ELEKTRA TuffTec 30 User manual

www.elektra.eu
•Tuff Tec™30
•Tuff Tec™30/400 V
TuffTec™
Instrukcja instalacji PL
Installation manual UK
ELEKTRA
Инструкция по монтажу RU
HEATING CABLES

Applications
ELEKTRA TuffTec™ heating cables are intended
for effective prevention of snow and ice deposi-
tion on:
•driveways, roads, footbridges, loading ramps
and parking spaces with asphalt or concrete
surface,
•roofs covered with bituminous materials,
•gutters and downpipes requiring the output of
60 W/m.
Characteristics
ELEKTRA TuffTec™ heating cables feature the
following characteristics:
•high mechanical strength
- cables intended for installations characte-
rised by increased risk of mechanical damages
•high thermal properties
- max. operating temperature: +110°C
- max. exposure temperature (10 min): +240°C
- min. installation temperature: -25°C
•UV-Resistant
•resistance against chemical agents, including
bituminous substances.
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Heating Cables
ELEKTRA
ELEKTRA TuffTec™ cables are intended for
installation in the conditions of increased risk
of mechanical damages, e.g. in case when
concrete consolidation machinery is utilized for
surface works.
Due to their exceptionally high thermal properties,
as well as resistance against bituminous
substances, the TuffTec™ cables can be safely laid
in asphalt.
Also, the cables can be laid on the roofs with
bituminous coverings.
FEP (Teflon)
first insulation layer
Multi-wire
heating core
HDPE second
insulation layer
Tinned
copper braiding
UV resistant
HFFR outer sheath
Construction of the ELEKTRA TuffTec™ heating cable
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•“cold” power supply conductor
•ELEKTRA TuffTec™heating cable
•connecting joint between the power supply
conductor and the heating cable
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Technical properties
The ELEKTRA TuffTec™ heating cables are pro-
duced in ready-made units, manufactured in
compliance with the EN 60335-1 standard.
The ready-made units include heating cables
terminated with a power supply conductor.
Power output 30 W/m
Power supply voltage 230 V, 400 V ~ 50/60 Hz
Cable diameter ~ 6.8 mm
Min. installation temperature -25°C
Max. operating temperature +11 0 ° C
Max. exposure temperature (10 min.) +240 °C
Power supply conductors 1 x 4 m; 3 x 1.5 mm²
or 3 x 2.5 mm² rubber
insulation and outer
jacket
Heating cables double-core, screened,
single-side powered
Insulation double layer, FEP + HDPE
Outer sheath UV-resistant HFFR
Rated power output tolerance +5%, -10%
Min. cable bending radius 3.5 D
IP rating IPX7
System certication according to ISO 9001
IQNET, PCBC
Markings CE
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Heating Cables
ELEKTRA
Single-side powered
heating cables
Self-adhesive label
Note:
ELEKTRA TuffTec™ 30 heating cables are designed
for the rated voltage 230 V/50 Hz, and TuffTec™
30/400 heating cables – for the rated voltage
400 V/50 Hz.
Heating cables’ heating output may vary with
+5% and -10% from the nameplate values.
!
The label features the following pictograph:
Note:
Never cut the heating cable.
Never trim the heating cable, only the power
supply conductor may be trimmed if required.
Never squash the “cold tail”.
Do not ever undertake on your own any attempts
to repair the heating cables, and in case any
damage is detected, report the damage to an
ELEKTRA authorized installer.
Never stretch or strain the cable excessively, nor
hit it with sharp tools.
Do not install the heating cables when ambient
temperature drops below -25°C.
!
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General information
Surface protection against snow
and ice deposition
When protecting external areas from snow and ice
deposition, it is required to assess the required heat
output value per m2of the surface. Recommended
heat output depends on the regional climate condi-
tions, i.e. minimum ambient temperature, snowfall
intensity and wind strength.
Higher output is required if the heated area is:
•exposed to wind from below:
- bridges, stairs, loading ramps, overpasses
•located in a regions of intense snowfall
Ambient
temperature
Heat output
[W/ m2]
> -5°C
-5°C ÷ -20°C
-20°C ÷ -30°C
< -30°C
200
300
400
500
Note:
Never lead the end joint and the connecting
joint between the heating cable and the power
supply conductor out of the surface. Both joints
must be placed – depending on the type of sur-
face – within the layer of sand, dry concrete or
directly in concrete.
Never bend the joint and end seal.
Heating cables must be installed according to
the Instructions.
Mains connection of the heating cables should
be performed by an authorized electrician.
Power supply conductors (”cold tails”) in asphalt
should be positioned in the protective metal
installation conduit. Alternatively, power sup-
ply conductors can be led out of the area where
asphalt will be poured out.
!
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Heating Cables
ELEKTRA
Applying insulation layer to the surfaces exposed
to wind from below can improve effectiveness.
Depending on the cable spacing, it is possible
to obtain required output per m2of the heated
area.
Cable spacing cannot drop below 5 cm.
To protect large areas against snow and ice depo-
sition, one option is application of 400 V voltage
heating cables, which would evenly load the elec-
tric circuit. Application of such cables would also
reduce installation works, limiting the required
number of heating cables.
Heat output 30 W/m
[W/m2][cm]
300
375
430
500
600
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Protection of bituminous roofs,
gutters and downpipes against snow
and ice deposition
Thanks to their exceptionally high resistance
against damaging inuence of any bituminous
substances, ELEKTRA TuffTec™ heating cables are
ideally suited for the purposes of heating roofs
covered with tar paper, roof tiles or bituminous
shingles.
Selection of the required heat output depends on
the regional climate conditions of the zone where
the installation is to be positioned.
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It is recommended to heat gutters and roof edges
adjoining them on the width of approximately 50
cm, as well as roof channels. Effective heating
of these elements will facilitate roof outow of
melted snow, and will prevent icicles.
Tar paper-covered roofs are usually at (up to
15°) and require higher heat output. Especially
roof valleys and channels are exposed to snow
deposition.
Heat output for the moderate climate zone
ELEKTRA TuffTec™ heating cables can be installed
in gutters or downpipes of buildings located
in cold climate zones, where it is also necessary
to execute high heat output, i.e. 60 W/m by
double-laying the cables in gutters.
Application Heat output
[W/ m2]
Roof channels 200-300
Roof edges approx. 200
Roof stretches
excessing the building’s facade approx. 300
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Heating Cables
ELEKTRA
Anti-snow and anti-ice controls
•for the protection of surfaces
ELEKTRA ETOG2 controller – max. load up to 3x16 A.
For applications in extended heating systems.
ELEKTRA ETR2 controller – max. load up to 16 A,
total output of installed heating cables must not
exceed 3600 W. As standard, equipped with one
temperature and moisture sensor with installation
tube.
Controls
Properly selected control system will ensure ad-
equate operation of the heating system only during
snow and freezing rainfall. A temperature control-
ler with a temperature and moisture sensor will
automatically recognize the weather conditions.
The heating system will be then kept on standby
and only switched on when actually necessary. For
this purpose, DIN-bus installed controllers ELEKTRA
ETR2 and ETO2 can be utilised.
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•for the protection of roofs,
gutters and downpipes
ELEKTRA ETR2R controller – as standard,
equipped with one air temperature sensor and
moisture sensor.
ELEKTRA ETOR2 controller – as standard, equipped
with one air temperature sensor and moisture sen-
sor. Additional moisture sensor can be connected
to this controller, which will enable protection of
two independent roof areas.
Additionally, it is possible to control two indepen-
dent areas, e.g. a garage driveway and gutters,
with one controller only.
As standard, equipped with one temperature and
moisture sensor and an installation tube. Addition-
al temperature and moisture sensor can be con-
nected to this controller, which will enable protec-
tion of two outdoor areas.
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Heating Cables
ELEKTRA
To maintain xed positioning of the cable and
steady spacing conforming to the calculated
values, the cables need to be attached with the
ELEKTRA TMS installation tape (the tape should be
positioned with the distances of 40 cm) or instal-
lation mesh of 5 cm x 5 cm grid, made of Ø 2 mm
wire.
The heating cable layout should be commenced
from the side of the power supply conductor,
in such a way to enable easy reach to the switch-
board.
If the cold tail needs to be extended, a heat
shrink joint must be used. Ensuring that the con-
nection is safely sealed.
TMS installation tape
Installation
Stage 1: Heating cable’s
installation
1) in the surface
Before commencing the installation of the sys-
tem, it is required to assess the necessary heat
output per m2, as well as calculate the required
spacing of the heating cable.
In order to calculate the required heating cable’s
spacing, apply the following formula:
a-a = S/L
where:
a-a: distances between cables,
S: surface area, for the surface heated with
the heating cable,
L: heating cable’s length.
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The heating cable layout will depend from
the surface type.
Asphalt surfaces
Stages of works:
•Metal installation tape or mesh is placed on the
compacted (hard core) base, with the heating
cable attached to it – installation tape’s tongues
should be folded so that they would not
straighten up during asphalt rolling
•Power supply conductors (”cold tails”) in
asphalt should be positioned in the protective
metal installation conduit. Alternatively, power
supply conductors can be led out of the area
where asphalt will be poured out
•The 40-50 mm-thick layer of asphalt is laid out
manually – Stage 4
•The asphalt surface is rolled – Stage 4
Cross section of a driveway or road with asphalt surface
40-50 mm-thick
layer of asphalt
Temperature
and moisture sensor
in installation tube
Compacted
base
TM
ELEKTRA TuffTec
heating cable
Metal installation mesh
or ELEKTRA TMS
steel installation tape
Concrete surfaces
Concrete surfaces require epansion joints. Unreinforced
concrete slabs should be divided into expanded areas
of the surface no larger than 9 m
2
, reinforced concrete
agstones – into areas no larger than 35 m
2
. The length
of the heating cables should be selected so that they
would not cross the expansion joints. Only the power
supply conduits (“cold tails”) can cross the expansion
joints. They are to be placed in a metal protective con-
duit of the length of approx. 500 mm.
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Heating Cables
ELEKTRA
ELEKTRA TuffTecTM
heating cable
Temperature
and moisture sensor
in installation tube
Expansion joint
Compacted
base
Concrete slab
min. 50 mm thick
Cross section of a pavement or driveway made of concrete slab
Cross section of a pavement or driveway
made of concrete slab
Reinforced concrete agstones
Heating cables can be fastened to the reinforce-
ment of the ferroconcrete agstones. Alterna-
tively, the installation mesh of 100 mm x 100 mm
grid made of Ø 4 mm wire can be applied, which
would facilitate maintaining steady spacing of the
cable, conforming to the calculated values.
ELEKTRA TuffTecTM
heating cable
Roadway layer
(e.g. resin, quartz)
Reinforcement
of the f
erroconcrete
flagstone
Metal
mesh
Layer of plaster,
e.g. acrylic,
on plastering mesh
Thermal
insulation
Cross section of a suspended loading ramp
Cross section of a suspended loading ramp
Unreinforced concrete surfaces
Stages of works:
•The compacted base is levelled
•ELEKTRA TMS installation tape or installation
mesh are laid on the compacted base, the
heating cable is fastened to them
•The concrete slab works follow – Stage 4
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Applying thermal insulation layer to ferroconcrete
agstone surfaces exposed to wind operation
from below (ramps, bridges, overpasses) can im-
prove the system’s effectiveness.
2) on roofs covered with tar-paper,
roof tiles or bituminous shingles
Fastening cables to roofs’ edges
The grips are attached to the roof’s stretches with
pieces of heat-sealing tar paper glued across the
grips.
Titanium-zinc or copper holders
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Heating Cables
ELEKTRA
Fastening cables
in roof valleys
ELEKTRA TMS steel installation tape or installation
strips are attached to the roof’s stretches with
pieces of heat-sealing tar paper glued across
the tape or strips.
Downpipes receiving water from roof valleys
require heating:
•internal downpipes at the length of approx. 1 m
•external downpipes at their entire length
ELEKTRA TMS
steel installation tape
Installation strip
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Gutter holder
Gutter spacing wire
(this method of installation will greatly facilitate cleaning)
Downpipe spacing clip
Downpipe spacing wire
Basic accessories for installation of heating cables
in gutters and downpipes:
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Heating Cables
ELEKTRA
Stage 2: After the heating
cable has been laid
At this stage, it is necessary to undertake
the following steps:
•Stick into the Warranty Card the self-adhesive
label, positioned on the power supply con-
ductor of the heating cable
•In the Warranty Card, prepare a sketch of the
heating cable’s layout positioning
•Feed the power supply conductor of the he-
ating cable into the switchboard
•Perform the measurements of:
– heating wire resistance
– insulation resistance
The measurement results of the heating
core’s resistance should not vary from the
one given on the label value with more than
- 5 % , +10 % .
The heating cable insulation’s resistance,
as measured with an appliance of the rated
voltage 1000 V (megaohmmeter), should not
drop below 50 MΩ. Enter the results into the
Warranty Card.
After the surface has been completed, repeat
the measurements to check whether the
heating cable has not been damaged while
conducting works.
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(brown
or black)
(yellow-green)
Power supply conductor
Ohmmeter
Megaohmmeter
(brown
or black)
(blue)
Heating wire’s resistance measurement
Insulation’s resistance measurement
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Heating Cables
ELEKTRA
Stage 3: Temperature and
moisture sensor’s
installation:
preparation to
in-surface installation
•Establish the optimal positioning for the tem-
perature and moisture sensor – a place which
would be especially vulnerable to prolonged
low temperatures and increased moisture
deposition (e.g. in a shade or exposed to
wind).
•Feed the protective conduit with the so called
“draw wire” from the planned sensor’s posi-
tioning to the switchboard (after the surface
has been completed, the protective conduit
will enable feeding the temperature and
moisture sensor’s wire).
Note:
Fill the spot selected for the sensor’s installa-
tion with material to be removed after con-
crete or asphalt has been cured (e.g. a wooden
block of 100 x 100 mm and the height equal to
the planned thickness of the nished surface).
!
Note:
The protective conduit should be run in such
a way to enable the future exchange of the tem-
perature and moisture sensor, if required.
!
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