Bartec PSB Guide

Design Guide
Self-regulating trace heating systems
for hazardous / industrial applications
Design guide
BARTEC Self-regulating trace heating systems
for pipes and tanks in hazardous locations
with BARTEC self-regulating trace heating cables PSB and MSB
Origin Design Guide

Table of content
Design Guide 1
Self-regulating trace heating systems for hazardous / industrial
applications 1
Overview 2
Applications 3
Certifications / Approvals / Marking 3
Safety 3
Intended use 3
Specific Conditions of Use 4
Foreseeable Misuse 4
Personal Qualification 4
Applicability 5
Technical data 6
Self-regulating trace heating system 6
Trace heater 6
Trace heater Installation Enclosure as Power Box kit 7
Trace heater Installation Enclosure as End of Line Light kit and
End of Line Seal kit 8
System design 9
Trace heater selection 9
Determination of the required trace heater length 16
Determination of the required number of heating circuits 17
Selection of the required components for power connection,
control and monitoring, end termination etc. 19
Trace heaters 25
Power connection, splice and junction components 26
Control and monitoring units 27
End termination 28
Spare parts 29
Installation self-regulating trace heaters on pipes and vessels 30
Preparation 30
Required tools / equipment 30
Unrolling the trace heater 30
Installation on pipes 30
Fastening 31
Trace heater routing 31
Installation on tanks and vessels 33
Tests and commissioning 36
Measurement of the insulation resistance 36
Acceptance test and acceptance test report 37
Commissioning 37
Operation 37
System documentation 37
Maintenance 38
Visual and functional inspection 38
Electrical inspection 38
Inspection intervals 38
Personnel training courses 38
Repairwork on piping or thermal insulation 38
Disposal and Recycling 38
Disposal 38
The appliance must be disposed of in accordance with local laws
and regulations according to its components. 38
Checklist customized entry port 39
Acceptance report / Record of inspection 40
Troubleshooting 41
Limited Product warranty (Worldwide, excepting North
America) 42

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 2 / 42
Overview
This manual covers the design and general installation of BARTEC Self-regulating trace heating systems for use in hazardous locations using the
following self-regulating heating cables, hereinafter called trace heaters:
BARTEC PSB (07-5853-*)
BARTEC MSB (07-5854-*)
A trace heater unit comprises the power termination, a trace heater and an end termination. The trace heater unit can be made of a single trace
heater or multiple trace heaters connected by a splice or for a tee which are pre-determined by BARTEC.
The trace heating system consists of one or more trace heater units grouped by a common power termination; the junction box is pre-determined
by BARTEC as Installation Enclosure for trace heating. Each trace heating system is associated with design and installation documentation.
One or more trace heating systems can be merged by a common branch circuit to a heating circuit group with a joint over current device.
Optional components for temperature control or limitation and for annunciation can be included in the trace heating system.
Besides the components the system consists of rules for design and installation and it’s documentation.
The self-regulating trace heater features a temperature-dependent resistive element between two parallel copper conductors that regulates and
limits the heat output of the trace heater according to the workpiece temperature. If the workpiece temperature rises, the power output of the
trace heater is reduced. This self-regulating property prevents overheating which would cause damage to the trace heater. Even crossing or
overlapping with other trace heaters (or other portions of the same trace heater) are possible.
high power output
low temperature
high temperature
low power output
The trace heaters are fixed equipment heating systems for pipes in ordinary and hazardous areas. Thanks to the parallel design the trace heater
can be cut and installed to any required length (up to the maximum heating circuit length as shown on page 18).
Multiple options for connection, splicing and end termination of the heating circuit are available to meet the individual requirements on site. A large vari-
ety of accessories allows for easy customization and extensibility. The following illustration shows a typical electric trace heating system:
Power distribution
wiring(3rd party)
Transformer
Trace heater
Attachment tape
Warning label
Power distribution panel
(incl. ground fault protection)
End seal
Power termination kit
cold pipe
warm pipe
hot pipe

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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 3 / 42
Applications
Trace heating compensates for the heat loss through the insulation to
maintain the pipe and fluid at temperatures above the freezing or solidifi-
cation point. Thus, trace heating is critical for pipe freeze protection sys-
tems that are expected to have stagnant fluids for prolonged durations.
Freeze protection:
Water, and fluids containing significant water, expand as they freeze.
This expansion can cause the pipe to be blocked or break leading to:
Economic losses: A frozen water pipe leading to a critical process
like a frozen pipe in a waste water treatment plant or cooling tower
can shut down the operation causing high economic losses.
Safety issues: A frozen pipe to safety showers can jeopardize per-
sonnel safety in the event of hazardous chemical exposure.
Temperature maintenance:
A process temperature maintenance system can maintain the temper-
ature of the fluid in a pipe to the desired level over a broad range of
temperatures.
Maintaining liquids within the specified temperature range allows you
to cost-effectively transport the fluids from one location to another, op-
erate your processes at maximum efficiencies, and safely start/shut
down your operations.
Certifications / Approvals / Marking
PSB/MSB
DEKRA 20ATEX0093 X
IECEx DEK 20.0055X
BARTEC Self regulating trace heating systems
with BARTEC PSB or MSB trace heaters
Safety
WARNING
Risk of fire or electrical shock. Follow these guidelines to avoid per-
sonal injury or material damage.
WARNING
Risk of fire or electrical shock due to electric trace heating system.
Risk of bursting of the cable gland.
At temperatures below -40°C, make sure that no mechanical shock
of x>4 joule is applied to the cable gland type Wiska ESKE/1 25 LT.
Protect the cable gland from mechanical shock.
CAUTION
Danger of burning due to electric heating system
Danger of burning from hot surface
Disconnect the heating circuit from the power supply before removing
the pipe insulation. Allow the heating system to cool down.
Disconnect the heating circuit from the power supply before working
on the enclosure. Allow the enclosure to cool down.
WARNING
Risk of fire or electrical shock due to electric trace heating system.
Risk of lost explosion protection.
After opening the enclosure, check that the enclosure sealing is in
good condition. Ensure that the enclosure sealing is elastic and free
of cracks. If the enclosure sealing is damaged, contact BAR-
TEC GmbH.
CAUTION
The trace heating system is only applicable in case of workpiece tem-
perature is higher than the layout ambient temperature.
For safe installation and operation of BARTEC Self-regulating trace
heating systems the technical requirements and instructions given in
this Design Guide, all applicable documents and the corresponding
manuals of the installed products or products to be use must be fol-
lowed. Keep these instructions for future reference. If applicable,
leave them with the end user. Retain the trace heating system docu-
mentation for each trace heating circuit as long as the system is in
use.
All electrical systems and installations must comply with BARTEC
GmbH requirements and be installed in accordance with the relevant
electrical codes and any other applicable national and local codes.
Use BARTEC Self-regulating trace heating cables in accordance with
the intended use and strictly comply with the operational data speci-
fied in section Technical Data. Install all components of the trace heat-
ing system carefully.
Any defective component of the trace heating system must be re-
placed before installation. Replace each defect component of the
trace heating system.
Use only original BARTEC accessories and spare parts.
Note that the Applicable Documents listed below shows further im-
portant information and must be observed in addition to this manual.
Applicable Documents
DesignGuide System (for PSB and MSB)
21-1S00-7D0001
Installation Instructions
Self-regulating trace heating cables
01-5800-7D0003
Storage conditions
21-0000-7Q0001
corresponding manuals of the installed prod-
ucts or products to be use
Intended use
BARTEC Self-regulating trace heating cables types
BARTEC PSB (07-5853-*)
BARTEC MSB (07-5854-*)
can be used to create BARTEC Self-regulating trace heating systems
types PSB or MSB in combination with BARTEC splice kits and junc-
tion boxes as follows:
Installation Enclosures types PBS, PBM, ELL, PBTW, PBTC
ESTM controller
PLEXO TCS connectors
It is designed for industrial purposes in shown trace heating systems
for freeze protection and temperature maintenance applications. It is

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 4 / 42
intended for use in hazardous (potentially explosive) gas or combus-
tible dust atmospheres (“hazardous locations”).
Operation is allowed with
one kind of heating cable in each heating circuit only
respect to the maximum heating circuit length
installed earth fault equipment protection and overcurrent protection
for each branch circuit
The approval and marking of the respective heating system, the tech-
nical data of the BARTEC Self-regulating trace heating cables and the
applicable documents must be observed.
For use with electrical systems, the relevant installation and operating
conditions (e.g. according to ATEX Directive 2014/34/EU,
EN 60079-0, EN 60079-14, EN 60079-17, EN 60079-30-2 and any
other relevant national standards) must be observed.
Specific Conditions of Use
For Specific Conditions of use see documents of components, the
system is built with, as it is:
General (IECEx DEK 20.0055X); (DEKRA20ATEX0093 X)
All power and data line cable entries to the trace heater boxes shall
be installed with Ex eb or Ex tb cable glands or blanking elements
providing a minimum ingress protection of IP66.
Supply cables and power cable entry glands shall be selected per
manufacturer’s installation instructions for appropriate conductor size
and temperature range (see chapter “Checklist customized entry
port”).
When used in TT and TN systems a residual current device according
to IEC/IEEE 60079 30-1, clause 4.4 point c) 1) shall be installed.
When used in IT systems an insulation monitoring device according to
IEC/IEEE 60079 30-1, clause 4.4 point c) 2) shall be used.
For the electrical data that are not marked, see Annex 1 to
NL/DEK/ExTR20.0058/00.
Coated aluminium Power boxes, type 27-54P2-****/**** and Cable
entries PS-120* type 27-59-G2-*
The enclosure must not be used in areas affected by charge-produc-
ing processes, mechanical friction and separation processes, electron
emission (e.g. in the vicinity of electrostatic coating equipment), and
pneumatically conveyed dust.
PBTW, Ex d Temperature Controller Type 27-54D*-****/****
The width of gap of the Ex d Temperature Switch is below the maxi-
mum values according to IEC 60079-1. Contact BARTEC for mainte-
nance or repair of Ex d Temperature Switch.
The capillary of the PBTW and PT100 wiring shall be part of a fixed
installation and shall be effectively clamped to prevent pulling or twist-
ing.
PBTW, PBTC, Temperature Controller Type 27-54**-****/****
Shall be applied for maintaining temperature only.
The capillary of the PBTW and PT100 wiring shall be part of a fixed
installation and shall be effectively clamped to prevent pulling or twist-
ing.
Heating system PLEXO TCS type 27-59P*-****/****
The classification of the temperature class of the PLEXO TCS Heating
System is done from the operator depending on the used heating ca-
ble. The ambient temperature range of PLEXO TCS Heating System
depends also of the used heating cable. This information is recorded
on the operator side in accordance with the specifications in the oper-
ating instructions / acceptance report. The documentation must be
kept secure.
Temperature Controller, ESTM type, 17-88C1-*22H/****
Cable glands shall be used that are certified for the applicable type of
protection and with suitable ratings. For EPL Db only cable glands
with integrated seal or gasket may be used.
In order to ensure safe operation of the Ex ib circuits, the ground or
earth connections of all electrical circuits connected to the Tempera-
ture Controller shall be installed using potential equalization between
the hazardous area and the non-hazardous area.
Shall be applied for maintenance temperature control only. The use of
optional Limiter ESTM-L, 17-88C1-*22H**** is not in the scope.
Self-Regulating Heating Cable Series PSB, type 07-5853-**** and
MSB, type 07-5854-****
Connections and terminations for installation with the Self-Regulating
Heating Cable Series PSB and MSB shall be certified according to the
requirements of the applicable standards for the types of protection for
potentially flammable gas or combustible dust atmosphere, or as the
requirements of IEC/IEEE 60079-30-1 as integral components. The
connections and terminations shall be suitable for the application and
correctly installed.
Foreseeable Misuse
The following activities are a misuse of the product and are not al-
lowed:
Use of the BARTEC Self-regulating trace heating cables for pur-
poses other than those described in the intended use
Installation, commissioning, operation, maintenance or disposal by
unauthorised or unqualified personnel
Work on live parts or circuits without switching off the BARTEC
Self-regulating trace heating cables or the system
Commissioning of damaged or faulty system components or incom-
plete installation.
Recommisioning after dismounting the heating grommet without re-
placing the heating grommet.
Unauthorized technical modification of the BARTEC Self-regulating
trace heating cables
Personal Qualification
For system planning, installation, commissioning, operation and mainte-
nance observe the requirements for personnel qualification according to
DIN/EN 60079-14, note appendix A.

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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 5 / 42
Applicability
This document covers the design of BARTEC PSB and MSB trace heating systems. It includes mainly engineering procedures for certified com-
ponents as set out in section System design.
The manuals shipped together with the individual components will contain additional relevant content to this document.
Relevancy of individual sections of this document is highlighted at the beginning of each section.
The self-regulating trace heating system type 27-1S** is a trace heating system for fixed installation in hazardous areas with explosive gas, va-
pour or dust atmosphere. It is to be used for frost protection, to raise or maintain the temperature of a workpiece where it is externally applied.
CAUTION
The trace heating system is only applicable in case of workpiece temperature is higher than the layout ambient temperature.
WARNING
Risk of fire or electrical shock.
Risk of lost explosion protection.
The maximum Trace heater stady-state current is to be observed!
Protecting of all components of the Trace heater Installation Enclosure against over-heat is controlled by maximum Heating circuit length, depending
on design parameters.
Observe the trace heater stady state current listed on table “Installation Enclosures for Trace Heating as Power Box kit”!

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 6 / 42
Technical data
Self-regulating trace heating system
Protection classification
II 2G Ex db eb mb [ib] 60079-30-1 IIC T6…T3 Gb
II 2D Ex tb [ib] 60079-30-1 IIIC TL80 °C… TL170 °C Db
Trace heater
PSB
MSB
Max. continuous operating
temperature, energized
65 °C
110 °C
Max. continuous exposure
temperature, de-energized
85 °C
130 °C
Min. start-up temperature
-55 °C
-60 °C
Min. installation temperature
-55 °C
-60 °C
Power Output1
10, 15, 25, 33 W/m
10, 15, 30, 45, 60 W/m
Nominal voltage
110 V to 120 Vac /
208 V to 277 Vac
110 V to 120 Vac /
208 V to 277 Vac
Max. braid resistance
< 18.2 Ω/km
< 18.2 Ω/km
Braid material
Tinned copper
Nickel-plated copper
Min. bending radius
25 mm (Do not bend on the
narrow axis.)
10 mm (Do not bend on the
narrow axis.)
Cable weight
13 kg/100 m
11.5 kg/100 m
Heater
dimensions
fluoropolymer outer
jacket
11.6 x 5.6 mm
10.2 x 4.8 mm
polyolefin outer jacket
11.8 x 5.8 mm
-
Temperature classes
T6: 3PSB2, 5PSB2
T5: 8PSB2, 10PSB2
T4: 3MSB2, 5MSB2
T3: 10MSB2, 15MSB2,
20MSB2
Protection classification
II 2G Ex 60079-30-1 IIC
T5, T6 Gb
II 2D Ex 60079-30-1 IIIC
T95 °C, T80 °C Db
II 2G Ex 60079-30-1 IIC
T3, T4, T5, T6 Gb
II 2D Ex 60079-30-1 IIIC
T170°C, T130°C, T95 °C,
T80 °C Db
1
nominal heat output at 10 °C

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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 7 / 42
Trace heater Installation Enclosure as Power Box kit
Junction box with mounting stand
PBS-200-E
/-E10 / -E16
PBS-300-E
/-E10 / -E16
PBM-200-E
/-E10 / -E16
PBM-300-E
/-E10 / -E16
PBTW-200-E
PBTW-300-E
PBTC-200-E
PBTC-300-E
Max. workpiece
temperature mounting
stand2
+240 °C
-
+240 °C
-
+240 °C
-
+240 °C
-
Max. trace heater entries
2
1
3
3
2
1 (33)
1
1
Terminals
Spring clamp Ex e; 2x3
lines, 1x3 PE
Spring clamp Ex e; 3x3
lines, 2x3 PE
Spring clamp Ex e; 4x3 lines,
2x3 PE
Spring clamp Ex e; 2 x lines,
2 x neutral, 2 x PE
Maximum circuit breaker
size4
32 A
16 A
32 A
Power supply
max. 277 Vac
Ambient temperature range
-55 °C to +55 °C
-40 °C
Min. installation temperature
-55 °C
-40 °C
Power supply cable
Service temperature at con-
ductor 5
MSB:
70 °C @ Ta max 40 °C
80 °C @ Ta max 55 °C
PSB:
70 °C @ Ta max 40 °C
85 °C @ Ta max 55 °C
80 °C @ Ta max 55 °C (@ 24 A max.)
Ingress Protection
IP 66
IP 64; IP 66 (EN 60529)
Connection Technology (CAK)
Maximum withstand tem-
perature / max. service tem-
perature end seal
+200 °C
Min. installation tempera-
ture
-60 °C
Connected
trace
heater type
Trace
heater
rated
power out-
put [W/m]
Tamb max
[°C]
Limitation of operating current (stady state) of trace
heating circuit at Tamb max [A]
Max. surface temperature
“TL” [°C]
T-class
PBS/PBM
ESTM
PBTC
PBTW **
Installation
enclosure
#
Trace
heater ##
System
###
PSB
10, 15
+40
30
16
19
16
+110
+80
T4
27
16
18
15
+95
+80
T5
23
16
-
9
+80
+80
T6
+55
26
16
12
16
+110
+80
T4
24
16
12
15
+95
+80
T5
18
16
-
9
+80
+80
T6
25, 33
+40
30
16
19
16
+110
+95
T4
27
16
18
15
+95
+95
T5
+55
26
16
12
16
+110
+95
T4
24
16
12
15
+95
+95
T5
MSB
10, 15
+40
20
16
19
16
+110
+130
T4
+55
18
16
*12
16
+110
+130
T4
30, 45, 60
+40
20
16
19
16
+110
+170
T3
+55
18
14
*12
16
+110
+170
T3
2
Maximum workpice temperature depending on the type of trace heater, used
3
On request
4
Protecting of all components of the branch circuit against over-current; choice depending on design parameters
5
For supply cable type selection, the permissible operating temperature at the conductor is to be observed with respect to the maximum ambient temperatue of the power box.

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 8 / 42
Notes
* Limitations may apply to the trace heater circuit length, in order not to exceed the maximum allowed operating current (steady state). Consult
the manufacturers trace heating system design documentation, containing the calculated operating current of the applicable trace heating circuit.
** PBTW is limited to use in trace heating circuits protected by a 16 A rated over current protection, see electrical data above.
# Maximum surface temperature of installation enclosures:
- with trace heaters installed and operating (with steady state operating current);
- with the installation enclosures positioned in the worst case orientation with maximum amount of accumulated dust layer (limitations to the ori-
entation of installation do not apply).
## Maximum sheath temperature trace heater, installed on workpiece.
### System comprising installation enclosure and trace heaters.
Trace heater Installation Enclosure as End of Line Light kit and End of Line Seal kit
Junction box with mounting stand
ELL-200-E
ELL-300-E
ELS-200-E
Max. workpiece temperature
mounting stand3
+240 °C
-
+240 °C
Terminals
Spring clamp Ex e: 1x3 PE
ComEx Lamp module
Spring clamp Ex e: 1x3 PE
ComEx Lamp module
-
Max. power conductor size
Trace heater bus wires only
Maximum circuit breaker size:6
32 A
Power supply
max. 277 Vac
Ambient temperature range
-55 °C to +40 °C
-55 °C to +55 °C
Min. installation temperature
-55 °C
Ingress Protection
IP 64; IP 66 (EN 60529)
IP 66 (EN 60529)
Connection Technology (CAK)
Maximum withstand temperature /
max. service tem-perature end seal
-
+200 °C
Min. installation temperature
-60 °C
System components
Plexo TCS Heating System
ESTM Temperature Controller
Workpiece temperature
range7
-60 °C to +160 °C
-
Terminals
Spring clamp
0,5 mm² to 4 mm²
Spring clamp
Power cable 6 mm², Control cables 2.5 mm²
Maximum circuit breaker
size8
32 A
32 A
Power supply
max. 254 Vac
230 V +10%-20%, 50 Hz
Ambient temperature range
-
-55 °C to +55 °C
Min. installation temperature
-55 °C
-55 °C
Minimum Temperatur re-
sistance of supply cable9
PSB:
+80 °C for system in T5
+75 °C for system in T6
MSB:
+125 °C for system in T3
+95 °C for system in T4
-
Sealing area supply cables
9 mm to 16 mm (for types 27-59P1…/…)
12 mm to 17 mm power cable
5 mm to 8 mm control cable
Ingress protection
IP 65
IP 66, IP 68 (EN 60529)
IP 65
6
Protecting of all components of the branch circuit against over-current; choice depending on design parameters
7
Observe Technical Data of the Heating Cable
8
Protecting of all components of the branch circuit against over-current; choice depending on design parameters
9
For supply cable type selection, the permissible operating temperature at the conductor is to be observed with respect to the maximum ambient temperatue of the product

21-1S00-7D0001/-
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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 9 / 42
System design
For the design of trace heating systems with BARTEC self-regulating trace heaters, the following steps are necessary:
Trace heater selection
Determination of the total required trace heater length
Determination of the required number of trace heating circuits
Selection of the required components and accessories for power connection, control and monitoring, end termination etc.
The following sections provide step-by-step instructions on how to proceed with each step.
Trace heater selection
Step 1: Familiarize yourself with the trace heater types and their properties
BARTEC self-regulating trace heaters are available in various types to suit different applications. Each trace heater is marked with a product code
that contains relevant information as shown in the following example:
Trace heater family
PSB (07-5853)
MSB (07-5854)
Trace heater output
in W/m @ 10 °C
Outer jacket
CT(F) = fluoropolymer
CR (P) = polyolefin
Voltage rating
1 = 120 Vac
2 = 277 Vac
Trace heater output in W/ft @ 10 °C
→Example
A trace heater that bears the marking 10PSB2-CT...PSB33...Type 07-5853-733Fhas the following specifications:
Trace heater output @ 10 °C: 33 W/m (10 W/ft)
Trace heater family: PSB
Voltage rating: 230 Vac
Outer jacket: fluoropolymer
Step 2: Determine the heat loss of your pipe setup
For proper system design it is essential to know the effective heat loss of your pipe setup. To determine it, the following data will be required:
Pipe diameter
Insulation thickness
Insulation material
Maintain temperature
Minimum ambient temperature
Temperature differential ΔT: ΔT = maintain temperature - minimum ambient temperature
BARTEC® 10PSB2-CT ... PSB33 ... Type 07-5853-733F
pipe diameter
insulation thickness
minimum
ambient temperature
maintain
temperature

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 10 / 42
Next, obtain the basic heat loss in W/m using the following table
10
:
Table A: Basic heat loss in W/m
Pipe ø in
DN(inch)
DN8
(1/4")
DN10
(3/8")
DN15
(1/2")
DN20
(3/4")
DN25
(1")
DN32
(1 1/4")
DN40
(1 1/2")
DN50
(2")
DN65
(2 1/2")
DN80
(3")
DN100
(4")
DN125
(5")
DN150
(6")
DN200
(8")
DN250
(10")
DN300
(12")
Insulation thickness in mm
15
25
5.0
5.8
6.7
7.8
9.2
11.0
12.1
14.5
17.6
20.1
25.0
29.9
35.5
45.3
55.6
65.4
35
7.2
8.3
9.5
11.2
13.1
15.6
17.3
20.6
25.0
28.6
35.6
42.6
50.5
64.5
45
9.3
10.8
12.4
14.5
17.0
20.3
22.4
26.8
32.5
37.1
46.3
55.4
65.6
75
16.0
18.5
21.2
24.9
29.3
34.8
38.5
46.0
55.8
100
22.1
25.6
29.4
34.5
40.5
48.2
53.3
125
28.9
33.5
38.4
45.0
52.9
20
25
4.3
4.9
5.6
6.5
7.5
8.9
9.8
11.6
13.9
15.8
19.5
23.3
27.4
34.9
42.7
50.1
35
6.1
7.0
8.0
9.2
10.7
12.6
13.9
16.5
19.8
22.5
27.8
33.1
39.1
49.7
60.8
45
7.9
9.1
10.3
12.0
13.9
16.4
18.0
21.4
25.7
29.2
36.2
43.0
50.8
64.5
75
13.6
15.6
17.7
20.6
23.9
28.2
31.0
36.7
44.2
50.2
62.1
100
18.9
21.6
24.5
28.4
33.1
39.0
42.9
50.8
61.1
125
24.6
28.2
32.1
37.2
43.2
50.9
56.0
25
25
3.8
4.3
4.9
5.6
6.5
7.6
8.3
9.8
11.7
13.2
16.2
19.2
22.6
28.6
34.9
40.8
35
5.4
6.2
7.0
8.0
9.2
10.8
11.8
13.9
16.6
18.8
23.1
27.4
32.2
40.7
49.7
58.2
45
7.1
8.0
9.1
10.4
12.0
14.0
15.4
18.1
21.6
24.4
30.0
35.6
41.8
52.8
64.5
75
12.2
13.8
15.6
17.9
20.6
24.1
26.4
31.0
37.1
41.9
51.5
61.1
100
16.8
19.1
21.5
24.7
28.5
33.3
36.5
42.9
51.3
58.0
125
22.0
24.9
28.1
32.3
37.3
43.5
47.7
56.1
30
25
3.5
4.0
4.4
5.0
5.8
6.7
7.3
8.6
10.2
11.4
14.0
16.5
19.3
24.3
29.6
34.6
35
5.0
5.6
6.3
7.2
8.2
9.6
10.4
12.2
14.5
16.3
19.9
23.5
27.5
34.6
42.2
49.3
45
6.5
7.3
8.2
9.3
10.7
12.4
13.6
15.8
18.8
21.2
25.9
30.5
35.7
45.0
54.8
64.0
75
11.1
12.5
14.0
16.0
18.4
21.3
23.3
27.2
32.3
36.4
44.4
52.4
61.4
100
15.4
17.3
19.4
22.2
25.4
29.5
32.2
37.6
44.6
50.3
61.4
125
20.1
22.7
25.4
29.0
33.2
38.5
42.0
49.1
58.3
40
25
3.1
3.4
3.8
4.3
4.9
5.6
6.1
7.0
8.2
9.2
11.2
13.0
15.2
19.0
23.0
26.7
35
4.4
4.9
5.4
6.1
7.0
8.0
8.6
10.0
11.7
13.1
15.9
18.6
21.6
27.0
32.7
38.1
45
5.7
6.3
7.0
8.0
9.0
10.3
11.2
13.0
15.2
17.1
20.6
24.2
28.1
35.1
42.5
49.4
75
9.8
10.9
12.1
13.7
15.5
17.8
19.3
22.3
26.2
29.3
35.4
41.5
48.3
60.3
100
13.5
15.1
16.7
18.9
21.4
24.6
26.6
30.8
36.2
40.5
49.0
57.4
125
17.6
19.7
21.8
24.7
28.0
32.1
34.8
40.3
47.3
52.9
50
25
2.8
3.1
3.4
3.8
4.3
4.9
5.3
6.1
7.1
7.9
9.4
11.0
12.7
15.7
19.0
22.0
35
4.0
4.4
4.9
5.4
6.1
7.0
7.5
8.6
10.1
11.2
13.4
15.6
18.1
22.4
27.0
31.3
45
5.2
5.7
6.3
7.1
8.0
9.1
9.8
11.2
13.1
14.6
17.4
20.3
23.5
29.1
35.1
40.7
75
8.9
9.8
10.8
12.2
13.7
15.6
16.8
19.3
22.4
25.0
30.0
34.9
40.3
50.0
60.2
100
12.3
13.6
15.0
16.8
18.9
21.5
23.2
26.7
31.0
34.6
41.4
48.2
55.8
125
16.0
17.8
19.6
22.0
24.7
28.1
30.4
34.8
40.6
45.1
54.1
100
25
2.2
2.4
2.5
2.8
3.1
3.4
3.6
4.1
4.6
5.0
5.9
6.7
7.6
9.2
10.8
12.3
35
3.1
3.3
3.6
4.0
4.4
4.9
5.2
5.8
6.6
7.2
8.4
9.5
10.8
13.0
15.4
17.6
45
4.0
4.3
4.7
5.2
5.7
6.3
6.7
7.5
8.5
9.3
10.9
12.4
14.0
17.0
20.0
22.8
75
6.8
7.5
8.1
8.9
9.8
10.8
11.5
12.9
14.7
16.0
18.7
21.2
24.1
29.1
34.3
39.2
100
9.5
10.3
11.2
12.3
13.5
15.0
16.0
17.9
20.3
22.2
25.8
29.4
33.3
40.2
47.5
54.2
125
12.4
13.5
14.6
16.0
17.6
19.6
20.8
23.3
26.5
29.0
33.7
38.4
43.6
52.6
62.0
70.9
10
Heat loss calculations are based on IEC/IEEE 60079-30-1:2015 Annex C and IEC/IEEE 60079-30-2:2015 Annex E. The following assumptions have been made:
Medium not in motion
Single layer insulation
No gap between pipe and insulation layer
No gap between insulation layer and weather shielding
Ambient temperature: -20 °C
Outdoor installation, wind speed: 20 m/s
Application of a safety factor of +10 %
For other values contact your local BARTEC distributor.
ΔT in °C

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Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 11 / 42
Finally, you must apply the following correction factors depending on your insulation material:
Table B: Insulation Correction Factors
Correction Factor*
thermal conductivity at 20 °C
in W/m×K
Insulation
material
Rockwool / Mineral Fibre (ASTM C547-15 Type II)
1.00
0.0370
Calcium Silicate (ASTM C533 Type I)
1.47
0.0567
Cellular glass (ASTM C552-15 Type II)
1.46
0.0481
Rigid cellular urethane (ASTM C591-13 Type I)
0.83
0.0275
Foamed elastomer Grade 2 (ASTM C534-14)
1.29
0.0425
Expanded perlite (ASTM C610-15)
2.06
0.0678
Pyrogel XT (ASTM C1728-12)
0.56
0.0206
→Example
Pipe diameter: DN25
Insulation thickness: 20 mm
Insulation material: calcium silicate
Minimum ambient temperature: -20 °C
Maintain temperature: 25 °C
We obtain the basic heat loss in W/m from Table A on page 10:
Now, the correction factors from Table B must be checked and, if necessary, applied:
The effective heat loss of the setup is determined as follows:
effective heat loss = basic heat loss ×correction factor insulation
= 13.9 W/m × 1.47
= 20.4 W/m
correction factor insulation: 1.47
ΔT = 25 °C - (-20 °C) = 45 °C
}
basic heat loss: 13.9 W/m

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 12 / 42
Step 3: Choose a trace heater family
Determine the requirements for your trace heating application:
Maximum exposure temperature (power on / power off)
Minimum operation / installation temperature
Required heat output to compensate for the effective heat loss as calculated in Step 2
Required temperature class (“T-Rating”)
Select the trace heater family that meets your requirements using the following table:
Table C: Trace heater family selection
PSB
MSB
Max. continous operating
temperature, energized
65 °C
110 °C
Max. continuous exposure
temperature, de-energized
85 °C
130 °C
Min. start-up temperature
-55 °C
-60 °C
Min. installation temperature
-55 °C
-60 °C
Power output11
10, 15, 25, 33 W/m
10, 15, 30, 45, 60 W/m
Nominal voltage
110 to 120 Vac
208 to 277 Vac
110 to 120 Vac
208 to 277 Vac
Braid resistance
< 18.2 Ω/km
< 18.2 Ω/km
Minimum bending radius
25 mm
Do not bend on the narrow axis.
10 mm
Do not bend on the narrow axis.
Heater dimensions
11.6 x 5.6 mm (fluoropolymer outer jacket)
10.2 x 4.8 mm
11.8 x 5.8 mm (polyolefin outer jacket)
Temperature classes12
Product approach:
10 W/m → T6
15 W/m → T6
25 W/m → T5
33 W/m → T5
Product approach:
10 W/m → T4
15 W/m → T4
30 W/m → T3
45 W/m → T3
60 W/m → T3
Systems approach:
Operating temperature / T-Class is obtained by
Heloc Pro calculation tool with respect to maximum
Heating circuit length.
NOTICE
If you want to use plastic piping within your installation, contact your local BARTEC distributor for verification that the design does not exceed the
maximum withstand temperature of the pipe material. Also, adjustments in heat loss calculations may be required.
→Example
Maximum exposure temperature: 50 °C (“power on”), 70 °C (“power off”)
Minimum operation temperature: -20 °C
Required heat output: 20.4 W/m
Required temperature class: T5
Trace heater family that meets the requirements: PSB
11
nominal heat output at 10 °C
12
applies for the trace heater models with 208 to 277 Vac rated voltage; temperature classes according to IEC/IEEE 60079-30-1:2015 (max. surface temperature)

21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 13 / 42
Step 4: Determine the required power rating
Since the power output of self-regulating trace heaters depends on the pipe temperature, the conditions within your application must be consid-
ered when choosing the trace heater:
Determine the maintain temperature (= pipe temperature) of your application and the effective heat loss as calculated in Step 2.
Find the required power output in the graph that contains the trace heater type and voltage you use (see tables on pages 14 to 14).
If the required power output is between 2 trace heater types, choose the one with the higher rating.
If the required power output exceeds the output of the trace heater with the highest rating, you may:
Use 2 or more trace heaters on the same pipe.
Use a thicker insulation or insulation material with a lower thermal conductivity.
Contact your local BARTEC distributor for further assistance.
→Example
Trace heater family as determined in Step 3: PSB
Power supply voltage: 230 V
Maintain temperature: 25 °C
Effective heat loss: 20.4 W/m
Trace heater that meets the required power output: 10PSB2
25 °C
20.4 W/m

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 14 / 42
Table D: PSB 230V
For MSB trace heaters see next page.

21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 15 / 42
Table E: MSB 230V
For PSB trace heaters see previous page.

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 16 / 42
Step 5: Select the appropriate outer jacket material
BARTEC self-regulating trace heaters are available with 2 different types of outer jackets. Choose the outer jacket that suits the chemical envi-
ronment it will be exposed to. For questions regarding the chemical resistance please contact your local BARTEC distributor.
Table E: Chemical resistance of outer jackets
Application
Catalog No.
Type key (example)
Polyolefin outer jacket
exposure to aqueous, inorganic chemicals
…-CR
07-5853-733P(PSB only)
Fluoropolymer outer jacket
exposure to organic chemicals
…-CT
07-5853-733F(PSB)
07-5854-730F(MSB)
→Example
Trace heating systems for process applications in the oil industry: fluoropolymer outer jacket
Trace heater catalog no. that meets the required power output and environmental conditions: 10PSB2-CT, Type 07-5853-733F
Determination of the required trace heater length
The total required trace heater length is determined by taking into account the trace heater length for piping as well as allowances for valves,
pumps, flanges, pipe supports and connection kits.
Step 6: Determine the required trace heater length for the piping:
The required trace heater length for piping corresponds to the pipe length.
→Example
50 m of piping = 50 m of trace heater
Step 7: Determine the required allowance for connection kits:
The required trace allowance for connection kits is 0.5 m for each kit.
→Example
Heating circuit with 1 power connection kit and 1 end of line lamp
The total required allowance is calculated as follows:
total required allowance = no. of connection kits × 0.5 m
= 2 × 0.5 m
= 1.0 m
allowance for valves,
pumps and flanges
allowance for
pipe supports
trace heater
on piping
allowance for
connection kits

21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 17 / 42
Step 8: Determine the required allowance for pumps, valves, flanges and pipe supports:
Determine the required allowances for pumps, valves, flanges and pipe supports using the following table:
Table F: Allowance values and pipe support intervals
Pipe diameter
in DN / inch
DN8
1/4"
DN15
1/2"
DN20
3/4"
DN25
1"
DN32
11/4"
DN40
11/2"
DN50
2"
DN65
21/2"
DN80
3"
DN100
4"
DN150
6"
DN200
8"
DN250
10"
DN300
12"
Allowance for pumps
in m
1.5
2
2
2.1
2.3
2.3
2.4
2.4
2.4
2.6
3
3.5
4
4
Allowance for valves
in m
0.5
0.5
0.5
0.6
0.6
0.7
0.7
1
1
1.3
1.5
1.6
1.8
2
Allowance for flanges
in m
0.2
0.2
0.3
0.3
0.3
0.3
0.4
0.4
0.5
0.7
0.9
1
1.2
1.2
Allowance for pipe supports
in m
0.2
0.2
0.3
0.3
0.3
0.3
0.4
0.4
0.5
0.7
0.9
1
1.2
1.2
Typical pipe support interval
in m
1
1.5
1.5
2
2
2.5
3.1
4
4
5
6
7
8
8
→Example
Pipe diameter: DN25
1 pump
2 valves
6 flanges
24 pipe supports
The total required allowance is calculated as follows:
total required allowance = no. of pumps × pump allowance value +
no. of valves ×valve allowance value +
no. of flanges × flange allowance value +
no. of pipe supports × pipe support allowance value
= 1 × 2.1 m + 2 × 0.6 m + 6 × 0.3 m + 24 × 0.3 m
= 12.3 m
Step 9: Add all lengths / allowances together:
Add the lengths for piping (as determined in step 6) and allowances (as determined in step 7 and step 8) together to obtain total required trace
heater length.
→Example
required trace heater length for piping (step 6): 50 m
required allowances for connection kits (step 7): 1.0 m
required allowances for pumps, valves, flanges and pipe supports (step 8): 12.3 m
total required trace heater length = required trace heater length for piping + required allowances
= 50 m + 1.0 m + 12.3 m
= 63.3 m
Determination of the required number of heating circuits
Step 10: Confirm the number of electrical circuits required for the application:
Using Table G on page 18, compare the required heater length and start up temperature to the available circuit breaker allowances to determine
the number of electrical circuits that will be required.
→Example
total required trace heater length: 63.3 m
circuit breaker voltage: 230 Vac
selected trace heater: 10 PSB
circuit breaker amperage: 25 A
required start-up temperature: -20 °C
allowable trace heater length from table below = maximum of 69 m at -20 °C on 25 A circuit breaker at 230 Vac
= 63.3 m calculated < 69 m maximum allowable for 25 A = 1 circuit

Design Guide for Hazardous / Industrial
Self-regulating trace heating systems
21-1S00-7D0001/-
05/2023-EHT-466853
Notice Technical data subject to change without notice.
No claims for damage arising from alternations, errors or misprints shall be allowed.
Page 18 / 42
The following table shows the maximum sum of trace heater lengths per branch circuit when connected to power through one or more system
junction boxes.
If feeding multiple trace heating system circuits from the single circuit breaker, the maximum sum of trace heater lengths can then be extended.
Please refer to BARTEC Heloc Pro design software or contact BARTEC technical support.
Breaker sizing should be based on international electric codes or any other local or applicable code. Use only circuit breakers with type C tripping
characteristics.
WARNING
Risk of fire, electrical shock or dysfunction. Observe the maximum amperage of all components of the trace heating circuit. If the required trace
heater length exceeds the maximum heating circuit length you must install multiple heating circuits.
The following tables G1 and G2 must be observed when selecting the max. heating circuit length.
Table G1 considers the fuse protection in relation to the min. switch-on temperature.
Table G2 considers the fuse protection in relation to the max. ambient temperature of the enclosure in which the heating cable is connected. The
table refers to the Limitation of Operating Current (stady state) of the trace heating circuit at Tamb max [A].
Finally, the determined shorter length from both tables is to be applied.
Table G1: Maximum heating circuit length for circuit breakers with Type C tripping characteristics
Circuit
breaker size
Start-up
temperature
PSB trace heaters
Operating voltage: 230 Vac
3PSB2
5PSB2
8PSB2
10PSB2
16 A
+10 °C
202 m
153 m
91 m
57 m
0 °C
202 m
144 m
86 m
54 m
-20 °C
163 m
115 m
70 m
44 m
20 A
+10 °C
202 m
165 m
120 m
76 m
0 °C
202 m
165 m
107 m
67 m
-20 °C
202 m
144 m
87 m
55 m
25 A
+10 °C
202 m
165 m
128 m
95 m
0 °C
202 m
165 m
128 m
84 m
-20 °C
202 m
165 m
109 m
69 m
32 A
+10 °C
202 m
165 m
128 m
97 m
0 °C
202 m
165 m
128 m
97 m
-20 °C
202 m
165 m
128 m
88 m
Circuit
breaker size
Start-up
temperature
MSB trace heaters
Operating voltage: 230 Vac
3MSB2
5MSB2
10MSB2
15MSB2
20MSB2
16 A
+10 °C
230 m
164 m
92 m
67 m
52 m
0 °C
217 m
155 m
87 m
64 m
49 m
-20 °C
195 m
141 m
79 m
58 m
45 m
20 A
+10 °C
231 m
188 m
115 m
82 m
65 m
0 °C
231 m
188 m
109 m
79 m
61 m
-20 °C
231 m
177 m
98 m
72 m
56 m
25 A
+10 °C
231 m
188 m
133 m
82 m
75 m
0 °C
231 m
188 m
133 m
82 m
75 m
-20 °C
231 m
188 m
123 m
82 m
70 m
32 A
+10 °C
231 m
188 m
133 m
82 m
75 m
0 °C
231 m
188 m
133 m
82 m
75 m
-20 °C
231 m
188 m
133 m
82 m
75 m