nvent RAYCHEM BTV Manual

Industrial Heat Tracing
Installation and Maintenance Manual for
Self-Regulating and Power-Limiting
Heating Cable Systems
nVent.com

Heating Cable Selection
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IMPORTANT SAFEGUARDS
AND WARNINGS
WARNING: FIRE AND SHOCK HAZARD.
nVent RAYCHEM heat-tracing systems must be installed
correctly to ensure proper operation and to prevent shock
and fire. Read these important warnings and carefully follow
all the installation instructions.
• To minimize the danger of fire from sustained electrical
arcing if the heating cable is damaged or improperly
installed, and to comply with nVent requirements, agency
certifications, and national electrical codes, ground-fault
equipment protection must be used on each heating cable
branch circuit. Arcing may not be stopped by conventional
circuit breakers.
• Approvals and performance of the heat-tracing systems
are based on the use of nVent specified parts only. Do not
substitute parts or use vinyl electrical tape.
• Bus wires will short if they contact each other. Keep bus
wires separated.
• Components and cable ends must be kept dry before and
during installation.
• The black heating cable core and fibers are conductive and
can short. They must be properly insulated and kept dry.
• Damaged bus wires can overheat or short. Do not break
bus wire strands when preparing the cable for connection.
• Damaged heating cable can cause electrical arcing or fire.
Do not use metal attachments such as pipe straps or tie
wire. Use only RAYCHEM approved tapes and cable ties to
secure the cable to the pipe.
• Do not attempt to repair or energize damaged cable.
Remove damaged cable at once and replace with a new
length using the appropriate RAYCHEM splice kit. Replace
damaged components.
• Re-use of the grommets, or use of the wrong grommet, can
cause leaks, cracked components, shock, or fire. Be sure
the type of grommet is correct for the heating cable being
installed. Use a new grommet whenever the cable has been
pulled out of the component.
• Use only fire-resistant insulation which is compatible with
the application and the maximum exposure temperature of
the system to be traced.
• To prevent fire or explosion in hazardous locations, verify
that the maximum sheath temperature of the heating cable
is below the auto-ignition temperature of the gases in the
area. For further information, see the design documentation.
• Material Safety Data Sheets (MSDSs) are available on-line
at nVent.com.

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Table of Contents
1 General Information 1
1.1 Use of the Manual 1
1.2 Safety Guidelines 1
1.3 Electrical Codes 1
1.4 Warranty and Approvals 2
1.5 General Installation Notes 2
2 Heating Cable Selection 3
3 Heating Cable Installation 4
3.1 Heating Cable Storage 4
3.2 Pre-Installation Checks 4
3.3 Installation 5
4 Heating Cable Components 16
4.1 General Component Information 16
5 Control and Monitoring 19
6 Thermal Insulation 21
6.1 Pre-Insulation Checks 21
6.2 Insulation Installation Hints 21
6.3 Marking 21
6.4 Post-Insulation Testing 21

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7 Power Supply and Electrical Protection 22
7.1 Voltage Rating 22
7.2 Electrical Loading 22
7.3 Ground-Fault Protection 22
8 Commissioning and Preventive Maintenance 23
8.1 Tests 23
8.2 Preventive Maintenance 24
9 Test Procedures 25
9.1 Visual Inspection 25
9.2 Insulation Resistance (Megger) Test 25
9.3 Power Check 28
9.4 Fault Location Tests 29
10 Troubleshooting Guide 34
11 Installation and Inspection Records 36

General Information
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1.1 Use of the Manual
This installation and maintenance manual is for nVent
RAYCHEM Self-Regulating and Power-Limiting
heat-tracing systems on thermally insulated pipes and
vessels only. This includes nVent RAYCHEM BTV, HBTV,
QTVR, HQTV, XTV, HXTV, KTV, VPL heating cables and
the appropriate RAYCHEM components.
For information regarding other applications, design
assistance or technical support, contact your nVent
representative or nVent directly.
nVent
7433 Harwin Drive
Houston, TX 77036
USA
Tel: [phone]
Fax:[phone]
[e-mail]
nVent.com
Important: For the nVent warranty and agency
approvals to apply, the instructions that are included in
this manual and product packages must be followed.
1.2 Safety Guidelines
The safety and reliability of any heat-tracing
system depends on proper design, installation and
maintenance. Incorrect handling, installation, or
maintenance of any of the system components can
cause underheating or overheating of the pipe or
damage to the heating cable system and may result in
system failure, electric shock or fire.
Pay special attention to the following:
• Important instructions are marked Important
• Warnings are marked WARNING
1.3 Electrical Codes
Sections 427 (pipelines and vessels) and 500
(classified locations) of the National Electrical Code
(NEC), and Part 1 of the Canadian Electrical Code,
Sections 18 (hazardous locations) and 62 (Fixed Electric

General Information
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Space and Surface Heating), govern the installation of
electrical heat-tracing systems. All heat-tracing-system
installations must be in compliance with these and any
other applicable national or local codes.
1.4 Warranty and Approvals
RAYCHEM heating cables and components are
approved for use in hazardous and nonhazardous
locations. Refer to the specific product data sheets for
details.
1.5 General Installation Notes
These notes are provided to assist the installer
throughout the installation process and should be
reviewed before the installation begins.
• Read all instruction sheets to familiarize yourself with
the products.
• Select the heating cable type and rating in accordance
with the Industrial Product Selection and Design
Guide (nVent literature #H56550), or TraceCalc Pro
software, or the website design software.
• Ensure all pipes, tanks, etc., have been released
by the client for tracing prior to installation of the
heating cables.
• Typically, heating cables are installed at the 4 and
8 o’clock positions on a pipe.
• All heat-traced pipes, tanks, vessels, and equipment
must be thermally insulated.
• Do not install heating cables on equipment
operating above the heating cable’s maximum rated
temperature.
• The minimum bending radius for VPL Power-Limiting
cables is 3/4 inch (19 mm). The minimum bending
radius for Self-Regulating cables is 1/2 inch (13 mm).
• Never install heating cables over expansion joints
without leaving slack in the cable.
• Do not energize cable when it is coiled or on the reel.
• Never use tie wire or pipe straps to secure heating
cables.
• The minimum installation temperature for heating
cables is –40°F (–40°C).

Heating Cable Selection
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Check the design specification to make sure the proper
heating cable is installed on each pipe or vessel. Refer
to the Industrial Product Selection and Design Guide,
TraceCalc Pro or the nVent web site, nVent.com, to
select the proper heating cable for your application.

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3.1 Heating Cable Storage
• Store the heating cable in a clean, dry place.
Temperature range: –40°F (–40°C) to 140°F (60°C).
• Protect the heating cable from mechanical damage.
3.2 Pre-Installation Checks
Check materials received:
• Review the heating cable design and compare the list
of materials to the catalog numbers of heating cables
and components received to confirm that proper
materials are on site. The heating cable type and
voltage is printed on its jacket.
• Ensure that the heating cable voltage rating is
suitable for the service voltage available.
• Inspect the heating cable and components for
in-transit damage.
• Verify that there no holes in the heating cable
jackets by conducting the insulation resistance test
(refer to Section 9) on each reel of cable.
Check piping to be traced:
• Make sure all mechanical pipe testing (i.e. hydrostatic
testing/purging) is complete and the system has
been cleared by the client for tracing.
• Walk the system and plan the routing of the heating
cable on the pipe.
• Inspect the piping for burrs, rough surfaces, or sharp
edges. Remove if necessary.
• Verify that any surface coatings are dry to the touch

Heating Cable Installation
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3
3.3 Installation
Paying out the cable
Pay out the heating cable, loosely stringing it along the
pipe, making sure that the cable is always next to the
pipe when crossing obstacles. If the cable is on the
wrong side of an obstacle such as a crossing pipe or
I-beam, you will need to reinstall it or cut and splice it.
Single cable
Pipe
Pipe
Multiple cables
from two reels
Multiple cables
from a single reel

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HEATING CABLE PAYING OUT TIPS:
• Use a reel holder that pays out smoothly with little
tension. If heating cable snags, stop pulling.
• Keep the heating cable strung loosely but close to the
pipe being traced to avoid interference with supports
and equipment.
• Meter marks on the heating cable can be used to
determine heater length.
• Protect all heating cable ends from moisture,
contamination, and mechanical damage.
WHEN PAYING OUT THE HEATING CABLE, AVOID:
• Sharp edges
• Excessive pulling force or jerking
• Kinking and crushing
• Walking on it, or running over it with equipment
WARNING: Fire and Shock Hazard. Do not install
damaged cable. Components and cable ends must be
kept dry before and during installation.
Positioning heating cables
If possible, position the heating cable on the lower
section of the pipe, at the 4 and 8 o’clock positions, as
shown below, to protect it from damage.
Two heating cablesOne heating cable
ATTACHMENT TAPES
Use one of the following RAYCHEM attachment tapes to
secure the heating cable on the the pipe: GT-66 or GS-54
fiberglass tape, or AT-180 aluminum tape.

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nVent RAYCHEM GT-66 fiberglass tape
• General purpose tape for installation at 40°F (5°C)
and above
nVent RAYCHEM GS-54 fiberglass tape
• Special application tape for stainless steel pipes
• For installations at –40°F (–40°C) and above
GT-66 or GS-54 glass tape
across heating cable
nVent RAYCHEM AT-180 aluminum tape
• Heat-transfer tape for plastic pipes, pump bodies, and
odd-shaped equipment
• Install above 32°F (0°C)
• Tape lengthwise over the heating cable as required by
the design
AT-180 aluminum tape
over heating cable
WARNING: Fire and Shock Hazard. Do not use
metal attachments such as pipe straps or tie wire.
Do not use vinyl-based electrical or duct tape.
Use only RAYCHEM approved tapes.

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ATTACHING THE HEATING CABLE
Starting from the end opposite the reel, tape the heating
cable on the pipe at every foot, as shown in the figure
above. If aluminum tape is used, apply it over the entire
length of the heating cable after the cable has been
secured with glass tape. Work back to the reel. Leave
extra heating cable at the power connection, at all sides
of splices and tees and at the end seal to allow for
future servicing.
Allow a loop of extra cable for each heat sink, such
as pipe supports, valves, flanges, and instruments, as
detailed by the design. Refer to “Typical installation
examples” on page 12 for attaching heating cable to
heat sinks.
Install heating cable components immediately after
attaching the heating cable. If immediate installation
is not possible, protect the heating cable ends
from moisture.

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MULTIPLE CABLES AND SPIRALING
There are two situations where multiple heating cable
runs may be required:
• Redundant heat-tracing runs are used in situations
where a backup is required. Each run should be
installed per the design specifications.
• Double or multiple heat-tracing runs are used when a
single heat-tracing run alone cannot compensate for
larger heat losses. Double heat-tracing runs should
have extra heating cable installed at heat sinks, as
called out in the design. It is recommended to supply
the extra heating cable at heat sinks alternately from
both runs in order to balance out both circuit lengths.
SPIRAL TRACING
When the design calls for spiralling, begin by
suspending a loop at every 10-foot pipe section.
To determine the loop length, obtain a spiral factor from
the design and multiply by 10. For example, if the spiral
factor of 1.3 is called for, leave a 13-foot loop of heating
cable at every 10-foot section of pipe. Attach the
loop to the pipe at each interval using the appropriate
RAYCHEM attachment tape.

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10 feet
Glass tape
(typical)
Apply glass
tape before
spiraling
heating cable
on pipe
Pull heating cable loop length
Wrap loops
in opposite
directions
Tape after spiraling
heating cable on
pipe
Heating
cable
BENDING THE CABLE
Power-limiting
minimum bend radius
3/4"
Self-regulating
minimum bend radius
1/2"
When positioning the heating cable on the pipe, do not
bend tighter than 1/2” for self-regulating cables and
3/4” for power-limiting cables.

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The heating cable does not bend easily in the flat plane.
Do not force such a bend, as the heating cable may be
damaged.
CROSSING THE CABLE
Self-Regulating cables, BTV, HBTV, QTVR, HQTV,
XTV, HXTV, KTV allow for multiple overlapping of the
heating cable.
Power-Limiting cable, VPL, allows for a single
overlap of the heating cable per zone.
FOR VPL HEATING CABLE ONLY:
CUTTING THE CABLE
Cut the heating cable to length after it is attached to
the pipe.
Heating cable can be cut to length without affecting the
heat output per foot.

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Typical installation examples
Wrap pipe fittings, equipment, and supports as shown
in the following examples to properly compensate for
higher heat-loss at heat sinks and to allow easy access
for maintenance. The exact amount of heating cable
needed is determined in the design.
VALVE
Valve body
Multiple crossovers allowed
for self-regulating cables
Single crossover only, allowed
for power-limiting cables
Glass tape Pipe
Heating cable
Pipe
Heating cable
Note: Cable loop length
varies depending on
heat loss
FLANGE
Glass tape
(typical)
Heating cable Loop length is twice
the diameter of the pipe

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PIPE SUPPORT SHOE
Heating cable secured to pipe
Glass tape
Heating cable loop
Support shoe Pipe
ELBOW
Heating cable
Glass tape
(typical)
For pipe diameters of 2"
and larger, the heating
cable should be installed
on the outside (long)
radius of the elbow.

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PRESSURE GAUGE
Heating cable
Glass tape
Pipe
SPLIT CASE CENTRIFUGAL PUMP
Glass tape
Pump discharge
Pump body
Heating cable
Pump
suction
Use AT-180
tape
Motor
To power connection

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PIPE HANGER
Heating cable
Heating cable
Glass tape Do not clamp heating
cable with support
Pipe hanger
Pipe hanger
No additional
heating cable is
required for pipe
hangers unless
called for in the
design specification,
then use loop length
specified.

Heating Cable Components
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4.1 General Component Information
RAYCHEM components must be used with RAYCHEM
self-regulating and power-limiting heating cables.
A complete circuit requires a power connection and an
end seal. Splices and tees are used as needed.
Use the Industrial Product Selection and Design Guide
or TraceCalc Pro to select appropriate components.
Installation instructions are included with the
component kit. Steps for preparing the heating cable
and connecting to components must be followed.
RAYCHEM self-regulating and power-limiting heating
cables are parallel circuit design. Do not twist the
conductors together as this will result in a short circuit.
Component Installation Tips
• Connection kits should be mounted on top of the pipe
when practical. Electrical conduit leading to power
connection kits should have low-point drains to keep
condensation from accumulating in the conduit.
All heating cable connections must be mounted
above grade level.
• Special adapters are available for mounting on small
pipes. Be sure to use these adapters if installing
cables on pipes of 1 inch O.D. or less.
• Be sure to leave a service loop at all components
for future maintenance, except when temperature-
sensitive fluids are involved or when the pipe is
smaller than 1 inch.
• Locate junction boxes for easy access, but not where
they may be exposed to mechanical abuse.
• Heating cables must be installed over, not under,
pipe straps used to secure components.
• For VPL, cut cable 12” (30 cm) from last active
node (indentation) to be sure an inactive zone is
used to enter the component. Refer to component
installation instructions.