eltherm ELK-AE User manual

eltherm GmbH
Ernst-Heinkel-Str. 6-10
57299 Burbach
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QAA - 024
Installation of Fluoropolymer Insulated Series
Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
QAA 024
INSTALLATION MANUAL
Installation of Fluoropolymer Insulated Series Trace Heaters
in Non-Ex Areas
Types ELK-AE, -AG, ELW-VA, -GS, -GN

QAA - 024
Installation of Fluoropolymer Insulated
Series Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
Seite 2 von 6
Content
0. Applications......................................................................................................................3
1. Receipt of Goods ..............................................................................................................3
2. Storage .............................................................................................................................3
3. Length of Heating Circuit...................................................................................................3
4. Protective Measures .........................................................................................................3
5. Mounting Instructions ......................................................................................................4
6. Testing..............................................................................................................................5
7. Operation and Maintenance .............................................................................................6

QAA - 024
Installation of Fluoropolymer Insulated
Series Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
Seite 3 von 6
0. Applications
Fluoropolymer insulated series trace heaters are suitable for use on tanks, pipes and pipe
attachments like valves, pumps etc. in industrial and commercial environments.
1. Receipt of Goods
On receipt of the goods check the trace heaters and the accessories and compare with the
data on the delivery note to ensure that the correct material was supplied. It is recommended
that the resistance and the insulation resistance be checked (see 6. Testing).
2. Storage
The goods have to be stored in a dry place at an ambient temperature of –20 … +60°C. If dry
storage is not possible, ends of heating cable or tapes need to be sealed by means of a
termination kit. This is to be done also when a heating circuit remains unfinished at the end of
a working day.
3. Length of Heating Circuit
The circuit lengths of factory terminated goods are designed by eltherm. For shortening or
elongation, please contact eltherm. The design of “off the reel” goods is to be done in
accordance with the supplied product data sheet. The given voltage, operating temperature
and output per metre must not be exceeded. Cross sections of the cold leads are to be
designed to suit the nominal heating circuit current as per applicable local installation codes
4. Protective Measures
•Design and installation of heating circuits is to be made compliant to the standards EN
60519-10 and EN 62395-2 as well as to any other locally applicable codes and standards
•Series trace heaters should be operated with a controller. A controlled or stabilised mode
of operation as per EN 62395-2 is to be implemented
•Suitable positioning of the temperature sensors will avoid overheating of pipeline / tank,
medium and trace heater. Make sure the sensors are properly attached.
•We highly recommend to use a residual current device (30mA).
For use of the cable as trace heater according to IEC EN 62395-1 andIEC EN 60519-10, a
residual current device (30mA) is mandatory!
•When using the trace heaters on metallic surface, this surface also has to be integrated in
the leakage current protection acc. to DIN VDE 100, part 410 before operation of the
system.
•The protective braid of the trace heaters is to be connected to potential earth.

QAA - 024
Installation of Fluoropolymer Insulated
Series Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
Seite 4 von 6
•For outdoor use of trace heaters without outer protective sheath, suitable measures have
to be taken on site to protect the metallic sheath (protective braid) against mechanical or
chemical damage.
•Prior to installation work or maintenance, the relevant heaters need to be disconnected
from power supply. If required, heated surfaces need to cool down to become accessible.
5. Mounting Instructions
•Installation is to be done by personnel that has been trained for installation of trace
heaters
•Heaters and sensors need to be placed on the designated pipes / tanks in the planned
positions in order to avoid overheating of equipment as well as insufficient temperature
maintenance
•Remove any sharp irregularities (burrs etc.) from the surface to be heated
•Clean and degrease the surface
•Mark the spacing of the trace heaters on the surface to be heated
•For single conductor trace heaters that are fed from both ends: Arrange cable entry and
exit next to each other for the ease of power supply
•Installation of the heating circuit should be done with original eltherm accessories. Firstly,
attach the trace heaters to the surface with self adhesive aluminium tape (approx. one
patch every 300 mm).
Caution: Take care that the trace heaters are not twisted and that the installed sections do not
touch nor cross, as it might otherwise lead to local overheating and destruction of the trace
heaters. The minimum bending radius is 10 mm for trace heaters without jacket (ELK-AE, ELW-
VA, -GS, GN) and 2.5 x OD for trace heaters with jacket (ELK-AG). Trace heaters with flat cross
section are to be bent in the flat plane only.
•The trace heater and its supply lead is to be secured to the heated surface directly before
and after the connection sleeve (e.g. by adhesive tape or temperature resistant wire
straps)
•Attach heater to pumps, valves and other components in such way that those components
are accessible for maintenance or exchange without major mechanical stress for the
heater
•The electrical termination of the heating cable/tape is to be done with eltherm
termination kits only.

QAA - 024
Installation of Fluoropolymer Insulated
Series Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
Seite 5 von 6
Suitable accessories:
Trace Heater
Termination Kit
Gland
ELKM-AE
ELVB 26
-
ELKM-AG
ELVB 30,
ELVB 30-1
-
ELK-AE, -AG
-
Range 3-7 mm
ELW-GN, -GS, -VA
-
Range 8-13 mm
•The max. operating temperature of the heated device as defined by the plant owner as
well as the maximum trace heater temperatures (max. 220°C powered, 260°C unpowered,
max. 25 W/m heater output depending on maintenance temperature) must not be
exceeded.
•Make sure the heater has a good contact to the surface to be heated. In case of gaps, fill
those with thermally conductive and temperature resistant materials.
•The heater should be fully covered (the entire length) with aluminum foil in order to
prevent insulation material from slipping between the cable and surface to be heated.
•If thermal insulation with metallic cladding is used, provide an insulation entry kit to
protect the supply lead or heating tape against cuts
•Upon completion of the installation, the heating circuit needs to be marked by fitting an
appropriate label to the associated junction box or to the trace heater close to the junction
box. The label shall be weatherproof and bear relevant information of the installed system
including the Ex marking.
•Electrically heated parts have to be identified in reasonable distances with warning labels
“Electrical Heating” on the thermal insulation (approx. 5 m distance between each label on
pipelines or at least 1 warning label per pipe-branch respectively).
6. Testing
After the completion of a heating circuit and prior to the installation of the thermal insulation,
the following steps have to be taken:
•A visual check of the trace heater regarding possible mechanical damages and/or incorrect
installation
•Test of the insulation resistance
−The insulation resistance of each heating-circuit is to be measured between each single
bus wire and the metal sheath (protective braid) and is recorded afterwards.
−Test voltage: min. 500 VDC, max. 2500 VDC (recommended)
−Irrespective of the heating circuit length, the insulation resistance must not be lower
than 20 MOhm. In case of lower isolation resistance the source of the defect has to be
determined and removed.

QAA - 024
Installation of Fluoropolymer Insulated
Series Trace Heaters in Non-Ex Areas
Author
Peter Schmidt
Revision 5
13.11.2013
Seite 6 von 6
•Check of the function of the heat circuit (monitor the trace heater temperature to avoid
any overheating).
•Possible damages have to be fixed immediately. Short trace heaters may be replaced.
Longer trace heaters may be repaired by cutting off the defective part and insert a new
piece (refer to Connection Kit Instructions)
•Make sure heating circuit label is in place and information is legible
•All testing procedures have to be repeated after the thermal insulation has been applied.
7. Operation and Maintenance
•During operation of the system, local laws and regulations for the use of electrical trace
heaters in hazardous areas as well as all other applicable standards and safety regulations
are to be followed
•The permissible operating conditions as stated on the label, print or in the data sheets (i.e.
voltage, amperage, exposure temp., operating temp., IP protection classification) are to be
followed accordingly
•The maximum operating temperature given on the label must not be exceeded
•Trace heaters ELK- … and ELW-… generally operate maintenance free. However, it is
recommended that the system be checked by qualified personnel in regular intervals for
visual damages and insulation resistance.
•Lids and cable entries of junction boxes, thermostats splices etc. to which trace heaters
are connected need to be closed and sealed as per manufacturers instructions.
•The opening of controllers, junction boxes and terminations is permitted only when the
heating system is not energised
•Installed trace heater has to be protected against damages that may occur during repair
work on heated components
•After completion of the repair, the heating circuit will once again need to be tested as
shown in paragraph 6 “Testing”
•Damaged heating circuits shall not be operated. This is the case when:
−heater or attached leads show damage or deformation
−the circuit is electrically defective (open circuit, high leakage current)
−after thermal or mechanical overstress
−after failure of temperature controls
−after damage to the workpiece to which the heater is installed
•Temperature control units and control devices are to be checked at least annually by
trained workers or authorized persons.