eltherm ELK-MI-AY825 User manual

eltherm GmbH
Ernst-Heinkel-Str. 6-10
57299 Burbach
T.: [phone]
F.: [phone]
[email protected]
86500043
QAA – 021-Ex
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
0080083
03.02.2020
Operating Manual
Mineral-Insulated Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA in
Hazardous Locations (Ex)

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 2 of 21
Inhalt
2. System Components ...................................................................................................... 3
2.1 The Single Core Heating Systems comprise the following components:............................ 3
2.2 The Twin Core Heating Systems comprise the following components:.............................. 4
3. Technical Data ............................................................................................................... 4
4. Available Resistances ..................................................................................................... 5
4.1 ELK-MI-VA and VA-T ............................................................................................................ 5
4.2 ELK-MI-AY825 ...................................................................................................................... 7
4.3 ELK-MI-AY825 T ................................................................................................................... 8
5. Marking ......................................................................................................................... 9
6. Restrictions on thickness and material of thermal insulation........................................... 9
7. Heating Circuit Design .................................................................................................... 9
8. Location of temperature sensors .................................................................................... 9
8.1 Temperature controllers ..................................................................................................... 9
8.2 Temperature limiters......................................................................................................... 10
9. Summary of Conditions of Safe Use as per Type Approval Certificate............................. 11
10. Installation of the Heat Tracing System ELK-MI-**** Ex................................................. 12
10.1 Application......................................................................................................................... 12
10.2 Receipt of Goods ............................................................................................................... 12
10.3 Storage .............................................................................................................................. 12
10.4 Length of Heating Circuit................................................................................................... 12
10.5 Protective Measures.......................................................................................................... 13
10.6 Heater Installation............................................................................................................. 13
10.7 Test and Commissioning.................................................................................................... 15
10.8 Operation and Maintenance: ............................................................................................ 16
11.Installation of ELK-MI Trace Heaters ............................................................................. 17
11.1 Typical Installation of Mineral-Insulated Trace Heaters on Pipes..................................... 17
11.2 Typical Installation of Mineral-Insulated Trace Heater on Flanges................................... 18
11.3 Typical Installation of Mineral-Insulated Trace Heater on Elbows ................................... 18
11.4 Typical Installation of Mineral-Insulated Trace Heater on Valves .................................... 19
11.5 Typical Installation of Mineral-Insulated Trace Heater on Pumps.................................... 19
12. Installation of Gland..................................................................................................... 20
12.1 Design and Technical Data ................................................................................................ 20
12.2 Installation......................................................................................................................... 20
12.3 Operation and maintenance ............................................................................................. 21

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 3 of 21
1. Einsatzbereich
The Heat Tracing System ELK-MI-**** Ex is suitable for industrial use on piping, vessels,
instrumentation and related equipment in areas where combustible gases or dust may be
present. For details please refer to the attached type plate.
The system is based on series and twin heaters and is to be operated in controlled or stabilized
design as per IEC EN 60079-30-1 and -2. All electrical connections must be made to a suitable
junction box approved for Hazardous Areas or connected outside the Hazardous Area.
Furthermore, the heat tracing installation must meet the requirements of IEC EN 60079-14.
Installation is to be done by eltherm or by a specialist contractor for installation of electrical
systems in hazardous areas.
The T ratings for heating circuits are determined by eltherm (this includes confirmations of T
ratings made by third parties).
2. System Components
The Heat Tracing System ELK-MI-**** Ex comes prefabricated and ready for installation.
2.1 The Single Core Heating Systems comprise the following components:
•1 (each) Mineral insulated single core trace heater as per table 1, 2 and 3
•2 (each) Laser welded splices
•2 (each) Mineral insulated cold leads
•2 (each) Potted end seals with pigtails
•2 (each) Glands
potted end seal and pigtails
1 x phase 2.5 mm²
1 x earth 2.5 mm²
eltherm gland threaded
M20x1.5 , M25x1.5 , ½” NPT
or ¾” NPT
integral mineral
insulated cold lead, sheath
material same as heater
ELAK-Ex-3d or other IECEx / ATEX
approved junction box suitable for
area rating (separate)
integral mineral insulated
splice, internally and
externally laser welded,
material same as heater
sheath
mineral insulated single core
heater, sheath stainless
steel, alloy 825 or alloy 600

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 4 of 21
2.2 The Twin Core Heating Systems comprise the following components:
•1 (each) Mineral insulated twin core trace heater as per table 1, 2 and 4
•1 (each) Laser welded splice
•1 (each) Mineral insulated cold lead
•1 (each) Potted end seal with pigtails
•1 (each) Gland
•1 (each) Laser welded end termination
3. Technical Data
Sheath material VA / VA-T: stainless steel 1.4541 (AISI 321)
AY600 / AY600-T: Mat. 2.4816 (Alloy 600)
AY825 / AY825-T: Mat. 2.4858 (Alloy 825)
Gland material stainless steel 1.4404 (AISI 316L)
Min. bend radius 6 x cable diameter (see type plate or Tables 1, 2, 3 and 4 for
details)
Max. voltage 600VAC (AY600 / VA / AY825 / AY825-T; refer to type plate)
500VAC (AY600; refer to type plate)
400VAC (AY600-T / VA-T; refer to type plate)
300VAC (AY825-T; refer to type plate)
Max. exposure temp. 700°C (AY825 / AY825-T)
565°C
80°C (potted end seals)
Max. operating temp. refer to type plate
Min. installation temp. -60°C
Min. start up temp. -60°C
integral mineral insulated end
termination, material same as heater
sheath, internally and externally laser
welded
eltherm gland threaded M20x1.5,
M25x1.5 , ½” NPT or ¾” NPT
potted end seal and pigtails
(2 x phase [cross section same as cold lead
conductor], 1 x earth 1.5 mm²)
integral mineral insulated cold lead
(cross section 2.0, 2.5, 3.3 or 5.0 mm²),
sheath material same as heater
integral mineral insulated
splice, material same as heater
sheath, internally and
externally laser welded
mineral insulated twin core heater, sheath
stainless steel, alloy 825 or alloy 600
ELAK-Ex-3d or other IECEx / ATEX
approved junction box suitable for
area rating (separate)

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 5 of 21
4. Available Resistances
4.1 ELK-MI-VA and VA-T
Table 1: Available resistances and bend radii ELK-MI-VA and ELK-MI-VA-T
No.
Resistance Ω / m
Outer diameter (mm)
Bending radius (mm)
VA:
1
10,000
3,20
19
2
6,300
3,20
19
3
5,200
3,50
21
4
4,000
3,20
19
5
3,300
3,50
21
6
2,500
3,40
21
7
1,600
3,60
22
8
1,000
3,90
24
9
0,630
4,30
26
10
0,400
4,70
28
11
0,250
5,30
32
12
0,160
6,50
39
cold:
13
0,007
5,70
34
VA-
T:
1
36,000
3,70
22
2
24,600
4,00
24
3
19,680
3,80
23
4
13,120
4,40
26
5
9,840
5,10
31
6
6,600
5,00
30
7
4,600
5,30
32
8
3,200
4,00
24
9
2,460
5,00
30
10
1,600
4,70
28
11
1,000
4,40
26
12
0,750
5,10
37
13
0,330
6,70
40
cold:
14
0,022
7,50
45

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 6 of 21
4.2 ELK-MI AY600 and AY600-T
Table 2: Available resistances and bending radii for AY600 and AY600-T
Nr.
Resistance Ω / m
Outer diameter (mm)
Bending radius (mm)
AY
600:
1
10,000
3,20
19
2
6,300
3,20
19
3
5,200
3,50
21
4
4,000
3,20
19
5
3,300
3,50
21
6
2,500
3,60
22
7
1,600
3,80
23
8
1,000
4,10
25
9
0,630
4,50
27
10
0,400
5,00
30
11
0,250
5,60
34
12
0,160
6,50
39
cold:
13
0,007
4,90
29
AY
600
-T:
1
36,000
3,70
22
2
24,600
4,00
24
3
19,680
3,80
23
4
13,120
4,40
26
5
9,840
5,10
31
6
6,600
5,00
30
7
4,600
5,30
32
8
3,200
4,00
24
9
2,460
5,00
30
10
1,600
4,70
28
11
1,000
4,40
26
12
0,750
5,10
37
13
0,330
6,70
40
cold:
14
4,90
29
15
7,50
45

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 7 of 21
4.3 ELK-MI-AY825
Table 2: Available resistances and bending radii ELK-MI 825
No.
Resistance Ω / m
Outer diameter (mm)
Bending radius (mm)
AY825
1
6,560
4,30
26
2
5,250
4,30
26
3
4,270
4,30
26
4
3,280
4,30
26
5
2,790
4,30
26
6
2,300
4,30
26
7
1,640
4,30
26
8
1,250
4,30
26
9
0,980
4,30
26
10
0,820
4,30
26
11
0,660
4,40
26
12
0,560
4,60
28
13
0,490
4,30
26
14
0,330
4,30
26
15
0,260
4,30
26
16
0,230
4,30
26
17
0,200
4,30
26
18
0,130
4,40
26
19
0,100
4,70
28
20
0,070
5,10
31
21
0,034
4,30
26
22
0,021
4,60
28
23
0,014
4,80
29
kalt:
24
5,30
32
25
5,70
34
26
6,40
38
27
7,20
43

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 8 of 21
4.4 ELK-MI-AY825 T
Table 3: Available resistances and bend radii ELK-MI 825-T
No.
Resistance
Ω / m
300 V Outer
Diameter (mm)
300 V Bend
Radius (mm)
600 V Outer
Diameter (mm)
600 V Bend
Radius (mm)
AY825-T:
1
36,100
4,10
25
5,60
34
2
29,500
4,10
25
5,70
34
3
24,600
4,10
25
4
19,700
4,10
25
5,80
35
5
16,400
4,10
25
6
13,100
4,10
25
6,10
37
7
10,500
4,10
25
8
8,860
4,10
25
9
8,200
4,10
25
10
6,560
4,10
25
11
6,530
6,50
39
12
5,580
4,10
25
13
4,590
4,10
25
14
3,280
4,20
25
6,50
39
15
2,300
4,60
28
6,70
40
16
1,640
4,80
29
7,10
43
17
0,980
4,30
26
7,60
46
18
0,820
4,30
26
19
0,660
4,33
26
6,50
39
20
0,490
4,40
26
6,70
40
21
0,330
4,80
29
7,10
43
22
0,230
5,20
31
7,50
45
23
0,160
5,70
34
7,90
47
24
0,130
8,30
50
25
0,098
8,80
53
26
0,066
6,90
41
27
0,052
7,10
43
28
0,043
7,40
44
29
0,033
7,60
46
cold:
30
7,10
43
31
8,00
48
32
8,90
53
33
9,70
58
34
11,00
66

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 9 of 21
5. Marking
Trace heaters ELK-MI-**** Ex are marked as follows
6. Restrictions on thickness and material of thermal insulation
Insulation materials need to withstand at least the expected cable sheath temperatures,
otherwise no restrictions.
7. Heating Circuit Design
Design of heating circuits is to be done by eltherm based on data provided by the user.
Alternatively, users may design heating circuits with eltherm design software and provide
eltherm with the designs for final approval and issuance of circuit labels.
8. Location of temperature sensors
8.1 Temperature controllers
Temperature sensors may be used either as ambient sensing devices or attached
directly to the equipment/device that is to be heated.
In case of ambient sensing, place the sensor in the coldest expected spot of the area
where the heated equipment is located. This is typically a shaded place (e.g. on the
northern side of buildings) on low ground. However, ambient sensing is recommended
only for frost protection applications and when the permissible temperature band of
maximum permitted maintain
temperature

86500043
Operating Manual Heat Tracing System
ELK-MI-AY825 / ELK-MI-VA
In Hazardous Locations (Ex)
Author
Peter Schmidt
Revision 3
03.02.2020
Page 10 of 21
the equipment to be heated and its contents is considerably wide (approx. 50K). Please
consult the eltherm project department if further assistance is required.
In cases where sensors are directly attached to the heated equipment/device, two
different applications need to be considered:
a) heated pipes
Place the sensor on the anticipated coldest section of the pipe. Avoid direct contact
between sensor and heating cable. Branched piping systems may require more than
one heating circuit (with a sensor each) or implementation of the “dead leg” technique
depending on the flow pattern of the piping system. If help is required, please consult
the eltherm project department for further assistance.
b) heated vessels
Place the heating on surfaces that always have contact to the contents of the vessel
(typically the bottom of the vessel and/or lower section). Then place the temperature
sensor in the heated area. Avoid direct contact between sensor and heating cable.
Large vessels may require more than one heating circuit, especially when they need to
be heated up at various filling levels. If help is required, please consult the eltherm
project department for further assistance.
Be aware of the fact that temperature sensors mounted on the surface of the heated
equipment never provide readings of the exact temperatures of the medium inside the
device that is being heated. Therefore, temperature settings may need to be
determined in an empirical way when exact temperatures are crucial for the process.
8.2 Temperature limiters
The use of temperature limiters is recommended to prevent excessive temperatures in
case of a failure of the temperature control. For controlled design of heating circuits in
Hazardous Areas, a temperature limiter is mandatory. Temperature limiter sensors are
to be installed in the anticipated hottest areas of the equipment that is to be heated.
Avoid direct contact between sensor and heating cable. A temperature offset between
the equipment and heating cable sheath needs to be considered for the temperature
settings. Please consult the eltherm project department if further assistance is
required.