 195
20 amp 105 110 115 130
15 amp 80 80 85 100
*Contact RayChem for assistance, or change the voltage to 277 volts and use
TraceGuard 277. (40 and 50 amp GFPD's are not standard for these voltages).
Ground -Fault Protection Devices (GFPDs)
Use a RayChem TraceGuard 277 GFPD for 277-volt applications, up to 50
amps. Equivalent 30mA ground-leakage protection is provided by Westinghouse GFPDs or Square-D QO-EPD ground-leakage circuit breakers at 208
and 240 volts (30-amp maximum rating).
Heating cable operating voltage
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Page 13
ElectroMelt System
Design Guide
Design Steps
Controls
Three control methods are commonly used with snow-melting and anti-icing
systems. All three methods require a contactor as shown in the diagram on the
next page. The contactor must be sized to carry the load. Each method offers a
tradeoff of initial cost against energy efficiency. Choose the one the best meets
the project performance and requirements.
Automatic snow controller
An automatic snow controller offers the highest system reliability and the lowest
operating cost. Raychem's SD-CIT-1 automatic snow controller detects both
precipitation and low temperature and automatically energizes the ElectroMelt
snow-melting system. When precipitation stops or the temperature rises above
freezing, the controller de-energizes the snow-melting system. However, the
pole-mounted sensor cannot detect runoff from adjacent areas, snow which is
tracked into the heated area, or freezing dew.
Ambient thermostat
An ambient thermostat can be used to energize the system whenever the ambient temperature is below freezing. Raychem's AMC-1A ambient thermostat
should be used whenever the design objective is to prevent surface icing under
all conditions (anti-icing). Since the number of hours of freezing temperatures is
two to ten times the number of snowfall hours, the energy usage of a system
under control of an ambient thermostat is two to ten times that of a system controlled by an automatic snow controller.
Manual control
Under manual control the system is operated by a manual switch controlling the
system power contactor. In some small installations, the system may be controlled directly by operating the circuit breakers.
13
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ElectroMelt System
Design Guide
Design Steps
Typical Control Diagram
Supplied Power 480 V/277 3 , 4 wire
100 A
3
MCB
50 A
GFPD
TraceGuard 277
Contactor**
100 A
E 104
100 A/Pole,
120 V
Power Connection
Kit EMK-XP
ElectroMelt Cable
with Braid
End Seal Kit
(part of EMK-XP)
N*
1
100 A
2
Control Power 120 Vac
Snow
Sensor
15 A
Up to
2000 Ft.
Off Delay Timer
0.5-5.0 Hr
20 A
20 A
Automatic Snow
Controller
SD-CIT-1
(120 V @ 50 W
Installation and Testing
14
* Neutral wire must pass through TraceGuard 277 (see Illustration Instructions).
** In 208-volt and 240-volt systems, means should be provided to disconnect both phases.
After the design is completed, the system should be installed and tested. Follow
all design, installation, assembly, and test instructions to ensure proper operation and to prevent shock or fire. Use only Raychem ElectroMelt connection
components and follow the installation instructions included with them.
Install the ElectroMelt system in accordance with Raychem's ElectroMelt
System installation and Operation Manual (H53392) and the installation instructions (APP-910B) supplied with the heating cable and components.
Test the insulation resistance of the ElectroMelt heating cable with a 2500-Vdc
Megger. Test after installation, during the concrete pour, and annually thereafter. Refer to the ElectroMelt Installation and Operation Manual (H53392) for
the proper testing procedure.
Page 15
ElectroMelt System
Design Guide
Supplemental Design
Information
Factors Affecting
Snow Melting System Design
Snow-melting systems are installed for convenience and safety. They are often
thought of only in terms of snowfall, but an important-and often the principalfunction may be anti-icing.
Anti-icing is the ability of the system to prevent the formation of ice on the pavement surface; it is the ability to maintain all points on the surface above 32°F for
given temperature and wind conditions. The anti-icing behavior of a system
must be considered when the primary objective of the system is to reduce slipping hazards or when tracking or runoff of water from adjacent unheated pavement areas is a potential problem.
All surface points above 32°F.
Snowfall
Snowfall patterns vary widely with location. A system design that works well in
one city may be inadequate in another. The energy required to melt snow
varies with air temperature, wind speed, relative humidity, snow density, and
the depth of the snow on the pavement.
The effective power of a snow-melting system (that is, the power delivered to
the top surface on the pavement) is used to warm the fallen snow to melting
temperature, to supply the heat to melt the snow, to make up for evaporation
losses from the surface, and to make up for both convection- and radiation-heat
losses from the pavement surface.
The power required in a given situation is strongly influenced by whether the
surface is kept clear as snow falls. If snow is melted immediately as it falls, the
system must make up for convection-, radiation-, and evaporation-heat losses
as well as melt the fallen snow. However, if a light film of snow is allowed to
cover the surface, the insulating blanket of snow reduces or eliminates the losses due to convection, radiation, and evaporation, and more of the effective system power is available for melting snow.
Heat loss varies with snow cover.
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ElectroMelt System
Design Guide
Supplemental Design
Information
Icing
Virtually any level of power will melt snow if there is a sufficiently deep snow
cover to insulate the surface from convection-heat loss. However, icing problems may arise once the insulating blanket has been melted and the pavement
is subject to increased heat loss due to wind action on the exposed surface.
Icing problems also arise when water from adjacent unheated areas runs onto
the heated area or when snow and slush are racked onto the heated area by
pedestrians or vehicles. In many situations the expected anti-icing behavior of a
system imposes more severe constraints than the ability to melt snow does.
Snow-melting and anti-icing systems require only enough power to meet the
system performance requirements. Providing excess power increases system
cost and leads to higher energy costs.
Performance Requirements
In designing an ElectroMelt system it is therefore critical to specify system performance requirements accurately. This means determining both anti-icing and
snow-melting requirements, as shown below.
Sample Performance Specification
Anti-Icing requirements
Minimum ambient temperature 5°F
Average wind speed 10 MPH
Snow-melting requirements:
Surface clear 50% of snowfall hours
Snow accumulation 3% or less
As shown in the specification example above, a typical performance specification specifies the minimum ambient temperature and the average wind speed at
which all surface points must be above freezing. These are the anti-icing
requirements. It specifies the snow-melting requirements as well, in terms of the
percentage of all snowfall hours for which the operating system must keep the
surface essentially clear, and the allowable percentage of all snowfall hours for
which some snow accumulation is tolerable.
The sections that follow should help you determine and specify an application's
anti-icing and snow-melting requirements.
Anti-Icing Performance Requirements
16
Determining Ambient Temperature
Once you have determined the heating-cable spacing of an ElectroMelt System
you can determine the ambient temperature by referring to Table 3. Simply
locate the row corresponding to the design's heating-cable spacing. Move
across that row to the column corresponding to the average wind speed during
freezing periods and read the minimum ambient temperature at which all points
on the pavement surface will be at or above 32ºF.
Note: This procedure is derived from finite model studies of 4-inch slabs and is
applicable to standard concrete pavement from 4 inches to 6 inches thick
placed directly on grade. If your application involves other materials or constructions, contact your Raychem representative.
Page 17
ElectroMelt System
Design Guide
Supplemental Design
Information
Table 3. Ambient Temperatures (°F) for Ice-Free Surfaces
Heating-cable
spacing (in inches) 5 mph 10 mph 15 mph 20 mph
6 -40 -25 -10 0
8 -40 -10 0 10
10 -25 0 10 15
12 -15 5 15 20
Average wind speed during freezing periods
Snow Melting Performance
Requirements
Table 4. Figure Selections for Snow-Melting Performance Curves
USA
City Fig. City Fig. City Fig.
Albuquerque, N. Mexioco 1 Detroit, Mich. 1 Oklahoma City, Okla. 5
Boston, Mass. 6 Duluth, Minn. 4 Philadelphia, Pa. 2
Buffalo-Niagra Falls, N.Y. 1 Falmouth, Mass. 6 Pittsburg, Pa. 1
Burlington, Vt. 1 Great Falls, Montana 4 Rapid City, S.D. 4
Caribou-Limestone, Maine 3 Hartford, Conn. 6 Salina, Kansas 3
Cheyenne, Wyo. 5 Lincoln, Nebr. 4 Sault Ste. Marie, Mich. 3
Chicago, Ill. 1 Memphis, Tenn. 6 Spokane, Wash. 1
Colorao Springs, Colo. 3 Minneapolis-St. Paul, Minn. 3 St. Louis, Mo. 6
Columbus, Ohio 1 New York, N.Y. 2 Washington, D.C. 2
Obtaining Snowfall Data
Snowfall data is not available for all cities. However, you may still specify snowmelting performance if you can obtain snowfall data for a city with comparable
snowfall conditions for which published data are available.
Alternatively, you can use Table 4 below and Figures 1-6 on page 19 to determine the snow-melting performance to specify. Each figure contains a snowmelting performance curve from which you can determine cumulative snowfall
hours for your application.
Using Table 4
Which of the snow-melting curves you should use depends on the snowfall conditions for the city in which your application is located. Table 4 below lists typical
U.S. and Canadian cities and shows the figure number for the curve applicable
to snowfall conditions for each city. Using Table 4, locate the city with a snowfall
pattern similar to the location for which you are designing the ElectroMelt system.
Turn to the snow-melting curve in the figures listed for that city.
Canada
City Fig. City Fig. City. Fig.
Calgary, Alberta 4 Ottawa, Ont. 3 Sudbury, Ont. 4
Halifax, N.S. 6 Quebec City, P.Q. 3 Toronto, Ont. 1
Kamloops, B.C. 1 Regina, Sask. 4 Vancouver, B.C. 1
Montreal, P.Q. 3 Saint John, N.B. 1 Winnipeg, Man. 4
17
Page 18
ElectroMelt System
Design Guide
Supplemental Design
Information
Using Figures 1-6
Once you have determined the correct curve to use for your application, turn to
the correct figure for that curve and take the following steps:
1. Draw a horizontal line across the figure at the heating-cable spacing you
plan to use in the design.
2. Draw vertical lines from the points where the segmented snow melting per performance curves intersect your horizontal heating-cable-spacing line.
3. From the intersection of the left vertical line with the percentage axis read the
percentage of all snowfall conditions for which the pavement will be com pletely clear.
The distance between the left and right vertical lines is the additional percentage of all snowfall conditions for which the pavement may have a light snow
cover. The distance, if any, from the right line to the end of the percentage axis
is the percentage of snowfall conditions for which snow may actually accumulate while the system is in operation. If increased snow-melting performance is
required, reduce the heating cable spacing.
Example
To determine the snow-melting performance you should specify for ElectroMelt
heating cable installed on 10-inch centers in Chicago, Illinois, find the figure
number for Chicago in Table 4. The table refers you to Figure 1.
Using Figure 1, you see that the intersection of the 10-inch spacing line with the
"Surface Completely Clear" curve occurs at approximately 88%, and the intersection with the "Some Accumulation Possible" curve occurs at 0%
These percentages indicate that the system with 10-inch spacing will keep the
surface completely clear for 88% of all snowfall conditions occurring in Chicago,
and will allow no accumulation.
For the remaining 12% of conditions, the surface may have a light covering of
snow, but the system will be able to melt snow at the same rate at which it falls
(no accumulation).
18
Page 19
ElectroMelt System
Design Guide
Supplemental Design
Information
Figure 1.
6
)
s
e
h
inc
8
ing (
c
pa
S
10
ble
12
ing Ca
t
a
He
Surface Completely Clear
25
25
0
0
Cumulative Snowfall Hours (%)
Snow Accumulates
50
50
Light
Cover
Possible
75
75
100
100
Figure 3.
6
)
s
e
h
inc
8
ing (
c
pa
S
10
ble
12
ing Ca
t
a
He
Light
Cover
Possible
10
12
10
12
6
8
6
8
Figure 2.
Surface Completely Clear
0
25
Cumulative Snowfall Hours (%)
Figure 4.
Light
Cover
Possible
Light
Cover
Possible
100
50
75
19
Snow AccumulatesSnow Accumulates
25
0
Cumulative Snowfall Hours (%)Cumulative Snowfall Hours (%)
50
75
Figure 5.
)
6
s
e
h
inc
ing (
8
c
pa
S
10
ble
12
ing Ca
t
a
He
25
0
Cumulative Snowfall Hours (%)
Snow Accumulates
50
Light
Cover
Possible
75
100
100
10
12
6
8
0
25
Cumulative Snowfall Hours (%)
Figure 6.
0
25
Cumulative Snowfall Hours (%)
50
50
Snow Accumulates
75
Light
Cover
Possible
Snow Accumulates
75
100
100
Page 20
ElectroMelt System
Design Guide
Supplemental Design
Information
Electrical Performance Requirements
Electrical Design
The ElectroMelt EM2-XR self-regulating heating cable varies its power output at
every point along its length in response to the surface temperature or sheath
temperature of the heating cable. When the concrete in contact with the surface
of the heater is cool, the cable is cool and the resistance of the specially blended polymer core is low, resulting in high power output. As the pavement warms,
the heating cable core warms and the core resistance rises, resulting in lower
power output. A graph of the relationship between sheath temperature and
power output of the EM2-XR heating cable appears below.
)
ot
o
/f
ts
at
w
r (
we
o
P
0 275
During normal operation, the heating-cable output varies between the points
marked "Maximum Startup Power" and "Steady-State Operation." The heatingcable operating temperature varies with the concrete temperature and weather
conditions, but is usually about 60ºF warmer than the concrete surface. On a hot
summer day, the concrete in contact with the heating cable could reach 150ºF.
Heating Cable Sheath Temperature ( F)
Maximum Startup Power
Steady State Operation
Startup Temperature
The maximum length of heating cable allowed on a given size circuit breaker is
determined primarily by the current drawn by the heating cable during low-temperature (high-power) startup conditions. The maximum circuit length data
given in Table 1 on page 12 is based on starting the heating cable when the
concrete pavement is at 0ºF. A maximum length circuit started at 0ºF will result
in branch circuit loading of less than 80 percent of the circuit breaker rating
within 10 minutes.
Transformer Sizing
Transformers should be sized to handle the startup load of the heating cable
indefinitely. To determine the current load of each circuit, refer to the circuit
breaker rating tables on page 12. The actual current per foot of heating cable
and the transformer size are calculated as follows:
Current Circuit breaker rating
per foot Maximum allowed length of heating cable at design voltage
Transformer Current Total Heating Heating Cable
size per foot cable length operating voltage
Voltage Drop
Calculate the branch circuit voltage drop based on the current as computed
above. Note that the maximum size branch circuit conductor that can be terminated in the EMK-XP power connection kit is 4 AWG.
=
0.8 x
=
x
x
20
Page 21
ElectroMelt System
Design Guide
Supplemental Design
Information
Example
An application at a parking garage requires four heating cable circuits 275 feet
long. The heating cable is to be powered at 277 Vac.
Circuit Breaker Sizing
From Table 1 on page 12, up to 300 feet of heating cable may be connected to
a single 50-amp branch circuit breaker.
Transformer Sizing
The branch circuit current after startup at 0ºF is calculated as follows:
Current = 80% x 50 amp/300 ft
= 0.13 amp/ft
Transformer size = 0.13 amp/ft x 275 ft/circuit x 277 Vac
= 39,600 watts
= 39.6 kilowatts
21
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ElectroMelt System
Design Guide
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22
Page 23
ElectroMelt System
Design Guide
Design Steps
Project Data
Project or area name
Submitted by
Reference
Date
Design Data
Site Location
Minimum ambient temperature
Average wind speed
Heating cable spacing
Description of performance requirements
Pavement Data
Pavement material
Pavement thickness
Heating cable depth
Type of reinforcement
Description of area to be to be heated
Is pavement placed on grade?
(if not, please describe)
Product Data
Heating cable model
Heating cable manufacturer
Product approvals
Power connection kit model
Splice Kit
Expansion joint kit model
23
Electrical Data
Heating cable operating voltage
Branch circuit overcurrent protection device and rating
Heating cable junction box description
Control System description
Total Electrical Load
Page 24
ElectroMelt System
Design Guide
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24
Page 25
ElectroMelt System
Design Guide
EM2-XR
0.310"
Self-Regulating Heating Cable
For Concrete Snow-Melting
and Anti-Icing Applications
0.700"
Description
Specifications
Circuit Breaker Sizing
The ElectroMelt EM2-XR heating cable is a high-powered, self-regulating heating cable for concrete snow-melting and anti-icing applications. The uniquely
blended polymer core of the heating cable adjusts its power output at every
point along its length to eliminate hot spots and burnouts that can be experienced with constant-wattage heating cables. A heavy-duty, modified polyolefin
outer jacket resists abrasion, puncture, and damage caused by rough handlling.
Operating voltage 208 to 277 Vac
Overcurrent protection 50 amps, maximum
Maximum circuit length 300 feet at 277 Vac
Minimum bend radius 2 inches
Minimum installation temperature 30ºF
Maximum self-generated temperature 275ºF
Color: Orange
Maximum Heating Cable Circuit Length (in Feet) for Startup at Oº F
Heating Cable Operating Voltage
Circuit
Breaker 208V 220V 240V 277V
50 amp 245 250 265 300
40 amp 200 200 210 240
30 amp 145 150 160 180
20 amp 100 100 110 120
15 amp 75 75 80 90
25
Ordering Information
Catalog number EM2-XR
Part number 449561
Description Self-regulating heating cable
Packaging Random-length reels
Shipping weight 0.18 pound per foot
Page 26
ElectroMelt System
Design Guide
EMK-XP
EMK-XS
6"
6"
Power Connection and End Seal Kit,
and Splice Kit
For Use with EM2-XR
Self-Regulating Heating Cable
Power Connection EMK-XP
End Seal EMK-XP
10"
Splice EMK-XS
Description
Specifications
Odering Instructions
The ElectroMelt termination and splicing components are used to terminate the
end of the heating cable to power conductors or to splice one length of heating
cable to another. These water-resistant electrical assemblies are sealed with a
proprietary Raychem adhesive and protected by an outer heat-shrinkable tube
manufactured by Raychem of crosslinked, modified polyolefin polymers.
Temperature rating 90ºF
Storage temperature -40ºF to 140ºF
Minimum installation temperature 30ºF
Power connection wire range 14 to 4 AWG
Voltage rating 600 Vac
Power connection and end seal
Catalog number EMK-XP
Part number 579519
Description Power connection and end seal kit
Packaging One power connection and one
end seal per box
26
Shipping weight 0.4 pound
Splice kit
Catalog number EMK-XS
Part number 356667
Description Splice kit
Packaging One splice kit per box
Shipping Weight 0.2 pound
Page 27
ElectroMelt System
Design Guide
EMK-XEJ
Expansion Joint Kit
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
Specifications
Ordering Information
The ElectroMelt EMK-XEJ expansion joint kit provides physical protection for
the heating cable beneath slab joints. An expansion tube is used to form an
expansion loop for the heating cable.
Temperature rating 195ºF
Storage temperature -40ºF to 140ºF
Min. installation temperature 30ºF
Catalog number EMX-XEJ
Part number 472207
Description Expansion joint kit
Packaging One expansion joint per kit
Shipping Weight 0.3 pound
27
Page 28
ElectroMelt System
Design Guide
EMK-XJB
Junction Box
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
Ordering Information
The EMK-XJB is a large, UL Listed weatherproof enclosure suitable for terminating both ends of one EM2-XR circuit. The enclosure is made of molded
structural foam and provides high impact strength, excellent chemical resistance, high dielectric strength, and excellent weathering capabilities. It is suitable for outdoor applications.
Manufacturer Carlon, model CJ12106
Inside dimensions 12" x 10" x 6 "
Inside volume 825 cubic inches
Outside dimensions 15 ½" x 11¾" x 7 "
Temperature range -40ºF to 185ºF
UL Standard UL508
Catalog number EMK-XJB
Part Number 052577
Description Junction box
7/8
5/8
28
Packaging One junction box per kit
Shipping Weight 5.4 pounds
Page 29
ElectroMelt System
Design Guide
SD-CIT-1
Automatic Snow Controller
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
The ElectroMelt snow controller features a single snow sensor and a control
panel to automatically control the operation of heating cables. The sensor
detects snow as precipitation occurs at temperatures below 38°F. The panel
provides an adjustable hold-on timer, which allows the heating cable to continue to operate even after snow stops. This timer ensures complete melting of
snow or ice. The sensor can be located up to 2000 feet from the panel. The
panel has an internal contactor providing two contacts rated for 20 amps.
Snow Sensor
Control temperature 38°F
Operating temperature range -40°F to 140°F
AC supply voltage requirement 22 to 30V (provided by control panel)
Maximum power consumption 3 watts
Control Panel
Heater hold-on timer
adjustment range 0.5 to 5 hours
Control switch Automatic/Off/Manual
Indicators Supply/Relay
Ordering Information
29
Number of sensors supported One to six (one provided)
Supply voltage requirement 120Vac/240 Vac
Current (heater load) 20 amps
Catalog number SD-CIT-1
Part number 208875
Description Pole-mounted snow detector and control panel
Packaging One snow detector and panel per kit
Shipping weight 13.7 pounds
Page 30
ElectroMelt System
Design Guide
TraceGuard 277™
Ground-Fault Protection Device (GFPD)
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
Ordering Information
The TraceGuard 277 GFPD (Square D EHB-EPD) is a single-pole, thermalmagnetic circuit breaker with equipment ground-fault protection. The GFPD is
rated for use with 480/277-Vac heat-tracing systems with a maximum load of
40 A. It is used to provide overcurrent and equipment ground-fault protection,
but not to protect people from the hazard of electrical shock. The ground-fault
trip level of the 277-volt GFPD is 30 mA. The GFPD is available in bolt-on construction for installation in Square D's EHB panelboards. It comes in two versions, a base unit and a unit with bell alarm contacts.
Manufacturer Square D
Breaker frame E4
Amp rating 15 A to 50 A (refer to tables below)
UL interrupting rating: 120 Vac - 25 kA
277 Vac - 2 kA
125 Vdc - 5 kA
Description Ground-fault protection device
Packaging One circuit breaker and relay per kit
Shipping weight 15 pounds each
30
Catalog / Part No.: Amperes Base Unit Catalog No. Part No.
15 A GFPD EHB14015EPD 984563
20 A GFPD EHB14020EPD 833637
30 A GFPD EHB14030EPD 605703
40 A GFPD EHB14040EPD 021803
50 A GFPD EHB14050EPD 866711
Catalog / Part No.: Amperes Bell Alarm Unit Catalog No. Part No.
15 A GFPD EHB14015EPD2100 984563
20 A GFPD EHB14020EPD2100 833637
30 A GFPD EHB14030EPD2100 605703
40 A GFPD EHB14040EPD2100 021803
50 A GFPD EHB14050EPD2100 866711
Page 31
ElectroMelt System
Design Guide
E104
Contactor
For USe with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
Ordering Information
The E104 is a three-pole contactor housed in a thermoplastic enclosure that is
lightweight, dusttight, watertight, and corrosion resistant.
Enclosure Carlon CJ1085, NEMA 4X, corrosion
resistant, dusttight, watertight
Contactor ITE 2250-HI930 ABA
UL Listed and CSA Certified
Power Connection I/O - 14 AWG box lugs
Power Contacts Silver, cadmium plated
Rating 100 amps per pole @ 600 Vac
Coil connection 32 #6 screw terminals
Coil rating 120 Vac
Catalog number E104, 120 Vac
Part number C77046
Description Contactor
Packaging One contactor per kit
Shipping weight 5 pounds
31
Page 32
ElectroMelt System
Design Guide
AMC-1A
Ambient Sensing Thermostat
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
The AMC-1A thermostat responds to air temperature changes detected by a
stainless steel sensing probe. The AMC-1A can be used to control a contactor
coil.
Manufacturer Barksdale
Enclosure NEMA 4X; epoxy-coated aluminum
housing; exposed hardware is stainless steel
Approvals UL listed and CSA Certified
Range 15°F to 140°F
Sensor exposure limits -65°F to 160°F
Housing exposure limits -65°F to 160°F
Switch SP-DT UL Listed microswitch BM1R
Electrical rating 22 amps @ 125, 250, or 277 Vac
Connection Screw terminals on enclosed terminal block
through ½ NPT conduit hub
Differential 6°F maximum
Setpoint repeatability ± 1°F
Sensor type Fluid-filled probe
Sensor material Stainless Steel
Ordering Information
32
Catalog number AMC-1A
Part Number C77125
Description Ambient sensing thermostat
Packaging One thermostat per kit
Shipping weight 1.5 pounds
Page 33
ElectroMelt System
Design Guide
FH-2616A-1, EMK-CT,
EMK-XT, EMK-MARK
Accessories
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
The ElectroMelt product line has the accessories necessary for a complete
installation of EM2-XR cable. The propane torch (FH-2616A-1) is suitable for
heat-shrinking the connection kits. The crimping tool (EMK-XT) is the correct
size for the crimps in the connection kits. The cable ties (EMK-CT) are 7-inch
nylon industrial cable ties. The cable markers (EMK-MARK) are Raychem TMS
lables, which can be preprinted with the circuit numbers.
Torch (FH-2616A-1)
Description Includes hose, handle assembly;
equipped with regulating valve
Crimp Tool (EMK-XT)
Manufacturer Ideal
Model number 30-425
Length 10”
Cable Ties (EMK-CT)
Manufacturer Panduit
Model number PLT25-C
Length 7 3/8" ± 1/2"
Width 3/16"
Labels (EMK-MARK)
Description ShrinkMark-250-2.00-9 cable markers
Ordering Information
33
Torch Crimp Tool Cable Ties Labels
Catalog number FH-2616A-1 EMK-XT EMK-CT EMK-MARK
Part number 102049 980631 906441 228347
Description Propane Crimp Nylon Cable ShrinkMark
torch tool ties labels
Packaging One per kit One per kit 100 per pack Contact factory
Shipping Weight 5 pounds 1.2 pounds 0.5 pounds 1.2 pounds
per 100 markers
Page 34
ElectroMelt System
Design Guide
EMK-MEG
Insulation Resistance
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Description
Ordering Information
The EMK-MEG is a precision instrument that tests the insulation resistance of
heating cables. Battery operated and portable for field use, it features a pushto-read and lock-on button to conserve the battery. The Megger can test insulation resistance at voltages up to 5000 Vdc and has neon scale-selection indicators. The kit includes batteries, two test leads, probes, an operation manual and
leather carrying case.
Manufacturer Simpson
Model 405-2
Accuracy Megohm ranges ± 1.5% AC/DC voltage
ranges ± 5%; full scale to 1000 V
Supply Six 1.5-V batteries
Dimensions 9 3/5" x 5 1/2" x 4 1/8"
Catalog number EMK-MEG
Part number 130519
34
Description 5000-Vdc insulation tester/Megger
Packaging One instrument and case per kit
Shipping weight 5.0 pounds
Page 35
ElectroMelt System
Design Guide
EMK-XJR
Jacket Repair Kit
For Use with EM2-XR
Self-Regulating Heating Cable
Description
Specifications
Ordering Information
The ElectroMelt jacket repair kit is a wraparound sleeve for covering a damaged outer jacket. The repair sleeve is adhesive-lined and comes with a metal
closure channel.
Description Heat-shrinkable sleeve with adhesive lining;
removable metal closure
Approvals UL Listed for applications of 600 volts or less
Length 12 inches nominal
Catalog number EMK-XJR
Part number 693647
Description Jacket repair kit
Packaging One repair sleeve per kit
Shipping weight 0.8 pounds
35
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ElectroMelt System
Design Guide
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36
Page 37
ElectroMelt System
Design Guide
Condensed
Specification Guide
This is the product portion of a specification for the ElectroMelt System. For a
complete specification that includes installation and testing recommendations,
contact your Raychem representative.
PART 1 - GENERAL
Furnish and install a UL Listed and CSA Certified snow-melting system complete with heating cable, termination components, junction boxes, contactors,
and controls.
PART 2 - PRODUCTS
2.1 The heating cable and termination components shall be UL Listed as Deicing and Snow-melting Equipment and CSA Certified as Designation 1B, 2B.
2.2 The heating cable shall consist of two 14-gauge nickel-coated-copper bus
wires embedded in parallel in a self-regulating polymer core. Power output
shall vary in response to temperature all along its length, allowing the heat ing cable to be crossed over itself without overheating, to be cut to length in
the field, and to have no heater-to-cold-lead connections buried in the
pavement. The heating cable shall be covered by a crosslinked dielectric
jacket and protected by a tinned-copper braid and a 70-mil-thick modified
polyolefin outer jacket.
2.3 The heating cable shall be of parallel circuit construction to allow the cable to
be spliced if it is inadvertently cut during or after construction, and to be pow wered from both ends if it becomes advantageous to divide a circuit in two.
2.4 The heating cable shall operate on (select: 208, 220, 240, or 277) volts
without the use of transformers.
2.5 The heating cable shall be ElectroMelt EM2-XR as manufactured by
Raychem Corporation.
2.6 The system shall be controlled by (select: a switch, an ambient sensing ther-
mostat, or an automatic snow controller) through an appropriate contactor.
2.7 The heating cable power connection and end seal terminations shall be
made in an ElectroMelt EMK-XJB junction box.
2.8 Each circuit shall be protected by a 30-mA ground-fault protection device.
37
PART 3 - INSTALLATION
3.1 The heating cable shall be installed according to the manufacturer's recom-
mendations, the instructions supplied with the heating cable and compo nents, and the instructions in the ElectroMelt Installation and Operation
Manual (H53392).
3.2 The heating cable shall be installed only in concrete pavement designed for
long-term structural integrity. The pavement shall be reinforced with rebar
or wire mesh and the reinforcing supported such that the location of the
reinforcing and the attached heating cable is not disturbed during the con crete placement. The rebar shall be placed at the heating-cable depth
whenever possible.
3.3 The heating cable shall be protected from where it leaves the pavement to
the junction box by installing the cable in 1-inch rigid metal conduit. Use
one conduit for each heating cable.
3.4 The power connection and end seal junction box shall be mounted above
grade. The junction box shall be installed so that water can not enter it.
3.5 Heating-cable repairs and splices shall be made using a splice kit provided
by the manufacturer and specifically approved for the purpose. They shall
pass the Megger test after installation.
PART 4 - TESTING
The heating cable shall be tested for insulation resistance with a 2500-Vdc
Megger after installation, during the concrete pour, and annually thereafter
according to the manufacturer's recommendations and following the instruc tions provided in the ElectroMelt Installation and Operation Manual (H53392).
Page 38
ElectroMelt System
Design Guide
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38
Page 39
ElectroMelt System
Design Guide
Appendix A
Warranty; Suitablity
(a) Raychem warrants products delivered hereunder against faulty workmanship and use of defective materials for a period of eighteen (18) months from
the date of installation or twenty-four (24) months from the date of shipment,
whichever is sooner. When the contract calls for systems design, drawings,
technical advice, services, or instructions (collectively "Services") by Raychem,
in connection with the products, Raychem further warrants for the above stated
warranty period solely that such Services will be undertaken in accordance with
Raychem's reasonable technical judgment based on Raychem's understanding
of the pertinent technical data as of the date of performance of such Services.
The foregoing warranty with respect to products shall not be enlarged or affected by, and (except as expressly provided herein) no obligation or liability shall
arise or grow out of, Raychem's rendering Services in connection with the products. Such warranty is the only warranty made by Raychem and it can be
amended only by a written instrument signed by a duly authorized officer or
Raychem. If the products furnished by Raychem hereunder are determined to
contain a deficiency, Buyer's exclusive remedy shall be to have Raychem repair
such products or supply replacement products or credit Buyer's account for
such products and accept their return, whichever Raychem may elect in its sole
discretion. Notwithstanding the foregoing sentence, in no circumstances shall
Raychem have any liability or obligation with respect to expenses, liabilities, or
losses associated with the installation or removal of any products or the installation of replacement products or for any inspection, testing, or redesign occasioned by any deficiency or by the repair or replacement of products.
Raychem's obligations are subject to the further condition that Raychem shall
have no liability whatsoever for any deficiency unless (i) Raychem is notified in
writing promptly (and in no event later than 30 days) after discovery by Buyer of
the alleged deficiency, (ii) the products containing the alleged deficiency are
promptly returned to Raychem, F.O.B. Raychem's plant, and (iii) Raychem's
examination of such products discloses to Raychem's satisfaction that such
alleged deficiency actually exists and occurred in the course of proper and normal use and was not caused by accident, misuse, neglect, alteration or improper installation, repair, or testing. If any products so prove to contain a deficiency
and Raychem elects to repair or replace them, Raychem shall have a reasonable time to make such repair or replacement.
39
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY IMPLIED
WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NONINFRINGEMENT, AND OF ANY OTHER OBLICATION ON
THE PART OF RAYCHEM.
(b) It shall be the responsibility of the Buyer to determine, on the basis of the
most current written technical data, the suitability of the products and of any
systems design or drawings for the intended use and their compliance with
applicable laws, regulations, codes, and standards and the Buyer assumes all
risks pertaining thereto.
Page 40
TraceGuard and ShrinkWrap are trademarks of Raychem Corporation.
Megger is a trademark of Avo Biddle Instruments.
ElectroMelt and RayChem are registered trademarks of Raychem Corporation.
R
O
Listed
877Z
De-Icing and SnowMelting Equipment
DESIG. 1B, 2B
Raychem Corporation
Construction Products Group
40
®
should independently evaluate the suitability of each product for their application. Raychem
makes no warranties as to the accuracy or completeness of the information, and disclaims
any liability regarding its use. Raychem's only obligations are those in the Standard Terms
and Conditions of Sale for this product, and in no case will Raychem be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of
the product. Specifications are subject to change without notice. In addition, Raychem
reserves the right to make changes in materials or processing, which do not affect compliance with any applicable specification, without notification to the buyer.
Represented by:
Industrial Heater
2941 Kate Bond Blvd.
Suite 101
Bartlett, Tennessee 38033
Tel (888) 451-4328
Fax (901) 382-4766
All of the above information, including illustrations, is believed to be reliable. Users, however,
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