Emerson Easy Heat TSR Series User guide
READ CAREFULLY
PRINCIPLE OF OPERATION
Easy Heat TSR is a self-regulating heating cable that automatically
varies its heat output with changes in surrounding temperature.
Since this cable regulates its heat output with temperature,
a thermostat may not be necessary for some applications.
Easy Heat TSR cable can be used for pipe freeze protection or
temperature maintenance applications, in either ordinary or
-
opolymer overjacket for use in areas requiring enhanced chemi-
for maintaining grease and fuel lines at temperatures required for
The TSR cable is available with power densities of 3, 5, 8 and 10
-
ture of 50oF. At other temperatures, of course, the cable power
output will be considerably different. (See chart).
Nominal Power Output on
Metal Pipe
25 50 75 100 125 150
Pipe Temperature oF
WATTS/FT
8w/ft
5w/ft
3w/ft
10
8
6
4
2
0
10w/ft
CONSTRUCTION DETAILS
TINNED COPPER
GROUND
BRAID
BUS
WIRES
FLAME RETARDANT
TPE OUTER JACKET
POLYOLEFIN
OVER
JACKET
TPE INNER
JACKET
IRRADIATED SELF-REGULATING
HEATING CORE MATERIAL
16 AWG
TINNED
COPPER
Performance and Rating Data
Power Rating
oF (10o
M)
TSR SPECIFICATIONS/APPLICATION INFORMATION
Note:
oF (66oC) with
185oF (85o
Power Rating Multiplier
Cable 208 220 277
TSR Self-Regulating Pipe Tracing Heating Cable
©2008 Easy Heat www.easyheat.com 40252-001 Rev. 5
Because of the self-regulating feature of this cable, it can be
wrapped over itself (overlapped), if necessary, when installed on
Voltage
Cable Power
Watts/FT
Start-up
Temp
Maximum Total Cable Length vs. Circuit Breaker Rating
15A 20A 30A 40A
120
3
-20ooC)
0oF (-18oC)
50°f (10°C)
5
-20ooC)
0oF (-18oC)
50°F (10°C)
8
-20ooC)
0oF (-18oC)
50°F (10°C)
10
-20ooC)
0oF (-18oC)
50°F (10°C)
240
3
-20ooC)
0oF (-18oC)
50°F (10°C)
5
-20ooC)
0oF (-18oC)
50°F (10°C)
8
-20ooC)
0oF (-18oC)
50°F (10°C)
10
-20ooC)
0oF (-18oC)
50°F (10°C)
DESIGN PROCEDURE
The following procedure can be used to select a heating cable
system for your application. However, Easy Heat can also pro-
vide design assistance and will recommend appropriate cable,
controls and accessories. Call Easy Heat for further information.
To determine the heat loss that must be replaced by the heating
cable, the following should be determined:
FFluid temperature to be maintained
AMinimum ambient temperature
TYPICAL INSTALLATION
END
In-line splice
(under insulation,
not shown)
TAPE
HEATER
Power Connection Kit
PLEASE NOTE THAT THIS INSTALLATION IS FOR ORDINARY (NON-HAZARDOUS) LOCATIONS
Tee splice
(under insulation, not shown)
The use of ground fault protection
equipment for heating cable applica-
tions is required by NEC and CSA CEC.
TSR Cable with polyolefin overjacket
(suffix ‘J’) may also use SR Trace Kits
in nonhazardous applications.
Connection Kits
Controls
Ambient sensing adjustable
©2009 Easy Heat www.easyheat.com
1. TEMPERATURE DIFFERENTIAL
Determine the temperature differential (DT) to be maintained by
subtracting the ambient temperature (TA-
ture (TF) to be maintained (DT=TF-TA). Typically, for pipe freeze
protection applications, the pipe temperature should be main-
tained at 40°F. Pipe temperatures should be maintained at 110°F
for grease disposal lines and 40°F for fuel lines.
2. HEAT LOSS
Use Table 1 to look up the heat loss associated with the pipe
diameter and thickness of insulation. If a rigid insulation such as
calcium silicate is used, the pipe heat loss should be increased to
oversized when using any cable other than the standard self-reg-
ulating TSR, without overjacket. This will compensate for the space
diameter heat losses for 11/2 inch pipe heating application if rigid
safety factor.
3. ADJUSTMENTS TO HEAT LOSS VALUES
The heat losses in Table 1
other insulations are used, multiply the heat loss value by the cor-
rection factor (shown in
Table 2) for your insulation.
Heat losses are based on outdoor applications with 20 mph
4. DETERMINE CABLE P0WER
Using heat loss determined above, select appropriate cable
It is also possible to spiral cable on pipe such that the power ap-
-
ple, for heat loss of 13 W/ft, a 10 W/ft cable can be spiraled on
the pipe such that 1.3 feet of cable are wound on every foot of
not recommend spiraling. For further information on spiraling,
contact Easy Heat.
Insulation
∆T IPS 1/23/4111/411/22 21/23 4 5 8 10 12
Thickness
(°F) Tubing 3/4 111/4 11/2 2
(50mm) 50 1.2 1.3 1.4 1.6 1.7 2.0 2.3 2.6 3.1 4.2 5.2 6.3 7.3
(63mm) 50 1.0 1.2 1.3 1.4 1.6 1.8 2.0 2.3 2.7 3.6 4.4 5.2 6.0
(75mm) 50 1.0 1.1 1.2 1.3 1.4 1.6 1.8 2.0 2.4 3.1 3.8 4.5 5.2
Table 1 – Pipe Heat Loss, W/FT
Contact Easy Heat for larger sizes.
©2009 Easy Heat www.easyheat.com
6. DETERMINE CABLE LENGTH
Cable length = pipe length × N + heat sink adjustments × N + slack × N
N = number of traces
7. CABLE CONTROL
It is recommended that heating cables be controlled by a
thermostat to minimize energy consumption and provide appro-
priate temperature regulation of the pipe contents. Easy Heat
provides a full range of temperature control options, as follows:
ORDINARY AREAS
T4XA, Ambient sensing thermostat-
ent temperature falls below setting. Setting is adjustable from 15
protection applications.
C4XC Line sensing thermostat
enclosure. Use for freeze protection and fuel line temperature
maintenance.
T4XC, Line sensing thermostat
(pipe) temperature falls below setting. Setting is adjustable
-
ess control application, including grease lines.
HAZARDOUS LOCATIONS (CII, DIV. 2)
T9EA, Ambient sensing thermostat-
ent temperature falls below setting. Setting is adjustable from 15
protection applications.
T9EC, Line sensing thermostat
temperature falls below setting.
Setting is adjustable from 25 to 325°F (-4 to 163°C). NEMA 4, 7
EXAMPLE
1. CALCULATE TEMPERATURE DIFFERENTIAL
2. HEAT LOSS
Use Table 1-
ferential falls between two values, use interpolation:From Table 1:
3. ADJUSTMENT TO HEAT LOSS
Table 2, the adjusment
factor is 1.2.
Since the piping is outdoors, no adjustment is necessary for the
absence of wind.
4. DETERMINE CABLE POWER
Select 8 w/ft cable. Apply single cable straight along the pipe.
5. ADJUSTMENT FOR HEAT SINKS
From Table 3, an additional 3 feet of cable is required at each
valve.
6. DETERMINE CABLE LENGTH
Slack = 2 + 0 × 2 + 1 × 2 = 4
7. SELECT ACCESSORIES
set to 50°F.
Table 2 – Insulation Factors
Insulation Type Correction Factor
Calcium Silicate 1.72
Rigid Urethane 0.76
Foamed Elastomer 1.16
Mineral Fiber 1.20
Mineral Wool 1.04
Polystyrene 1.04
Polyisocyanarate 0.68
5. ADJUSTMENTS FOR HEAT SINKS
Any thermally conductive item that protrudes through the insulation
in Table 3 should be added to the required heater cable length
or spiraling cable, increase the cable adders proportionately.
Table 3 – Heat Loss Adder
Additional Heater Feet for Various Heat Sinks
Pipe Size Flange Pipe Support (1) Valve
.50 .5 1.0 1.0
.75 .5 1.5 1.5
1.00 .5 1.5 2.0
1.50 .5 1.5 2.5
2.00 .5 2.0 2.5
3.00 .75 2.0 3.0
4.00 .75 2.5 4.0
6.00 1.0 2.5 5.0
8.00 1.0 2.5 7.0
©2009 Easy Heat www.easyheat.com
HEAT TRACE CONSIDERATIONS
1. TYPES OF HEATER CONTROL
There are two types of temperature control:
projects, either of these types of control are achieved with indi-
it may be advantageous, in terms of cost and maintenance, to
use larger central control cabinets with electronic control.
LINE SENSING CONTROL
For line sensing control, a thermostat is used to sense the actual
pipe temperature. The heater is only energized when the pipe’s
temperature drops below the thermostat’s set point.
When controlling a heater circuit on a pipe that has both
heater circuits may be required.
Advantages of this system include more precise temperature
control and minimum energy usage. Initial control costs and
ongoing maintenance costs will rise in proportion to the number
of controllers used.
SENSING AMBIENT AIR
For ambient control, the heater is turned “off” and “on” de-
pending on the temperature of the surrounding air. The setpoint
temperature to turn on the cable may be adjustable or preset
(40°F is a typical value). When energizing multiple heater loads,
a contactor may be used to perform the actual switching. Ad-
consumption and loss of precise temperature control may result
(since heaters may be on when pipe temperature is warm).
2. EFFECTS OF HEAT SINKS
Any thermally conductive material that penetrates through the
insulation pulls heat away from the pipe or vessel at a high rate. If
be colder in those areas, which may result in freeze-up or loss of
process temperature.
3. HEAT-UP REQUIREMENTS
Heat loss tables do not include adequate power to provide
heat-up situations. Contact Easy Heat for further information.
4. HAZARDOUS AREA DESIGN CRITERIA
ignition temperature of the hazardous gas or dust that is
present. The method of limiting this temperature varies with
different types of products:
PIPE SENSING
THERMOSTAT
HEATING CABLE
TAPE BULB TO PIPE
LOCATE BULB AT
LEAST 90oFROM
HEATER
Self-regulating heaters may be used based on their maximum
“T Rating.” Under no conditions will they exceed those tem-
peratures.
Each heater installed in a hazardous area must have a metal
shield or sheath. This provides an effective return ground path as
well as providing added physical protection.
All connections and control equipment must meet the criteria
for hazardous area application. For Division I applications, please
consult Easy Heat.
5. NON-METALLIC SURFACES
Non-metallic pipes and vessels often have low
softening and melting points. Care must be taken in design not
to let the surface or heater reach that temperature.
TSR cables can be used safely without concern.
6. DESIGNING SELF-REGULATING HEATER
CABLES FOR PLASTIC PIPE
Plastic pipe is not very thermally conductive, which results in less
heat being transferred to plastic pipe than to metal pipe. There
are three methods of applying heater cable to plastic pipe:
a) Regular attachment at one-foot intervals—
Attachment of cable at one foot intervals along the pipe.
Sometimes adequate.
b) Foil over the cable—Fasten the cable at one-foot intervals
(as above) and then cover with a layer of adhesive-backed
foil tape. Usually adequate
c) Foil over/under (sandwiched) cable—Apply a layer of
adhesive-backed foil tape on the pipe.
Fasten the cable over the foil tape per a) above. Then ap-
ply another layer of foil tape over the cable. Almost always
adequate.
7. USE OF METAL FOIL TAPE TO LOWER
SHEATH TEMPERATURE ON METAL PIPE
Metal foil tape can be used on all types of heaters to lower
sheath temperature. This should only be done to improve life
DO NOT USE THIS TECHNIQUE TO LOWER SHEATH
TEMPERATURES FOR HAZARDOUS APPLICATIONS.
©2009 Easy Heat www.easyheat.com
8. TEMPERATURE “PILING” IN
VERTICAL INSTALLATIONS
piping run, it is possible to have a 1.5 to 3.0 degree F. rise per vertical
and circuit breakup should be used to overcome this temperature
control problem.
9. STATIC vs. FLOWING FLUID CONDITIONS
Most design concerns should center around static situations. For
10. TERMINATION AND SEALING OF
CABLE CONNECTIONS
Cable ends, splices, etc. must be properly sealed to prevent
through insulation lagging, are common moisture sources. Moisture
is a primary source of electrical arcing/failure in heating cable. Easy
Heat connection kits contain appropriate components and instruc-
tions to properly seal all connections. Use only Easy Heat connection
kits and follow instructions carefully.
11. FOAMED/POURED INSULATION
When heating cables are to be insulated with foamed, mudded
or poured insulation, the cable must be covered by foil. This is to
prevent the cable from being thermally isolated from the pipe. If
12. INSULATION QUALITY
It is recommended that all heat traced pipes have a minimum
traced pipes will not provide reliable performance. Water leaks
(around valves, hangers and lagging lap joints) will soak insulation.
The heating cable cannot maintain temperatures with wet insula-
tions, and once the insulation becomes wet, the heating cable will
In addition, insulation quality must be maintained. Crushed or wet
insulation will increase heat loss by 20 to 50 times the design rate.
13. ANNUAL SYSTEM CHECK-OUT
Check all freeze protection heating cable systems before each
freeze season. Process maintenance systems should be checked
annually. A system check should verify that all systems are function-
temperature control function, and whatever else is appropriate to
your situation.
©2009 Easy Heat www.easyheat.com
LIMITED WARRANTY AND LIABILITY
provide new products to replace any defective items, or we will refund the purchase price paid for the accessory or cable, not including any labor or other installation
costs. As an alternate, we may elect to repair the cable or accessory at our factory with all shipping and other removal costs borne by the purchaser.
We further warrant that any services performed for the Buyer hereunder will be performed in a good and skillful manner, based on our understanding of pertinent
technical data as of the date of performance of such services. Easy Heat’s sole responsibility and liability in the event of any defect, error, omission, or failure in the
services rendered hereunder shall be to provide corrected services of the type provided for herein, designed to correct such defect, error, omissions, or failure, and in
or electrical activities unrelated to the operation of the accessory or cable.
A refund of your purchase price, provision of replacement products, repair of the accessory or cable or provision of corrected services as described above, shall be
your sole and exclusive remedy for a breach of this warranty. THESE ARE THE SOLE AND EXCLUSIVE WARRANTIES GIVEN BY EASY HEAT WITH RESPECT TO THE GOODS AND
SERVICES AND ARE IN LIEU OF AND EXCLUDE ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING WITHOUT LIMITATION,
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHETHER OR NOT THE PURPOSE OR USE HAS BEEN DISCLOSED TO EASY HEAT IN SPECIFICATIONS, DRAWINGS OR
OTHERWISE, AND WHETHER OR NOT EASY HEAT’S PRODUCTS ARE SPECIFICALLY DESIGNED AND/OR MANUFACTURED BY EASY HEAT FOR YOUR USE OR PURPOSE.
that actual operating conditions or other conditions differ from those represented by you, any warranties or other provisions contained herein which are affected by
such conditions shall be null and void.
If within thirty (30) days after your discovery of any warranty defects within the warranty period, you notify Easy Heat thereof in writing, Easy Heat shall, at its option,
shipment of the repaired or replaced goods, whichever is longer.
This limited warranty does not cover any costs relating to the repair or replacement of any accessory or cable at the installation site
not easily accessible. A failed accessory or cable usually cannot be easily repaired. Replacement of a failed accessory or cable will require that the materials under
which it is installed be removed to permit replacement of the accessory or cable. We will not reimburse any costs relating to the repair or replacement of any accessory
or cable at the installation site.
IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT
OR OTHERWISE), SHALL EASY HEAT’S LIABILITY TO YOU AND/OR YOUR CUSTOMERS EXCEED THE PRICE PAID BY YOU FOR THE SPECIFIC GOODS PROVIDED BY EASY HEAT GIVING
RISE TO THE CLAIM OR CAUSE OF ACTION. YOU AGREE THAT WE SHALL NOT BE LIABLE TO YOU OR YOUR CUSTOMERS FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL
OR PUNITIVE DAMAGES. No agent, employee or representative of ours has authority to bind us to any afrmation, representation or warranty concerning the goods sold
unless such afrmation, representation or warranty is specically incorporated by written agreement.
purchase at the address noted herein.
ATTN: WARRANTY DEPARTMENT:
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8
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