nVent RAYCHEM FROSTEX Mounting instructions

Keep pipes from freezing
nVent RAYCHEM Frostex Pipe Freeze Protection System Using
the 9800 FlexFit Plug Kit Installation Instructions and User Guide
APPROVALS
-G
60J9 Residential and
Mobile Home Pipe
Heating Cable
FROSTEX

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ENGLISH
Before You Begin
Make sure your nVent RAYCHEM Frostex
9800 FlexFit Plug Kit is complete. It should
contain:
1 9800 FlexFit plug
1 Push-on end seal
2 Orange warning labels
1 Installation instruction
Make sure you have sufficient braided
Frostex heating cable for the job. Do not
use earlier versions of Frostex heating
cable that have no braid. Also make sure
you have the following items:
*Frostex 9610 application tape is
recommended.
Two 10-in (25 cm) plastic cable ties
(not included) may be used to secure
ground-fault unit to pipe insulation.
If you have any questions after reading this
guide, call this toll-free nVent number:
[phone].
Save this installation instruction and
user guide. It contains important safety
warnings and maintenance information.
Wire cutters
#2 Phillips
screwdriver
1/2 in–1 in
(13 mm–25 mm)
tape*
Contents
Five Important Safety Warnings ................. 3
General Instructions .................................... 3
Installation Instructions............................... 1
Cable Length Selection Tables .................. 4
Periodic Inspections .................................... 9
Troubleshooting........................................... 9
Limited Warranty .......................................10
9800 FlexFit plug
Reset button
Test button
Ground
fault unit
Indicator
light
TEST
Gel-filled
end seal

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SAFETY WARNINGS:
Follow all five of these instructions to
prevent fire or shock:
1. Use the correct heating cable.
• Use only braided versions of Frostex heating cable.
• Earlier versions of Frostex heating cable with no
braid are not compatible.
2. Use the right end seal and plug.
• Seal the heating cable only with the end seal
provided; do not use electrical tape.
• Use the 9800 FlexFit plug contained in this kit.
It has special safety features.
• Use the 9800 FlexFit Plug Kit only with Frostex
heating cable.
3. Do not twist wires together or allow
them to touch each other.
• Do not strip the heating cable. If wires touch, the
nonreplaceable fuse will blow and the system will
not work.
4. Keep the entire Frostex system dry.
This includes the insulation.
If the system gets wet, pipes may
freeze.
• Use the system only on insulated residential pipes
carrying water.
• Do not use the system on buried pipes.
• Do not use the system to de-ice roofs or gutters.
• Do not install any part of the heating system where
it would be under water.
• Do not use where water is likely to enter the plug.
5. The blue plastic heating cable and the
metal braid must not be cut or damaged.
• Before you begin, inspect the pipe. File and remove
any sharp edges. Make sure the heating cable
crosses only smooth, nonabrasive surfaces.
• Where the system might be damaged by animals
or objects, protect the complete system with a
solid cover, such as sheet metal or additional pipe
insulation.
• Do not use any wire or clamps to attach the
heating cable to the pipe. Instead, use the Frostex
9610 application tape, or equivalent 1/2 in–1 in
(13 mm–25 mm) tape, or plastic cable ties.
• Inspect the heating cable periodically for damage.
If you discover broken braid or other damage,
immediately disconnect the system and replace the
heating cable. Do not splice or repair a damaged
heating cable. You must replace any damaged
insulation or waterproof covering.
6. Do not install Frostex heating cable
close to flammable materials, liquids,
or fumes.
• Use only 1/2 in (13 mm) or thicker fire-retardant and
waterproof pipe insulation, in accordance with Table
1 or 2.
GENERAL INSTRUCTIONS
• Observe the safety warnings on page 1. Follow the
installation steps (pages 2–7) in the exact order given.
• To ensure the plug is properly connected, do not
assemble at temperatures below 0°F (–18°C).
• The Frostex system can be left plugged in all year,
however you will save energy by unplugging the system
when there is no risk of freezing.
• Use a properly grounded, 3-prong, 120-V outlet. If you
are not sure if your outlet is properly grounded, call a
professional service person.
• In manufactured housing installations, use the electrical
receptacle on the underside of the home. Do not use
an extension cord or there may be danger of fire or
shock. Using an extension cord is not in compliance with
national electrical codes.
• Frostex heating cable may be used on metal or plastic
pipes and tubing. Do not install on garden hoses or in
applications with tubing that is flexed frequently.
• Exposure to temperatures above 150°F (65°C) will
shorten the life of your Frostex heating cable. Before
installing the heating cable on hot water pipes, set the
water heater thermostat below 150°F (65°C), low to
medium on most thermostats.
• Remove any old heating tapes and insulation before you
install the Frostex heating cable.
• Do not use more than 50 feet (15 meters) of Frostex
heating cable with each 9800 FlexFit plug. Longer
lengths will blow the nonreplaceable fuse in the plug.
• The homeowner will need to keep these instructions for
future reference. It contains important safety warnings
and maintenance information.
• If you have any difficulty installing the system, please
contact nVent for information at [phone], or call a
professional service person for help.
• Remove the clear label that covers the test and reset
buttons after installation.
INSTALLATION INSTRUCTIONS
Step 1.
Determine the length of
heating cable you need
1A. Collect the necessary information
You will need to know the following:
• Type of pipe (plastic or metal).
• Length and diameter of pipe.
• Lowest expected air temperature (disregard windchill).
• Number of valves and spigots (requires additional
heating cable).
• If there is a crock (typically used for manufactured
housing applications).
1B. Determine the amount of Frostex
heating cable you will need
How to use the tables:
• Decide on the lowest temperature you can expect
in your area, down to –40°F (–40°C).
• Measure the diameter of your pipe in inches.
• Using Table 1 or 2 depending on pipe material,
determine how many straight runs of Frostex
heating cable required to protect the pipe. One run
is equal to the length of the pipe.
• To minimize the amount of heating cable required,
select the optimal insulation thickness from
Table 1 or Table 2.

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Cable Length Selection Tables
Table 1. Metal Pipe
Number of heating cable runs required
1/2 in
1/2 in
1 1 2 2
Pipe Size
Insulation
Thickness
20°F
(–10°C)
0°F
(–20°C)
–20°F
(–30°C)
–40°F
(–40°C)
3/4 in 1 1 2 2
1 in 1 2 2 2
1 1/4 in 1 2 2 3
1 1/2 in 1 2 3 3
1/2 in
3/4 in
1 1 1 2
3/4 in 1 1 2 2
1 in 1 1 2 2
1 1/4 in 1 2 2 2
1 1/2 in
3/4 in
1 in
1 1/4 in
1 1/2 in
2 in
3/4 in
1 in
1 1/4 in
1 1/2 in
2 in
1 2 2 3
1 in
1 1 1 2
1 1 2 2
1 1 2 2
1 1 2 2
1 2 2 2
1 1/2 in
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 2
1 1 2 2
Lowest Expected Temperature
Metal Pipe
Table 2. Plastic Pipe
Number of heating cable runs required
Lowest Expected Temperature
1/2 in1/2 in 1 2 2
Pipe SizeInsulation
Thickness
3/4 in 1 2 2 3
1 in 1 2 3 3
1 1/4 in 2 2 3
1 1/2 in 2 3 3
1/2 in3/4 in 1 2 2 2
3/4 in 1 2 2 3
1 in 1 2 2 3
1 1/4 in 1 2 3 3
1 1/2 in
3/4 in
1 in
1 1/4 in
1 1/2 in
2 in
3/4 in
1 in
1 1/4 in
1 1/2 in
2 in
2 3 3
1 in 1 1 2 2
1 1 2 2
1 2 2 3
1 2 3 3
1 2 3 3
1 1/2 in 1 1 1 2
1 1 2 2
1 1 2 2
1 1 2 2
1 2 2 3
Plastic Pipe
20°F
(–10°C)
0°F
(–20°C)
–20°F
(–30°C)
–40°F
(–40°C)
= Increase insulation thickness
1C. Calculate the total length of heating
cable required
Multiply the number of heating cable runs
by your pipe length. Add one extra foot
(30 cm) for each valve in your line. Add
one extra foot (30 cm) for the distance to
the power connection. For installations in
a crock, add an additional 2 feet (60 cm)
of heating cable. After cutting the Frostex
heating cable to the length you need,
proceed to Step 2.
Example:
Pipe size and
material:
1-inch diameter,
plastic
Lowest ambient
temperature:
–20°F (–30°C)
Pipe length: 16 feet (5m)
Valves: 1 ball valve is used
The water connection is in a crock.
From Table 2, Plastic Pipe, for –20°F
(–30°C), either two or three runs of Frostex
heating cable is required depending on pipe
insulation thickness.
Optimal pipe insulation thickness: 3/4 in
Selecting 3/4 in thick insulation requires two
runs of Frostex heating cable installed along
the entire length of the pipe (Table 2).
The total length of heating cable equals:
32 ft (10 m) 2 runs x 16 ft (5 m)
of pipe
+ 1 ft (0.3 m) for one ball valve
+ 1 ft (0.3 m) for one power connection
+ 2 ft (0.6 m) for installing in a crock
36 ft (11 m) total length
Note: Do not use more than
50 feet (15 meters) of heating cable
per plug. If the total
calculated length exceeds 50 feet
(15 meters), you will need additional
9800 FlexFit plugs and outlets.
Longer circuit lengths will blow the
nonreplaceable fuse in the 9800
FlexFit plug. If you require more than
50 feet per length
(15 meters), call nVent for
information on other products.

nVent.com | 5
Step 2.
Install the end seal
Note: The end seal can only be used
once, so do not install it until step 2D.
Heating Cable Construction
Clear plastic
wrap
Black core
(bus wires inside)
Braid Blue jacket
2A. Prepare the heating cable
Cleanly cut off one end of the heating cable.
2B. Push the braid back
Push the braid back 1 in (25 mm) from
heating cable end.
1 in
(25 mm)
2C. Remove the plastic wrap
Cut and remove the clear plastic wrap.
Do not cut into the blue jacket.
1 in
(25 mm)
2D. Install the end seal
Firmly push the end seal at least 3/4 in
(2cm) onto the heating cable. Some gel may
ooze out.
2E. Secure the braid
Slide the braid up against the end seal and
wrap it securely with a 4-in (10 cm) strip of
glass fiber or vinyl tape.

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Step 3.
Install the 9800 FlexFit plug
Cable guide
Ground contact
Indicator post
Back wall
Cover
TEST
Indicator
light
Ground-fault
unit
Reset button
Test button
Keep dry
Garder au sec
3A. Prepare the cable
Cleanly cut off the end of the cable. Push
back the braid 3/4 in (2 cm) and then twist
the end of the braid around the cable to
ensure the braid strands are not sticking up.
Note: The clear plastic wrap does not
need to be removed.
3B. Insert the cable
Insert the heating cable all the way into the
cable guide until the cable hits the back wall.
Be sure no braid wire strands enter cable
guide.
Back wall
3C. Complete the connection
Screw down the cable guide, alternating
between the two screws, until the cable guide
is flush with the indicator posts and the
screws bottom out.
3D.Install the cover
Install the cover by tightening the screws com-
pletely.
Note: The screws will require many turns
before the cover starts to close.
3/4 in
(2 cm)
Indicator
post

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Step 4.
Attach the heating cable to the
pipe
4A. Prepare to install the heating cable
Begin the installation at the electrical outlet.
Leave at least 1 foot (30 cm) of extra heating
cable so the ground-fault unit can be secured
to the outside of the thermal insulation, as
shown in Figures
1 and 2. This will relieve any strain on the
heating cable or plug. However, be careful not
to leave heating cable hanging in a loose loop
where it could be accidentally snagged and
pulled out.
Make certain you have removed any old
heating tapes and insulation.
Important: The ground-fault unit and plug
must be kept dry. It is important to include
the drip loop to prevent water from getting
into the ground-fault unit.
Thermal
insulation
Cable ties
or tape
End seal
Outlet
cover
Drip loop
9800
Flexfit
plug
Figure 1. Typical manufactured housing installation
Figure 2. Typical installation
4B. Install the heating cable
Single run method
Run the heating cable in a straight line
approximately a third of the way up from the
bottom of the pipe, as shown in Figure 3.
Frostex 9610
application tape;
1-foot spacing
Figure 3. Single run method
Multiple run method
When two or more runs are required, install
the heating cable in the 4 o’clock and
8 o’clock positions as shown in Figure 4.
When three runs are required, install the
heating cable as shown in Figure 5.
Figure 4. Double runs Figure 5. Triple runs
4C. Tape the heating cable and end seal to
the pipe
Fasten the heating cable to the pipe at
1-foot (30-cm) intervals, using two or three
thicknesses of 9610 application tape or
equivalent.
Provide extra heat at valves and spigots
by wrapping each with 1 foot (30 cm) of
additional heating cable, overlapping as
required.
If you have excess heating cable at the end
of your pipe, double it back along the pipe
where the insulation will completely cover it
as shown in Figure 6. Using 9610 application
tape or equivalent, tape the end seal to the
pipe as shown in Figures 1, 2, and 6.
Figure 6. Multiple run installation
Important: In a crock or standpipe, run
the Frostex heating cable down and back up
the pipe (as shown in Figure 6), so that the
end seal is well above the ground level and
will not be sitting in water.
8 4 8 4
12
Pipe
Crock
Ground
level
End seal
Thermal
insulation
Outlet
cover
Drip loop
9800
FlexFit
plug
Cable ties
or tape

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Step 5.
Install the insulation
Thermal insulation must be used. It protects
the Frostex heating cable from damage and
helps keep the pipes from freezing. Before you
insulate, be sure the Frostex heating cable is
undamaged—no nicks or cuts—and the braid is
intact. Replace the heating cable if necessary.
5A. Cover the system with the insulation
Cover the pipe, heating cable, connections,
valves, and spigots with clean, dry, waterproof,
fire-retardant thermal insulation, such as
closed-cell foam insulation, as shown in Figure
7. The insulation must be at least as thick as
selected in Table 1 or 2.
Secure the 9800 FlexFit plug to the insulation
with tape or plastic cable ties, being careful not
to cover the light or test buttons.
Figure 7. Thermal insulation
Do not leave the heating cable exposed, except
for the short distance from the pipe to the
power connection.
Fully insulate and weatherproof all exposed
piping. Put additional insulation on areas that
cannot be heat traced.
5B. Waterproof the insulation
Make sure the thermal insulation is waterproof
and stays dry. Install a watertight sleeve and
a solid cover or a barrier such as polyethylene
sheeting around the insulation wherever there
is any chance that the insulation might get wet.
5C. Install the warning label
Install the orange warning labels on the
insulation with one near the electrical outlet, as
shown in Figure 7.
Additional labels and installation tape are
available from nVent in the Frostex 9610 kit.
Step 6.
Start up the system
6A. Plug in the heating cable
After installing the heating cable and insulation,
remove the clear label that covers the test and
reset buttons. Then, plug the 9800 FlexFit plug
into a grounded and properly installed outlet.
If the Frostex heating cable length is longer
than 40 feet and the air temperature is lower
than 30°F, run water through the pipe before
plugging in the unit. This will warm up the pipe
and help avoid blowing the nonreplaceable
fuse in the 9800 FlexFit plug.
The signal light will go on indicating that the
ground-fault protection device and the fuse
are working properly. However, the light does
not confirm that the heating cable is properly
connected. See Step 7, “Test the System.”
6B. Test the plug
Press the white test button. The red reset
button should pop out from the surface of the
plug and the signal light should go out.
When the red reset button pops out, push it in
to restore power and proceed to Step 7.
If the red reset button fails to pop out, skip to
“Troubleshooting.”
If the red reset button pops out immediately
but cannot be reset, skip to “Troubleshooting.”
If the signal light does not light, skip to
“Troubleshooting.”
Step 7.
Test the system
Test the system using one of the two following
procedures.
7A. Test the water temperature
After plugging in the system, wait about an
hour. Turn on a water tap on the Frostex-
protected pipe and test the temperature of the
water. It should feel warm almost immediately
because the water heated by the Frostex
heating cable will be briefly running through
the pipe.
If the water is warm, you have completed the
installation.
If the water is not warm, skip to
“Troubleshooting.”
Warning
labels

nVent.com | 9
7B. Test the heating cable’s resistance.
It is possible to test the resistance of Frostex
heating cable using a multimeter. Follow these
steps:
• Be sure the 9800 FlexFit plug is unplugged.
• Push in the red reset button on the plug.
• Connect the two lead wires on the meter to the
two flat prongs on the plug. The meter reading
should be between 2 and
20,000 ohms.
If your reading is within this range, you have
completed the installation.
If your reading is not within this range, repeat
Step 3, “Install the 9800 FlexFit plug” and
retest.
If your reading is still not within this range or
you have questions, call nVent for technical
support at [phone].
PERIODIC INSPECTIONS
Each month
Test the 9800 FlexFit plug as described in Step
6B.
Periodically
Each time you plug in the system, and at least
once a year, do the following:
• Check the entire Frostex system for signs of
damage. Inspect any exposed portion of the
heating cable for evidence of cuts, nicks, abra-
sions, gnawing by animals, and any other physi-
cal damage.
• If there is damage, immediately replace the
damaged heating cable system and thermal
insulation. Do not attempt to repair any part of
the heating cable system.
• After a thorough inspection, start up the system
and test the 9800 FlexFit plug and system as
described in Steps 6 and 7.
TROUBLESHOOTING
Problem: The red button pops out immediately
when the plug is plugged in,
or the button will not reset.
What to do: A strand of braid may have entered
the heating cable guide during
Step 3B.
• Unplug the 9800 FlexFit Plug.
• Remove the cover (the reverse of Step 3D).
• Unscrew the two screws of the heating cable
guide (the reverse of Step 3C).
• Using a flat blade screwdriver, gently pry the
heating cable guide up until the heating cable
can be removed.
• Reinstall the screws completely into the heating
cable guide before re-attaching.
• Repeat installation steps 3A–3D, ensuring no
braid strands enter the heating cable guide
during Step 3B.
• Repeat Step 6, “Start up the system.”
Note: If the 9800 FlexFit Plug red test
button continues to pop out, your system
is damaged and must be replaced.
Problem: The signal light does not light up.
What to do: Check to be sure the outlet has
power. If you are not certain how to do this,
call a professional service person.
If the outlet has no power, correct the problem,
then follow Step 6, “Start up the system.”
If the outlet has power but the signal light
still does not light up after you conduct the
test described in Step 6B, “Test the plug,” the
internal nonreplaceable fuse is blown. This
means the Frostex system is damaged and
must be replaced.
Problem: The 9800 FlexFit plug does not trip
(red button does not pop out).
What to do: Check to be sure the outlet has
power. If you are not certain how to do this,
call a professional service person.
If the outlet has no power, correct the problem,
then follow the instructions in Steps 6 and 7.
If the outlet has power but the 9800 FlexFit
plug still fails to trip, the Frostex system is
damaged and must be replaced.
Problem: The heating cable fails to warm up or
water is not warm after testing the system.
What to do: The heating cable may not be fully
inserted into the heating cable guide, or the
guide may not be screwed down completely.
• Unplug the 9800 FlexFit Plug.
• Remove the cover (the reverse of Step 3D).
• Unscrew the two screws of the heating cable
guide (the reverse of Step 3C).
• Using a flat blade screwdriver, gently pry the
heating cable guide up until the heating cable
can be removed.
• Reinstall the screws completely into the heating
cable guide before re-attaching.
• Repeat installation steps 3A–3D, ensuring no
braid strands enter the heating cable guide
during Step 3B.
• Repeat Step 6, “Start up the system.”

LIMITED WARRANTY
nVent warrants all Frostex self-regulating
heating cables and components against faulty
workmanship and use of defective materials
for two (2) years from the date of purchase.
This warranty can be amended only by a written
instrument signed by a duly authorized officer
of nVent. Buyer’s exclusive remedy under
this warranty shall be to have nVent, within a
reasonable time, repair such goods or supply
replacement goods or credit Buyer’s account for
such goods and accept their return whichever
nVent may elect at its sole discretion. nVent shall
in no event be liable for the cost of removal or
installation, for loss or damage to or loss of use
of facilities or other property, loss of revenue, loss
of use of revenue, loss of anticipated profits, or
other damages or costs of any kind whatsoever,
whether direct, indirect, incidental,
or consequential.
Notwithstanding the foregoing, nVent shall have
no liability whatsoever unless: (a) Buyer promptly
notifies nVent in writing after discovery of an
alleged nonconformity and includes a detailed
explanation of the alleged nonconformity; (b)
Buyer promptly returns the goods to nVent
postage prepaid, at the address obtained by
calling Customer Service at 1-800-545-6258 or
650-216-1526; and (c) nVent examination of
such goods establishes to nVent satisfaction
that such alleged nonconformities actually exist
and occurred in the cause of proper and normal
use and were not caused by accident, misuse,
neglect, alteration or improper installation,
repair or testing or such other cause outside of
the responsibility of nVent under this Limited
Warranty.
THE FOREGOING WARRANTY IS IN LIEU OF ALL
OTHER REPRESENTATIONS, WARRANTIES, OR
CONDITIONS, EXPRESS OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY IMPLIED WARRANTY
OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR NONINFRINGEMENT,
AND OF ANY OTHER OBLIGATION OR LIABILITY
ON THE PART OF nVent, WHETHER BY STATUTE,
CONTRACT, STRICT LIABILITY, TORT OR
OTHERWISE.
If the goods are a consumer product in buyer’s
jurisdiction, the above exclusion or limitation of
incidental or consequential damages and the
above disclaimer of implied warranties may not
apply. The term of any such implied warranty
is limited to the term of this two-year Limited
Warranty. Some jurisdictions do not allow
limitations on how long an implied warranty
lasts, so the above limitation may not apply. This
warranty gives consumers specific legal rights,
and consumers may also have other rights, which
vary by jurisdiction.
©2018 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its aliates. All other trademarks are the property of their
respective owners. nVent reserves the right to change specications without notice.
Raychem-IM-H56581-FrostexFreezeProtection-EN-1805 PN 791791-000
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