nvent RAYCHEM HWAT-SYSTEM Manual

Installation and Maintenance Manual
for Pipes with Thermal Insulation
HWAT-SYSTEM

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IMPORTANT NOTES
Thermal Insulation
All heat-traced pipes and equipment must be thermally
insulated. The insulation is a very important part of the HWAT
system, to ensure its effective operation.
Safety warnings
The following instructions must be followed to avoid
fires or electric shock as well as to satisfy the nVent
warranty conditions and the requirements of the
product approvals.
nVent RAYCHEM HWAT 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.
• nVent require the installation of a 30 mA fault current
circuit breaker for circuit protection in case of damaged or
incorrectly installed heat-tracing cables.
• Warranty claims may be levied against nVent only if the
parts specified by nVent have been used exclusively. Do not
use untested material and/or material not manufactured by
nVent in the temperature maintenance system.
• Core wires will short if they contact each other. Avoid
contact of the core wires (Also known as Bus wires.)
• Connection kits and cable ends must be kept dry before and
during installation.
• The black heating-cable core is conductive and can short.
It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 cables can cause electrical arcing or fire.
Do not use metal attachments such as pipe straps or tie
wire. Use only nVent approved adhesive tapes and cable
ties to fasten the cable to the pipe.
• Damaged cables may not be energised or repaired by
unauthorised persons. Remove the damaged heating cables
immediately and replace them with a new cable of the
appropriate length.
Use the RAYCHEM RayClic-S-02 connection kit.
Replace damaged connection kits.
• Only use pipe insulating materials suitable for this
application according to the local regulations.

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1General information 4
2Heat-tracing cable selection 8
3Heat-tracing cable installation 9
4HWAT components 13
5Controlling and monitoring 15
6Thermal insulation 16
7Power supply and electrical protection 19
8Commissioning 20
9Troubleshooting 23
10 List of possible faults 26
11 Installation and test sheet 30

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1 GENERAL INFORMATION
1.1 Use of the manual
This installation and operation manual is for RAYCHEM
HWAT Hot Water Temperature Maintenance systems
installed on thermally insulated pipes only.
This manual details how to install and operate an
HWAT system. The HWAT system includes the heat-
tracing cables HWAT-L, HWAT-M and HWAT-R, RayClic
connection kits and the HWAT-ECO control unit. Itis
important to review this manual and the following
documents with the installation contractor.
• Product selection and design guidance for the HWAT
system according to specifications in the technical
manual (CDE-517)
• Installation instructions for the RayClic connection
kit (INST-168)
• HWAT-ECO Installation and Operation Manual
(INST-189)
• Safety Warnings (INST-193)
Further information: see overleaf
1.2 Safety guidelines
The safety and reliability of heat-tracing systems
depends on the quality of the products selected,
and on proper planning, installation and maintenance.
A faulty design, incorrect handling, improper installation
or maintenance of a system component can lead to the
pipe being heated too little or too much. This can also
cause damage to the temperature maintenance system
which may lead to system failure, electric shock or fire.
The guidelines and instructions contained in this guide
are important. Follow them carefully to minimise these
risks and to ensure that the HWAT System performs
reliably.

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1.3 Typical HWAT system
A typical HWAT System is shown in Figure 1 below.
The heat-tracing cable is cut to length in the field
and is attached to the pipe with cable ties. The
heat tracing cable connections are made using a
connection kit. Connection kits accommodate pipe
branches to connect two or three heat-tracing cables
together. The heat-tracing cables are terminated
using an end seal. A control unit is used to set the
maintain temperature and facilitate energy savings.
Thermal
insulation
Warning label Tee connection
End seal
Control unit
Power connection
Glass tape
Heat-tracing cable
Connection
Note: Partial pipe insulation
shown here for clarity. All pipes
must be insulated at least
according to the specified
regulations.
Figure 1: Typical HWAT heat-tracing cable system

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1.4 Electrical codes
All installations must comply with the local
regulations, technical connection conditions and
specifications.
1.5 Approvals
The heat-tracing cables HWAT-L, HWAT-M and
HWAT-R, the RayClic connection kits and the HWAT-
ECO are only approved for use in non-Ex areas. Refer
to the specific product data sheets for details.
1.6 Warranty
The warranty conditions for Europe must be taken
from the respective terms of sale and delivery
specific to the country.
1.7 Co-ordination of the different trades
Installation of an HWAT system can involve or
impact the work of numerous trades. Therefore,
effective and early coordination between trades is
a critical aspect of all HWAT System Installations.
The installation of the heat-tracing cables and
connections must be carefully planned. This
also applies to the risers and installation of the
insulation.
This manual guides the installation technician
through the installation process. All the affected
trades should therefore read it carefully before
starting installation of the HWAT system. In a “fast-
track” job, the HWAT System must be considered
a critical path item: pipe, heat-tracing cable and
insulation must be installed in the right order. If, for
example, the walls are constructed before the heat-
tracing cable has been tested, it may be necessary
to open the walls again in order to repair a damaged
or improperly installed system.
Ensuring that the installation of the HWAT System
is included in the overall construction schedule
will help ensure a successful and trouble-free
installation.

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1.8 General installation notes
Read and observe the instructions in this guide to
insure that the HWAT System is installed successfully.
• Please read the installation instruction carefully in
order to get familiar with the system components.
• All heat-traced pipes and equipment must be
thermally insulated. Insulation is an important
part of the HWAT System. For an effective
system, the heat loss must be checked for each
specific pipe size as detailed in Table2, page 16.
• To minimise the risk of damage to the heat-
tracing cables, the insulation must be installed
immediately after testing the heat-tracing cables.
• Do not install the HWAT System below the
minimum installation temperature.
• The minimum installation temperature for HWAT
cables and RayClic is –10°C.
• The minimum installation temperature for HWAT-
ECO is5°C.
• Ensure that your water heater temperature is set
at your desired pipe maintain temperature.
• Do not energise the heat-tracing cable when it is
coiled or on the reel.
• Never use metal tie wire or pipe straps to secure
heat-tracing cables to pipes.
Note: If the hot water tank temperature exceeds
65°C in the HWAT-L/-M or 80°C in the HWAT-R, the
heater life expectancy may be affected.
1.9 Tools required
For installing heat-tracing cables and connection kits:
• Knife
• Wire cutters
• Tape measure
• Torx T20 screwdriver (Provided in RayClic
connector kits).
• Heat gun or propane gas burner (when using
shrink kits)
For testing the heat-tracing cable:
• Insulation tester 500 VDC to 2500 VDC
• Multimeter (voltage, resistance and capacitance)
• Temperature measuring device
• Infrared thermometer, e.g. the CDE-IR-Temp
fromRAYCHEM

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2 HEAT-TRACING CABLE SELECTION
2.1 Heat-tracing cables
The HWAT System includes HWAT-L/-M and HWAT-R
heat-tracing cables designed to maintain the piping
at specific temperature settings with the use of the
HWAT-ECO controlunit.
Figure 2 shows the structure of the heat-tracing
cables.
Protective jacket
of modified
polyolefin
Protective tinned
copper braid
Aluminium laminated foil
(For protection against chemical
ingress)
Self-regulating heating element
Copper conductor (1.2 mm²)
Modified polyolefin insulation
Figure 2: Heat-tracing cables HWAT-M and HWAT-R

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3 HEAT-TRACING CABLE INSTALLATION
3.1 Heat-tracing cable storage
• Store the heat-tracing cable in a clean, dry
location. Temperature range: –40°C to 60°C
• Protect the heat-tracing cable from mechanical
damage and moisture.
3.2 Pre-installation testing
Check materials received:
• Review the HWAT cable design and compare the
list of materials to the catalogue numbers of the
heat-tracing cables and connection kits received
to confirm that the proper materials are on site.
The HWAT cable type is printed on its jacket.
• The HWAT System is limited to 230 V service
when using the HWAT-ECO control unit. Ensure
that the service voltage available is correct.
• Inspect the heat-tracing cable and connection kits
to ensure there is no in-transit damage.
• Make sure that the inner jacket of the heat-tracing
cables is not damaged. Carry out an insulation
resistance check on every reel for this (see
section9). Do not power the heat-tracing cable
when it is on thereel.
Check the pipe:
• Make sure that all mechanical pipe tests (i.e.
hydraulic pressure test/rinsing) have been carried
out completely and the pipe fittings are finally
tightened.
• Walk the system and plan the routing of the heat-
tracing cable on the pipe.
• Inspect the piping and remove any burrs, rough
surfaces or sharp edges.
3.3 Installation
• Reel off the heat-tracing cable. Pull it loosely
along the pipe. Make sure that the heat-tracing
cable always runs along next to the pipe when
there are obstructions.
• Install the cable in straight runs along the pipe.
Spiralling the heat-tracing cable is not necessary.
• When installing the heat-tracing cable, the cable
must not be compressed or pinched between
two objects. Wall and floor penetrations and pipe
straps are particular areas of concern.

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• When making floor or wall penetrations, make
sure the aperture is large enough to accommodate
the pipe and the thermal insulation. When sealing
around pipes at floor penetrations, avoid damaging
or cutting the heat-tracing cable, or pinching it
between the pipe and the concrete.
• The heat-tracing cable may not be embedded
directly in the sealing material. The pipe must
be fitted with a thermal insulation (if the local
regulations allow) or the heat-tracing cable must
be laid in a pipe or protective conduit through the
aperture. If the conduit must be sealed, use an
appropriate fire resistant material (Dow Corning
Fire Stop, 3M Fire Barrier, or T&B Flame-Safe)
that can be removed if necessary.
• On vertical piping groups, run the heat-tracing
cable along the inside of the pipe close to other
pipes so it will not be damaged if the pipe hits the
side of the floor aperture. Run the heat-tracing
cable over the outside of the pipe support. Do not
clamp the heat-tracing cable to the pipe with the
pipe support.
Reeling out the heat-tracing cable:
• Use a reel holder that spools out smoothly with
little tension. If the heat-tracing cable snags,
stop pulling.
• Keep the heat-tracing cable attached loosely
but close to the pipe being traced to avoid
interference with supports and equipment.
• Metre marks on the HWAT cable make it easier to
determine the length of the heat-tracing cable.
• Protect all heat-tracing cable ends from moisture,
contamination and mechanical damage.
Figure 3: Feed cable over pipe hangers, do not trap the cable!

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When reeling out the heat-tracing cable, AVOID:
• Sharp edges
• Excessive pulling force or over-tensioning
• Kinking and crushing
• Other mechanical damage (ie. walking on it, or
running over it with equipment)
Positioning of heat-tracing cables
If possible, position the heat-tracing cable on the
lower section of the pipe, at the 4 or 8 o’clock
positions, as shown below, to protect it from damage.
Figure 5: Positioning heat-tracing cable
Bending the heat-tracing cable
When positioning the heat-tracing cable on the pipe,
do not bend tighter than 10 mm radius. The heat-
tracing cable does not bend in the flat plane. Do not
force such a bend, as the heat-tracing cable will be
damaged.
Figure 4: HWAT cable layout

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Figure 6: Bending technique
Crossing the heat-tracing cable
Heat-tracing cables are self-regulating and may
be overlapped if necessary without the risk of
overheating.
Cutting the heat-tracing cable
Cut the heat-tracing cable to the desired length after
it is attached to the pipe. HWAT can be cut to length
without affecting the heat output.
Attachment tapes
To make sure that the heat-tracing cable comes
properly into contact with the pipe, fix it to the pipe
with KBL-10 cable ties or use the RAYCHEM GT-66
glass tape on plastic, iron or copper pipes. Please
use the GS-54 glass tape on stainless steel pipes.
Figure 7: Fastening the heat-tracing cable
CAUTION: Do not use metal attachments such
as pipe straps or tie wire. Do not use untested
adhesive tapes. Use only fastening materials
approved by nVent and listed in the Technical
Manual.
10 mm
max. 300 mm

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4 HWAT COMPONENTS
4.1 General connection kit information
nVent RAYCHEM RayClic connection kits must be
used with HWAT heat-tracing cables. A complete
circuit requires a power connection and an end seal.
Splices and tees and other connection kits are used
as needed. Select the suitable connection kits using
the Technical Manual for heat-tracing cables and
frost protection systems. Installation instructions
are included with every connection kit. Steps for
preparing the heat-tracing cable and installing
connection kits must be followed. The layout of the
connection kits should be noted on the revision plans.
Figure 8: RayClic connection system
Connection kit Installation
• Always install the connection kits so that they are
accessible at all times.
RayClic-PT
RayClic-CE
RayClic-S
RayClic-X
RayClic-T
RayClic-PS
RayClic-E

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Table 1: HWAT cable allowances for connector installation
Connection
kit name
Number of
cable entries
additional
cable length
RayClic-CE 1 0,3 m
RayClic-S 2 0,6 m
RayClic-T 3 1,0 m
RayClic-X 4 1,2 m
RayClic-PS 2 0,6 m
RayClic-PT 3 1,0 m
RayClic-E 1 NA
• Provide access to each connection kit to simplify
maintenance on the systems.
• Locate electrical junction boxes for easy
access but not where they may be exposed to
mechanical abuse.
• Heat-tracing cables must be installed above and
not below pipe straps.
CAUTION: The black heat-tracing cable core is
electrically conductive and can short. It must be
properly insulated and kept dry. Damaged bus wires
can overheat or short.
CAUTION: RAYCHEM specified components
must be used. Do not replace RAYCHEM
components with untested components.

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5 CONTROL AND MONITORING
5.1 HWAT-ECO Control Unit
The nVent RAYCHEM HWAT-ECO control unit is
designed exclusively for using with the HWAT-M and
HWAT-R heat-tracing cables. It is used to optimise
the HWAT temperature maintenance system. Refer
to the HWAT-ECO Installation and Operation Manual
for the installation and operation instructions of the
control unit (INST-189).
Figure 9: Control unit HWAT-ECO

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6 THERMAL INSULATION
6.1 Insulating the system
Pipes must be insulated with the correct thermal
insulation to maintain the desired pipe temperatures.
A good thermal insulation means
• Lower heat losses
• Lower operating costs
The data in table 2 can also be used as a guideline.
Table 2: Heat losses: Select the cable type based on its
power to compensate the heat loss
Heat losses in W/m, pipe 55°C in 18°C environment
Insulation
Type DN 15 DN 20 DN 32 DN 40 DN 50
15 mm 10 12 16 18 21
20 mm 9 10 14 15 18
30 mm 7 8 11 12 14
40 mm 6 7 9 10 12
50 mm 6 7 8 9 10
60 mm 5 6 8 8 9
Heat losses in W/m, pipe 55°C in 5°C environment
Insulation
Type DN 15 DN 20 DN 32 DN 40 DN 50
15 mm 13 16 21 24 28
20 mm 12 13 18 20 23
30 mm 10 11 14 16 18
40 mm 8 10 12 13 15
50 mm 8 9 11 12 13
60 mm 7 8 10 11 12

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Note: Table 2 is based on calculations with the
TTC-Software TraceCalc pro with the following
parameters:
• Maintain temperature 55°C
• Building inside room
• Safety factor 10%
• Rockwool, heat conductivity λ 0.041 W/mK at 40°C
Table 3: Minimum insulation thickness used with
HWATsystems
Insulation thickness
Pipe size (mm) 15 22 28 35 42 54
Insulation thickness
(mm)
20 20 25 30 40 50
Ambient temperature: 18°C
Thermal conductivity l = 0.035 W/(m.K)
For other thermal conductivity insulation materials,
contact your nVent representative.
6.2 Insulation installation
• Before insulating the pipe, visually inspect the
heat-tracing cable and connection kits to ensure
they are properly installed and there are no signs
of damage. Damaged cable or connection kits
must be replaced.
• Check the insulation type and its thickness
comply with the configuration principles and local
insulation regulations.
• Insulate the pipes immediately after the heat-
tracing cable is installed and has passed all tests
to minimise the risk of possible damage to the
heat-tracing cable.
• Also insulate the pipe in floor and wall
penetrations.
• Failure to do so will lead to cold places on the
water system and/or possible damages to the
heat-tracing cable
• Do not use staples to close the insulation. Use
tape or the adhesive-lined edge of the insulation
to ensure that the seam remains sealed. Staples
can damage the HWAT heat-tracing cable.

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• Make sure that all heat-traced pipes are insulated.
Correct temperature maintenance requires
properly installed and dry thermal insulation.
Uninsulated sections of pipe can result in heat
losses.
• After installing insulation, electrical codes require
that you install “Electric Traced” labels along
the piping at suitable intervals (5 m intervals
recommended) on alternate sides.
CAUTION: Only use thermal insulation
approved for hot water pipes according to local
insulationregulations.

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7 POWER SUPPLY AND
ELECTRICALPROTECTION
7.1 Voltage rating
Verify that the supply voltage is either 230 volts as
specified by the HWAT System design.
7.2 Power circuit breaker sizing
Power circuit breakers must be adapted to the heat-
tracing cable lengths specified in table 3. Do not
exceed the maximum circuit length specified for
every power circuit breaker size. Use residual current
devices with ground fault protection of 30 mA.
Table 4: Max. circuit length related to a minimum start-up
temperature of +12°C, AC 230 V
HWAT-L HWAT-M HWAT-R
10 A 80 m 50 m 50 m
13 A 110 m 65 m 65 m
16 A 140 m 80 m 80 m
20 A 180 m 100 m 100 m
7.3 Electrical loading
Over-current devices are selected according to the
HWAT cable type, supply voltage, and circuit length
to allow for start-up. The design specifies the size
and type of over-current device. Pipe systems are
often not installed as drawn in the installation plans.
If changes are made, make sure that all circuit
lengths comply with Table 4.
7.4 Ground-fault protection
Improper installation or mechanical damage to
the heat-tracing cable can cause a ground fault or
short. In the event of a ground fault, the fault current
must be conducted to protective earth (PE) through
the protective braid and the residual current device
(rcd 30mA) so that the rcd can interrupt the circuit.
It is therefore absolutely essential to connect the
protective braid correctly in accordance with the
installation instructions. This must be checked and
approved by the installation technician.
CAUTION: In order to reduce risk, nVent
recommendations for fault current circuit breakers
(max. 30 A) must be installed as protection against
ground faults.
CAUTION: Do not connect the HWAT cable and
the components with the power on.

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8 COMMISSIONING
nVent requires a series of commissioning tests be
performed on the HWAT System. Individual tests
are also recommended at regular intervals for
preventive maintenance. Results must be recorded
and maintained for the life of the system, utilizing
the “Installation and Inspection Record” (refer
to Section 11). Submit this manual with initial
commissioning test results to the owner.
Ensure that your water heater and/or mixing valve
temperature are set at your desired pipe maintain
temperature.
Note: If the temperature exceeds 65°C in the
HWAT-L/-M or 80°C in the HWAT-R, the heater life
expectancy may be affected.
The following tests must be done after installing
the RayClic connection kits, but before the thermal
insulation is applied to the pipe:
1. Visual Inspection
2. Insulation resistance measurement
After the thermal insulation has been installed on
the pipe, the following tests must be performed:
1. Visual Inspection
2. Insulation resistance measurement
3. Temperature check (hand test)
All test procedures are described in this manual.
The installation technician is responsible for
carrying out these tests. He may get an electrician
to assist. Record the results in the Installation and
Inspection Record in Section 11.
8.1 Visual inspection
• Check inside all power, splice and tee kits for
proper installation, overheating, corrosion,
moisture or loose connections.
• Check for damaged or wet thermal insulation.
The pipe must be completely insulated and
comply with local regulations.
• Check whether the identification labels are
attached to the thermal insulation.
• Check HWAT-ECO control unit for proper setpoint
and operation. Refer to the HWAT-ECO Installation
and Operation Manual for details.