nvent RAYCHEM BTV Manual

INSTALLATION AND
MAINTENANCE MANUAL
SELF-REGULATING
AND POWER LIMITING
HEATING CABLE SYSTEMS

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1General information Pg. 4
2Heating cable selection Pg. 8
3Heating cable installation Pg. 8
4Components installation Pg. 17
5Thermostats Pg. 22
6Thermal insulation and marking Pg. 23
7Power supply and electrical protection Pg. 25
8Heating cable testing Pg. 25
9Operation, maintenance and pipe
repairs Pg. 27
10 Heating cable damage Pg. 28
11 Troubleshooting guide Pg. 28

1 GENERAL INFORMATION
Use of the manual
The Installation and Maintenance manual is for nVent
RAYCHEM self-regulating and power limiting heating cable
systems on thermally insulated pipes and vessels only.
For information regarding other applications contact your
nVentrepresentative.
BTV, QTVR, KTV & XTV Self Regulating Heating Cables
L
N
• Power output varies with temperature.
As pipe temperature increases, power output decreases.
• At high temperatures, the polymer expands, reducing the
number of the conductive paths, and thus reducing current
ow.
• At low temperatures, there are many conductive paths,
allowing current to ow between the conductors.
VPL Power Limiting Heating Cables
L
N
Important
For the nVent warranty to apply, the instructions that are
included in this manual and product packages must be
followed. The installation must be compatible with local
requirements applicable to electric heat- tracing systems.
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Specic Conditions of Use
The following limiting temperatures for the end seals, splices
and power connections shall not be exceeded:
135°C for the S-21 and E-06
110°C for the GHG 960 923 P… cable gland and CCON
The end seals, splices and power connections have the
following associated minimum ambient temperatures:
-55°C for the E-06, S-21 and CCON
-50°C for the E-100, E-100-L, E-150, S-150, C-150, JBS-100, JBU-
100 and JBM-100
-40°C for the JBS-100-L, T-100, JBM-100-L, and JBU-100-L
-55°C for the GHG 960 923P… cable gland with silicone rubber
seals
-60°C for the Type E8XF cable gland
The end seals, splices and power connections have the
following associated ambient temperatures:
-50°C to +40°C for the C..-100
-50°C to +150°C for the C-150, S-150, and E-150
-50°C to +56°C for the T-100, JBM-100, JBS-100, JBU-100 and
E-100
-40°C to +40°C for the JBM-100-L, JBS-100-L, JBU-100-L and
E-100-L
The assembly of glands, splices and terminations shall be carried out in accordance
with the manufacturer’s instructions. The heating element supply circuit must
include an electrical protection device in conformity with Clause 4.4 of IEC 62086-1.
ATEX
Certicate No Code
BTV
Baseefa06ATEX0183X II 2 GD Ex e IIC T6 Gb
PTB 09 ATEX 1115X II 2 GD Ex tD A21 IP66 T80°C
QTVR
Baseefa06ATEX0185X II 2 GD Ex e IIC T4 Gb
PTB 09 ATEX 1116X II 2 GD Ex tD A21 IP66 T130°C
XTV Baseefa06ATEX0184X II 2 GD Ex e IIC T* Gb
PTB 09 ATEX 1118 X II 2 GD Ex tD A21 IP66 T**°C
KTV Baseefa06ATEX0186X II 2 GD Ex e IIC 226°C (T2) Gb
PTB 09 ATEX 1117 X II 2 GD Ex tD A21 IP66 T226°C
VPL Baseefa06ATEX0188X II 2GD Ex e II T* Ex tD A21 IP66 T**°C
*see schedule in hazardous area approval.
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Rated Voltage
BASEEFA BTV1, QTVR1, KTV1, XTV1, VPL1: 110V, 120V
BTV2, QTVR2, KTV2, XTV2, VPL2: 230V, 277V, VPL4: 400V, 480V
PTB BTV2, QTVR2, KTV2, XTV2: 230V, 277V
IECEx
Certicate No Code
BTV IECEx BAS 06.0043X Ex e IIC T6 Gb
IECEx PTB 09.0056X Ex tD A21 IP66 T80°C
QTVR IECEx BAS 06.0045X Ex e IIC T4 Gb
IECEx PTB 09.0057X Ex tD A21 IP66 T130°C
XTV IECEx BAS 06.0044X Ex e IIC T* Gb
IECEx PTB 09.0059X Ex tD A21 IP66 T**°C
KTV IECEx BAS06.0046X Ex e IIC 226°C (T2) Gb
IECEx PTB 09.0058X Ex tD A21 IP66 T226°C
VPL IECEx BAS 06.0048X Ex e II T* Gb Ex tD A21 IP66
*see schedule in hazardous area approval.
BTV TC RU C-BE.ME92.B.00056 1Ex e II C T6 Gb X
Ex td A21 IP66 T80°C
QTVR TC RU C-BE.ME92.B.00056 1Ex e II C T4 Gb X
Ex td A21 IP66 T130°C
XTV TC RU C-BE.ME92.B.00056 1Ex e II C T3 (195°C)/T2 (250°C) Gb X
Ex td A21 IP66 T195°C, T250°C
KTV TC RU C-BE.ME92.B.00056 1Ex e II C T2 (226°C) Gb X
Ex td A21 IP66 T226°C
VPL TC RU C-BE.ME92.B.00056 1Ex e II C T Gb X
Ex td A21 IP66 T
Certicate
No
Code
BTV QTVR XTV KTV VPL
Minimum
Bending Radius
–60°C ≤ T < –20°C 35 mm 35 mm 51 mm 26 mm 19 mm
–20°C ≤ T < –10°C 30 mm 30 mm 35 mm 20 mm 15 mm
–10°C ≤ T < 0°C 25 mm 25 mm 25 mm 15 mm 15 mm
0°C ≤ T < +10°C 20 mm 20 mm 20 mm 15 mm 15 mm
T ≥ +10°C 12 mm 12 mm 12 mm 12 mm 12 mm
Minimum Installation
Temperature –60°C –60°C –60°C –60°C –60°C
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Warning
As with any electrical equipment or wiring installation operating at line voltages, heat-
ing cable and component damage or incorrect installation that allows the penetration
of moisture or contamination can lead to electrical tracking, arcing and potential re
hazard.
Do not connect heating cable conductors together or this will result in a short circuit.
Any unconnected heating cable end must be sealed with a nVent approved end seal.
To prevent re or explosion in hazardous areas, 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 design documentation.
Maximum maintain (power on) temperature table
Cable 110 V 230 V 254 V 277 V 400 V 480 V
5VPL1-CT 235°C - - - - -
10VPL1-CT 215°C - - - - -
15VPL1-CT 190°C - - - - -
20VPL1-CT 150°C - - - - -
5VPL2-CT - 230°C 225°C 225°C - -
10VPL2-CT - 210°C 200°C 195°C - -
15VPL2-CT - 180°C 155°C 105°C - -
20VPL2-CT - 150°C - - - -
5VPL4-CT - - - - 230°C 230°C
10VPL4-CT - - - - 205°C 205°C
15VPL4-CT - - - - 160°C 160°C
20VPL4-CT - - - - 150°C 150°C
BTV QTVR XTV KTV VPL
Maximum Maintain
Temperature
(power on)
65°C 110°C 121°C 150°C
See
table
below
Maximum Exposure
Temperature (1000 hrs
cumulative exposure
power on)
85°C 110°C 250°C (*) 250°C (*) –
Maximum Exposure
Temperature (continu-
ous power off)
––––260°C
Self-limiting
Temperature in accor-
dance with EN62086-1
5.1.11
T6 T4
T3
(T2:
20XTV2,
15/20XTV1)
T2 T*
Power Limiting
Temperature
(*By design)
----T*
(*) The 250°C rating applies to all products printed “MAX INTERMITTENT EXPOSURE
250C”.
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2 HEATING CABLE SELECTION
Check the design specication to make sure the proper
heating cable is installed on each pipe or vessel. Refer to nVent
product literature and the TraceCalc software to select the
proper heating cable for each thermal, chemical, electrical and
mechanical environment.
3 HEATING CABLE INSTALLATION
• Warning
De-energise all power circuits before installation or servicing
Heating cable storage
• Keep ends of heating cable and kit components dry before
and during installation
• Temperature range: –40°C to +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 catalogue numbers of heating cables and
electrical components received to conrm that proper
materials are on site. The heating cable type is printed on its
outer jacket.
• Temperature exposure must not exceed that specied in
nVent product literature. Exceeding these limits will impair
product performance. Check that expected exposure is
within these limits.
• Ensure that the heating cable voltage rating is suitable for
the service voltage available.
• Do not energize cable when it is coiled or on the reel.
• Inspect heating cable and components for in-transit
damage. An insulation resistance test (see section 8) on
each reel is recommended.
Check piping to be traced:
• Ensure all pressure testing is complete and pipework has
nal paint coating.
• Walk the system and plan the routing of the heating cable on
the pipe.
• Check pipework against specication drawing. If different
consult design authority.
• Inspect piping for burrs, rough surfaces, sharp edges etc.
which could damage the heating cable. Smooth off or cover
with layers of glass cloth tape or aluminium foil.

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3.3 Heating cable handling
Heating cable handling tips:
• Paint and pipe coatings must be dry to the touch before
heating cable installation.
• When pulling the heating cable, avoid:
– sharp edges
– excessive pulling force
– kinking and crushing
– walking on it, or running over it with equipment
Heating cable pulling tips:
• Use a reel holder that pays out smoothly with little tension.
• Keep heating cable strung loosely but close to the pipe
being traced to avoid interference with supports and
equipment.
• Pay out designed length and mark (i.e. with xing tape) on
cable while still on reel.
• Leave the appropriate amount of heating cable at all power
connection, splice, tee and end seal locations.
(Refer to component installation instructions)
– Add additional heating cable to trace the ttings and
supports or for spiralling as required by the design
specications, or consult nVent product literature for
design.
• Protect all heating cable ends from moisture, contamination
and mechanical damage or other interference if left exposed
before component installation.
3.4 Heating cable attachment recommendations
• The heating cable may be installed straight, spiralled or in
multiple runs as required by the design specication, nVent
product literature or TraceCalc software.
– Do not use metal attachments, vinyl electrical tape or duct
tape as heating cable damage may result.
– Self-Regulating technology allows for the multiple
overlapping of the heating cable on to itself.
• Power Limiting technology dictates that the heating cable
can be overlapped only once on to itself. If VPL cables are
installed parallel to each other, please allow for minimum 15
mm clearance.
For VPL heating cable only:

• Fix in place with a minimum of two wraps the appropriate
self-adhesive glass cloth tape (see gure 1) or plastic cable
ties at 300 mm intervals and additionally where necessary.
• Plastic cable ties must have a temperature rating that
matches the system exposure temperature.
• The heating cable’s minimum bend radius must not be
exceeded (refer to p. 2)
Bend the cable only in upright position
• The heating cable does not bend easily in the at plane.
Do not force such a bend, as the heating cable may be
damaged.
3.4.1 Straight tracing
• Straight trace the pipe unless the design calls for spiralling
(see 3.4.2).
• On horizontal pipes x on lower quadrant as shown in Figure
1 and not on bottom of pipe.
• To prevent overheating, be sure the location of the power
limiting heating cable is planned so that the active heating
zone will not extend into the component. Read the kit
installation instructions and plan the component location
before permanently attaching the cable to the pipe. Ensure
that the active heating zones are located where heat is
required i.e. on the pipe.
• Thermally insulate and weatherproof to specication.
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Figure 1
Glass cloth tape
(typical)
Tight on pipe
Top
Pipe
Thermal
insulation
(typical)
45°
(nominal)
300 mm
nVent attachment tapes:
GT66 Self-adhesive glass cloth tape
General purpose tape. Not for stainless-steel surfaces
or for installation temperatures <4°C.
GS54 Self-adhesive glass cloth tape
Recommended for use on stainless-steel and cupra-
nickel surfaces or for installation temperatures <4°C.
Figure 2
ATE-180 Aluminium tape
Use only if the design requires it.
ATE-180 improves the heat transfer and increases the power
output of the heating cable.
Attach the heating cable to the pipe as shown in Figure 2.
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3.4.2. Spiral tracing
• Alternative spiralling methods are shown in
Figures 2a and 2b.
• Only spiral heating cable on pipe when called for by design.
• To prevent overheating, be sure the location of the power
limiting heating cable is planned so that the active heating
zone will not extend into the component. Read the kit
installation instructions and plan the component location
before permanently attaching the cable to the pipe. Ensure
that the active heating zones are located where heat is
required i.e. on the pipe.
Spiral Pitch Table (mm).
NB NPS Spiral Ratio
(mm) (inches) Metres of cable per metre of pipe
1.1 1.2 1.3 1.4 1.5
25 1 250 170 140 110 100
32 11/4 310 210 170 140 130
40 11/2 350 240 190 160 140
50 2 430 300 240 200 180
65 21/2 520 360 290 240 210
80 3 630 430 350 290 260
90 31/2 720 490 390 330 290
100 4 800 560 440 370 330
125 5 990 680 550 460 400
150 6 1180 810 650 550 480
200 8 1520 1050 840 710 620
Example:
For pipe of 80 mm NB (3” NPS) requiring 1.3 metres of heating
cable per metre of pipe, pitch is 350 mm.
Figure 2a
Glass cloth tape
(typical)
Heating
cable
Pipe length
Pipe
Apply glass
cloth tape
before spiralling
cable on pipe
Heating cable length
Wrap loops in
opposite
direction
Tape after
spiralling cable
on pipe
Pitch
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Heating cable length = pipe length x spiral ratio
Refer to design specication for spiral ratio
Step 1 Make starting loop as shown
Step 2 Grasp loop and wind around pipe
Step 3 Space evenly and attach to pipe.
Thermally insulate and weatherproof to specication
Figure 2b
Pipe
Heating cable
Glass cloth tape
(typical)
Pitch
Refer to design specication for spiral pitch
Mark the pipe at the spiral pitch or use a simple length gauge
Fix the heating cable as installation progresses
Thermally insulate and weatherproof to specication
3.5 Cutting the heating cable
• Cut the heating cable to length after it is attached to the
pipe. Before cutting it, conrm the tracing allowance as per
Sections 3.3 and 3.6.
• RAYCHEM heating cable can be cut to length without
affecting the heat output per metre.
3.6 Typical installation details
• Typical installation details for xing heating cable to pipe
ttings are shown hereafter.
General notes:
• Trace pipe ttings as shown to allow easy maintenance.
• Consult the design specication or nVent product literature
or TraceCalc software for the tracing requirements for
ttings and supports.
• Follow the recommendations for cutting and stripping
heating cables; they are included in the component
installation instructions.
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3.6.1 Valve
Figure 3
The heating cable conguration will
vary for different valve shapes and
heating cable lenghts.
Heating cable
Glass tape
Valve body
Pipe
• Refer to design specication for additional heating cable
length.
• Fix with self-adhesive glass cloth tape.
• Thermally insulate and weatherproof to specication
(including valve stem).
3.6.2 Elbow
Figure 4
Thermal insulation
Pipe
Glass cloth tape
(typical)
Heating cable
• Fix heating cable to outside (long) radius of elbow
• Fix with self-adhesive glass cloth tape
• Thermally insulate and weatherproof to specication
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3.6.3 Flange
Figure 5
Heating cable
Pipe Glass cloth tape (typical)
• Additional heating cable is 2-3 times diameter of pipe
(typical)
• Fix with self-adhesive glass cloth pipe
• Thermally insulate and weatherproof to specication
3.6.4 Pipe bar hanger
Figure 6
Glass cloth tape
(typical)
Bar hanger
Weatherproong
Thermal insulation
Pipe
Heating cable
Bar hanger
Sealer
Sealer
Heating cable
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– Do not clamp heating cable with support. Heating cable
must be over the support
• No additional heating cable is required for bar or rod pipe
hangers unless called for in the design specication, then
use loop length specied
• Fix with self-adhesive glass cloth tape
Thermally insulate and weatherproof to specication
3.6.5 Pipe support shoe
Figure 7
Side view
Heating cable Pipe
Support shoeGlass cloth tape
(typical) Pipe
• Refer to design specication for additional heating cable
length
• Fix with self-adhesive glass cloth tape
• Thermally insulate and weatherproof to specication
View from under
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4 COMPONENTS INSTALLATION
General notes:
Select the required components from nVent product literature or
use the TraceCalc software.
RAYCHEM component kits (including power connections,
splices and end seals) must be used to satisfy Standards and
Approval Body requirements.
Installation instructions included in the kit must be followed,
including those for preparation of the heating cable conductors
for connections. Before assembly, use the guide given in the
instructions to ensure that the kit is correct for the heating
cable and environment.
– 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.
4.1 Components required
• For the installation of all components refer to the relevant
component installation instructions.
• Required for each heating cable run:
Power connection and insulation entry kit
End seal.
• As required:
Splice. Tee-splice. Junction box. Three connection kits and
three insulation entry kits. Accessories (pipe straps, xing
tape, support brackets, labels, etc.).
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Valve
End seal
Heating cable
JBU-100
SB-100
4.2 Typical systems
Figure 8a
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Thermal insulation
Glass cloth tape
(typical)
Insulation
Entry kit
Splice (as required)
SB-101
Thermostat
C25-100
Connection kit
IEK-25-04
Insulation entry kit
JBU-100
Junction box for
modular system
Heating cable
Wallmounted
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T-100
Tee or splice
connection
JBM-100
Integrated power/
tee connection
JBS-100
Integrated power connection
(shown with light)
C-150
Low prole power connection
IEK-25-04
Insulation entry kit
Figure 8b
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