WarmTraceTM HSX™
Hot Water Temperature Maintenance
INSTALLATION PROCEDURES
WarmTraceTM HSX
Safety Comes First. . .
The safety and performance of a heat tracing system depends
on how the system was designed, installed and eventually
maintained. Improper handling, installation or maintenance of
the system could result in underheating or overheating of the
water or damage to the heating cable. This damage could result
in electrical shock, fire or system failure. The information, instructions, testing procedures and warnings addressed in this
guide are important. To minimize these risks, read this guide
prior to starting any heating cable or component installation
and follow the instructions carefully.
Familiarize yourself with the entire guide prior to installing
any heating cable or components. Throughout this guide, the
following symbols will appear to emphasize key points or an
installation tip:
This symbol is intended to alert the user to the presence of important installation, operation or mainte-
CAUTION
nance instruction within the guide.
Approvals/Code Compliances. . .
Thermon's WarmTrace systems comprised of HSX heating
cable and accessories are approved for hot water temperature
maintenance by:
WarmTrace systems comply with the applicable requirements
of the following code agencies:
• NEC, CEC
• Uniform Plumbing Code
• BOCA
• Southern Building Code Congress
• National Standard Plumbing Code
Be sure the electrical power connections comply with the
National Electrical Code (NEC) Article 427 and any other ap-
plicable national, state or local codes.
WarmTrace systems also meet or exceed the requirements of
the IEEE Recommended Practice for Testing, Design, Installa-
tion and Maintenance of Electrical Resistance Heat Tracing for
Commercial Applications, ANSI/IEEE Standard 515.1
This symbol identifies an installation, operation or
TIP
start-up tip that could save time, installation materials or make for an improved system.
Tools Required . . .
2
INSTALLATION PROCEDURES
Typical Heat Tracing Installation. . .
Refer to the “HSX Cable Testing Report” for required recording
of test data and circuit information.
Receiving, Storing, Handling . . .
1. Upon receiving heating cable, check to make sure the
proper type and output have been received. All cables are
printed on the outer jacket with part number, voltage rating
and watt output.
Cable Type (Catalog No.) Outer Jacket Color Voltage (Vac)
HSX 2105-2 Blue 208
HSX 2120-2 Green 208
HSX 2140-2 Red 208
2. Visually inspect cable for any damage incurred during shipment. The heating cable should be tested to ensure electri-
cal integrity with at least a 500 Vdc megohmmeter (megger)
between the heating cable bus wires and the heating cable
metallic braid. IEEE 515.1 recommends that the test voltage for polymer insulated heating cables be 2500 Vdc.
Minimum resistance should be 20 megohms. (Record 1 on
Cable Testing Report.)
A complete electric heat tracing system will typically include
the following components:
1. HSX self-regulating heating cable.
2. PowerSnap1 or PCA-COM power connection kit to
terminate heating cable.
3. TeeSnap or PCS-COM allows three heating cables to be
spliced together.
4. SpliceSnap or PCS-COM allows two heating cables to be
spliced together.
5. ET-6 cable end termination. Each PowerSnap1 and TeeSnap
includes two ET-6 terminations.
6. FT-1 Attachment tape secures cable to pipe; use on
300 mm (12") intervals.
7. CL "Electric Heat Tracing" label peel and stick to insulation
vapor barrier on a 3m (10') interval or as require by code or
specification.
8. Fiberglass thermal insulation and vapor barrier.
Megger
Heater Cable
Bus Wire
Ground Braid
Connect the positive lead of the megger to the cable bus wires
and the negative lead to the metallic braid.
DO NOT connect power to heating cable while
it is on reel or in shipping carton.
CAUTION
3. Store cable and accessories in a clean dry place where
temperatures will be between -40°C and 60°C (-40°F and
140°F).
CAUTION
5
6
3
1
4
8
2
7
The National Electric Code and Canadian
Electrical Code require ground fault protection
be provided for all electric heat tracing.
3
WarmTraceTM HSX
Prior to Installing Cable. . .
1. Verify Electrical Resistance with a megger.
• Refer to Cable Testing Section in this Installation Guide for
details.
2. Inspect the piping to be heat traced.
• Verify that the pipe has been pressure tested, and that all
pipe supports are in place.
• Compare layout of the installed piping vs plumbing
drawings.
3. Surface areas where heat tracing is to be installed must be
reasonably clean. Remove dirt, rust and scale with a wire
brush and oil or grease films with a suitable solvent.
4. Plan the installation.
• Some of the hot water supply may not require heating
cable. Note the extent of heat tracing required by
reviewing:
1. Project specication
2. Plumbing drawings
3. Drawings supplied by Thermon (If a drawing package
was part of heat trace system).
Initial Installation. . .
Begin temporary installation at the proposed end-of- circuit
location and lay out heating circuit on pipe, allowing extra cable
for the power connection and for any splice locations.
Locating Power, Tee and End Termination: Refer to the
plumbing, electrical or Thermon supplied drawings to determine the locations for connections and terminations. The symbols below are routinely used to show the various components
of a heat trace hot water supply system. Note that the electrical
drawings will typically only show the power connection point.
Power Connection Point
Heating Cable T-Splice Kit
Circuit Continued on Another Sheet
Electrically Heat-Traced Hot Water Line
End-of-Circuit Termination
• Allow sufcient cable to cover the longest runs rst. This
will insure that no additional cable or splice kits will be
required.
• The extent of heat tracing, location of power connection
points, splice and end terminations can be temporarily
identified with marking ribbon or spray paint.
5. Identify the heat tracing materials.
• The cable should have been identied upon receipt. Be
sure to make note that more than one water maintain
temperature, and therefore more than one HSX cable, may
be required for the project.
• Familiarize yourself with the connection kits and accessory
components included with the bill of materials.
Power Connection Points: The power (electrical) connec-
tion points must remain accessible, even after the building is
completed. If the facility will be finished out with a suspended
ceiling, power connection points can be located anywhere that
is convenient and accessible to electrical power. If the finished
ceiling is permanent, each power connection point should be
located within reach from the access door.
Tee Splice Connections and End Terminations: Thermon recommends that wherever possible, all connections and terminations be located in an area that allows future access should
changes or additions to the plumbing system be needed.
4
Installing Cable on Pipe. . .
INSTALLATION PROCEDURES
1. Placement Of Cable
The HSX cable will be installed on the pipe in a parallel pass.
There is no need for spiral wrapping. Locate the cable in the
10 or 2 o'clock position where possible. If accessibility is
a problem the cable may be installed in the 4 or 8 o'clock
position.
10 O'clock
8 O'clock
2 O'clock
4 O'clock
2. Attaching Cable to the Pipe
The HSX is held in place with temperature-rated attach-
ment tape (FT-1L). Circumferential bands of tape should be
installed at 300mm (12") intervals to ensure the cable main-
tains proper contact with the pipe.
Where space is a problem, Thermon approved plastic cable
ties may be used on the same interval as tape. Do not over
tighten cable ties.
NO NOT attach cable to pipe with metal hose
clamps, metal strapping, tie wire or similar
CAUTION
materials. Damaged to cable and system could
result.
Avoid pinch points when installing cable. Over
the course of time, the pipe will move due to
TIP
vibration, thermal expansion, contraction and
building settling. Do not allow the heating cable
to bind between items such as pipe supports,
wall or floor penetrations.
Pipe supports: Run the heating cable on the outside of any
pipe hanger or support that comes in contact with the pipe.
Thermon recommends the use of insulated pipe supports to
prevent additional heat loss at the point of support.
Install Cable Like This:
Do Not Install Cable Like This:
305mm
(12")
Heater Cable
FT-1L Tape
Hot Water Pipe
Attachment Tape
(Value Represents Approximate Linear Pipe Length Allowance Per Roll)
Tape
Length
33 m
(36 yd)
55 m
(60 yd)
½"-1" 1¼" 1½" 2" 3" 4" 6"
39 m
(130')
65 m
(215')
35 m
(115')
59 m
(195')
Pipe Diameter in Inches
23 m
(110')
55 m
(180')
29 m
(95')
49 m
(160')
23 m
(75')
38 m
(125')
20 m
(65')
32m
(105')
15 m
(50')
24 m
(80')
Insulated Pipe Support: For cork or polyurethane insulation
insert, cut small hole for cable to pass through.
Pipe Support
Insulation Insert
Cutout for Cable
5
WarmTraceTM HSX
Wall or Floor Penetrations: The heating cable must be pro-
tected when passing between floors or through a wall. This can
be accomplished with pieces of conduit or channel. If penetration requires fire protection, the conduit or channel may be
caulked with approved caulking material.
Heater Cable
Hot Water Pipe
Channel
Floor or Wall
Maximum Circuit Lengths. . .
To prevent excessive electrical currents at the branch circuit
breaker supplying power to the heating cable, the maximum
circuit length as shown in the chart below must be observed.
Completing the Installation. . .
1. Begin nal cable attachment by securing the end-of-circuit
termination kit and working back toward the power supply.
• Circumferential bands of tape should be installed at
300 mm (12") intervals to keep the cable in proper con-
tact with pipe.
• If applicable, refer to installation details provided with the
project drawings or contract Thermon for additional information regarding installation.
2. Complete splice connections (if required) in accordance
with the installation instructions provided with the splice kit.
3. Install power connection kit in accordance to detailed instal-
lation instructions provided with the kit.
4. Before making power connections, repeat the megger test
with at least a 500 Vdc megohmmeter (megger) between
the heating cable bus wire and heating cable metallic braid.
IEE 515.1 recommends that the test voltage for polymer insulated heating cable be at 2500 Vdc. The minimum accept-
able level for the megger reading for any polymer insulated
heat tracing cable is 20 megohms. (Record 2 on Cable Testing Report)
Maximum Circuit Length vs. Circuit Breaker Size
Catalog No. Voltage
HSX 2105-2(Blue) 208
HSX-2120-2 (Green) 208
HSX-2140-2 (Red) 208
Notes:
1. These maximum circuit lengths are dened as the total length of cable that
can be fed from a single power connection point, inclusive of all splices.
2. Be sure to verify the available amperage of the branch circuit breaker sup-
plying power to the heat tracing.
3. If the power supply voltage will be different than that listed in the chart
above, contact Thermon or your local Thermon representative before installing any cable.
4. Any number of shorter heat tracing circuits can be energized from a single
branch circuit breaker as long as the total length of heating cable does not
exceed the length stated above for a given branch circuit breaker's amperage rating.
15 Amp 20 Amp 30 Amp
331 m
(1085')
146 m
(480')
84 m
(275')
Breaker Size
366 m
(1200')
195 m
(640')
113 m
(370')
366 m
(1200')
293 m
(960')
169 m
(555')
6
INSTALLATION PROCEDURES
Thermal Insulation . . .
1. The need for properly installed and well-maintained thermal
insulation cannot be overemphasized. Without insulation,
heat losses are generally too high to be offset by a conventional heat tracing system.
2. Regardless of the type or thickness of insulation used, a
protective barrier should be installed. This protects the insulation from moisture intrusion, physical damage and helps
ensure the proper performance of the heat tracing system.
Seal around all penetrations through the thermal insulation.
3. After the installation of the thermal insulation and weather
barrier but BEFORE ENERGIZING THE HEATING CIRCUIT,
the megohmmeter test should be repeated. This should call
attention to any damage to the heating cable that may have
occurred during the insulation installation. (Record 3 on
Cable Testing Report)
4. Apply caution labels to insulation weather barrier at required
intervals along pipe
Thermal Insulation with Weather Barrier
Weather BarrierThermal Insulation
Heating Cable
(Typical)
Final Inspection and Documentation . . .
1. It is recommended that the circuit be temporarily energized
so that the volts, amps, pipe temperature and ambient
temperature may be recorded. This information may be of
value for future reference and should be maintained for the
historical operating data log (Record 4 on Cable Testing
Report).
Start-Up Procedure . . .
When a WarmTrace system has been installed per this guide,
start-up is easy. Simply follow the steps listed below. Please
note that the operating current for the cable will be higher
during start-up than during normal operating conditions. This
is because the water in the heat trace piping is usually at the
building ambient temperature. This condition has been accounted for in the breaker sizing and current length table pro-
vided so long as the ambient temperature is at or above 15˚C
(60˚F).
1. On closed loop systems a valve or faucet should be partially
opened to prevent excessive pressure accumulation as temperatures rise.
2. Energize the heating cable and allow the system to reach its
equilibrium temperature. The building water heater should be
operating and the building's environment should be at ambi-
ent temperature 22˚C-27˚C (72˚F-80˚F).
3. The water heater/mixing valve which controls the water
supply temperature should be set at the same temperature
as the heating cable's nominal value i.e. 45˚C (105˚F), 49˚C
(120˚F) or 60˚C (140˚F) Variations greater than ±5°C (10˚F)
could cause noticeable swings during operation.
4. Using a calibrated thermometer, check the water tempera-
ture at the water heater to be certain that it is within the
desired range.
5. Again, using a calibrated thermometer, check the water
temperature at various tap locations that are heat traced. Al-
low sufficient time for water to pass any unheated portion of
water line.
6. Test for ground-fault protection by manually tripping the
push-to-test button on the device (remember to reset after
the test).
If start-up is not successful, refer to the Trouble Shooting section of this guide for assistance.
2. Once power is connected but before putting the system
into operation, verify all heating cable testing and documentation have been completed for each heat tracing circuit.
This will ensure that the system has been installed per the
manufacturers recommendations.
Record the location of all terminations on plumbing
drawings after each termination has been completed.
TIP
This will ensure that no terminations are overlooked
and will document the extent of the heat tracing on
the drawing.
Disconnect power to heating cable (turn off
circuit breakers) during water heater start-
CAUTION
7
up and hot water system purging if water
temperature will exceed 65˚C (150˚F).
Troubleshooting
The following information is intended to assist in maintaining and troubleshooting a heat traced hot water system. The
primary goal of a heat tracing system is to provide an efficient
supply of hot water closer to the point of use than is possible
with a recirculated system.
Like many other systems installed in a facility, the successful
installation of a heat tracing system will require coordination
among several trades involved in the construction process.
Mechanical, electrical and insulation contractors must each
provide services that are critical to the proper operation of the
system.
Replace all damaged heating cable. Do not reconnect power to cable that has been exposed
CAUTION
to excessive heat moisture. Failure to replace
damaged cable can cause arcing or fire.
Before calling your heat tracing vendor when things aren't going right, make a visual inspection; perhaps the thermal insulation is wet, damaged or missing. Also, consider the possibility
that repairs or maintenance of nearby equipment may have
resulted in damage to the heat tracing or its power supply.
These are common causes of heat tracing problems, and they
are often overlooked. A number of other possibilities are listed
below, with their symptoms and remedies.
If at any time you feel that the heating cable has been damaged, a dielectric insulation resistance test with a megohmme-
ter (megger) is recommended.
Disconnect power to heating cable (turn off circuit breaker) when working on heat trace pipe,
CAUTION
or heat tracing systems.
Symptom - Water Not Hot Enough
Possible Causes Remedy
Water heater/mixing valve set point too low. ...................................Reset water heater temperature level, maximum temperature 65°C (149°F).
No power to heating cable ..............................................................Check power distribution panel to ensure breakers are energized or have not tripped.
Splice connection missed during installation ...................................Using drawing and visual inspection, check to see if any splice connection has been
overlooked. This may be evident if one area of a heat traced circuit is "cold".
Compressed, missing or wet insulation ...........................................Replace missing or damaged insulation, ensure that pipe and insulation have not been
forced against other pipes to cause heat sink along its length.
Pipes were not properly insulated .................................................Ensure that insulation is per the table. Reinsulate where needed.
No heating cable installed in area ....................................................Verify that the pipe in question was scheduled for heating cable.
Ambient temperature too low ..........................................................Measure ambient temperature in interstitial space where the heat traced pipe is located.
If the temperature is below 22°C (71°F), the ambient is too cool. Raise the ambient
temperature.
Cable not powered at correct voltage ..............................................Verify the proper design voltage and compare with measured value at power connection
point.
Heat loss at temperature limiting valve ............................................In some TLV's heat loss can occur between the hot and cold inlets via the non return
valves. Check that dirt from system is not causing malfunction of the non return valves.
Supply and install filter screens at inlet to valve body.
Symptom - Water Too Hot
Possible Causes Remedy
Water heater/mixing valve set point too high ..................................Reset water heater temperature level, maximum temperature 65°C (149°F).
Pipes were not properly insulated ...................................................Ensure that insulation is per the table. Reinsulate where needed.
Ambient temperature too high ........................................................Measure ambient temperature in interstitial space where the heat traced pipe is located.
If the temperature is above 27°C (80°F), the ambient is too high. Lower the temperature
interstitial space.
Cable not powered at correct voltage ..............................................Verify the proper design voltage and compare with measured value at power connection
point.
Symptom - Circuit Breaker Tripping
Possible Causes Remedy
Improper electrical connection ........................................................Cable could be damaged or improperly connected. Visually inspected heating cable,
connections and terminations. Test cable with megger.
Maximum circuit length exceeded ...................................................Verify the length of the heating cable, including all cable located on tee splices.
Compare this length with the maximum circuit length and circuit breaker sizing chart.
Increase breaker size or add additional circuit if needed.
Piping/building is too cold during start-up ......................................The building and the water in the pipe must be greater than 16°C (61°F). Raise building
temperature or purge hot water lines.
Damaged power feed wire leading to power connection ................Disconnect heat cable at power connection and test power feed wires running back to
power distribution panel.
Faulty branch circuit breaker ...........................................................Replace breaker and energize heating cable.
8
Maintenance Check List. . .
As part of an annual maintenance program or after any work
(repair or alteration) has been performed on or near the heat
traced piping, the following steps should be performed:
1. Visually inspect the pipe's thermal insulation looking for any
areas where the insulation appears repaired or replaced.
Any suspect areas should be examined for damage to the
heating cable. Verify that any new/repaired insulation meets
the specification.
2. While inspecting the insulation, verify that it is completely
dry. Wet insulation will not only cause temperature maintenance problems, but could also signal a more serious problem that could cause damage to the cable and the facility.
3. Test for ground-fault protection by manually tripping the
push-to-test button on the device (remember to reset after
the test).
4. Using a calibrated thermometer, check the water tempera-
ture at the water heater to be certain that it is within the
desired range.
INSTALLATION PROCEDURES
5. Again, using a calibrated thermometer, check the water
temperature at various tap locations that are heat traced. Al-
low sufficient time for water to pass any unheated portion of
water line.
6. Heating cable should tested with a megohmmeter (megger)
at the power distribution panel by a qualified electrician.
7. Record any observations on the project's as-built drawings
and any maintenance log kept for facility.
Do Not enter any power connection point, cable splice or end termination while heating cable
CAUTION
is energized. Disconnect power to heating cable
and seek qualified assistance.
9
WarmTraceTM HSX Cable Testing Report
1. Refer to Thermon Installation Procedures, FORM CPD 1014, for general installation procedures, requirements and guidelines.
2. Upon receiving heating cable, check the cable to make sure the proper type and output have been received. All exible cables
have the catalog number, voltage rating and watt output printed on the outer jacket.
3. Visually inspect cable for any damage incurred during shipment. The heating cable should be tested to ensure electrical integrity
with at least a 500 Vdc megohmmeter (megger) between the heating cable bus wires and the heating cable metallic braid.
IEEE 515.1 recommends that the test voltage for polymer insulated heating cables be 2500 Vdc. Minimum resistance should be
20 megohms. (Record 1 on Cable Testing Report.)
A. Connect the positive lead of the megger to the cable bus wires.
B. Connect the negative lead of the megger to the metallic braid.
C. Energize the megger and record the reading. Readings between
20 megohms and innity are acceptable. Readings below 20
megohms may mean the electrical insulation has been dam-
aged. Recheck the heating cable for physical damage between
the braid and the heating element; small cuts or scuffmarks on the outer jacket will not affect the megger reading unless
there was actual penetration through the braid and dielectric insulation jacket.
4. Once the installation is complete, but prior to installation of thermal insulation, recheck the heating cable with at least a 500 Vdc
megohmmeter (megger) between the heating cable bus wires and the heating cable metallic braid. IEEE 515.1 recommends that
the test voltage for polymer insulated heating cables be 2500 Vdc. Minimum resistance should be 20 megohms.
(Record 2 on Cable Testing Report.)
5. After the thermal insulation is installed, the megohmmeter test should be repeated. Minimum resistance should be
20 megohms. (Record 3 on Cable Testing Report.)
6. After the thermal insulation is installed and power supply is completed, record the panel and circuit breaker information.
Ensure all junction boxes, temperature controllers, cable glands, etc. are properly secured. Apply rated voltage to the heat
tracing circuit(s) for 10 minutes. Record the ambient temperature, measure and record the circuit(s) voltage and current.
(Record 4 on Cable Testing Report.)
NOTE: To ensure the heating cable warranty is maintained through installation, the testing outlined on this sheet must be
completed on the installed heating cables, and the test results recorded and mailed/faxed to:
Thermon Customer Service
100 Thermon Drive
San Marcos, Texas 78666
Fax: 512-754-2420
9
WarmTraceTM HSX Cable Testing Report
Customer: Contractor:
Address: Address:
Phone No: Phone No.
Project Reference:
Record 1: Prior to Installation
Cable Type:
Heater Length:
Heater Number:
Insulation Resistance M Ohms:
Tested By: Date:
Witnessed By: Date:
Record 2: After Installation
Insulation Resistance M Ohms:
Tested By: Date:
Witnessed By: Date:
Record 3: After Thermal Insulation is Installed
Insulation Resistance M Ohms:
Tested By: Date:
Witnessed By: Date:
Record 4: Final Commissioning
Panel Number:
Breaker Number:
Volts:
Ambient Temperature (deg. F):
Recorded Amps:
Tested By: Date:
Witnessed By: Date:
10
Form CPD1014-1008
THERMON . . . The Heat Tracing Specialists
®
100 Thermon Dr. • PO Box 609 • San Marcos, TX 78667-0609
Phone: 512-396-5801 • Facsimile: 512-396-3627 • 1-800-820-HEAT
www.thermon.com In Canada call 1-800-563-8461
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