Pentair Raychem HWAT System User manual

HWAT System
INSTALLATION AND OPERATION MANUAL
FOR HOT WATER TEMPERATURE MAINTENANCE
SYSTEMS FOR THERMALLY INSULATED PIPES
THERMAL MANAGEMENT SOLUTIONS WWW.THERMAL.PENTAIR.COM

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Raychem-IM-H57548-HWATsystem-EN 16/08
Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD
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.
• To minimize the danger of fire from sustained
electrical arcing if the heating cable is damaged or
improperly installed, and to comply with Pentair
Thermal Management requirements, agency certifi-
cations, 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 are based on the use of
Pentair Thermal Management parts only. Do not sub-
stitute parts or use vinyl electrical tape.
• Bus wires will short if they contact each other. Keep
bus wires separated.
• Connection kits and heating cable ends must be kept
dry before and during installation.
• The black heating cable core is 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 arc-
ing or fire. Do not use metal attachments such as
pipe straps or tie wire. Use only Pentair Thermal
Management 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 Raychem RayClic-S splice kit.
Replace damaged connection kits.
• Use only fire-resistant insulation which is
compatible with the application and the maximum
exposure temperature of the system to be traced.

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Raychem-IM-H57548-HWATsystem-EN 16/08
Table of Contents
1 General Information 1
1.1 Use of the Manual 1
1.2 Safety Guidelines 2
1.3 Typical HWAT System 2
1.4 Electrical Codes 3
1.5 Approvals 3
1.6 Warranty 4
1.7 Trade Coordination 4
1.8 General Installation Notes 5
1.9 Tools Required 6
2 Heating Cable Verification and Selection 7
2.1 Heating Cable 7
3 Heating Cable Installation 8
3.1 Heating Cable Storage 8
3.2 Pre-Installation Checks 8
3.3 Installation 8
4 Heating Cable Components 14
4.1 General Connection Kit Information 14
5 Control and Monitoring 16
5.1 HWAT-ECO and ACCS-30 Controllers 16
6 Thermal Insulation 17
6.1 Insulating the System 17
6.2 Insulation Installation 17
7 Power Supply and Electrical Protection 20
7.1 Voltage Rating 20
7.2 Circuit Breaker Sizing 20
7.3 Electrical Loading 20
7.4 Ground-Fault Protection 21
8 Commissioning and Preventive Maintenance 22
8.1 Tests 22
8.2 Preventative Maintenance 24
9 Test Procedures 25
9.1 System Tests 25
9.2 Fault Location Tests 31
9.3 Cable and Connection Continuity

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Raychem-IM-H57548-HWATsystem-EN 16/08
10 Test Procedures 34
11 Troubleshooting Guide 38

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Raychem-IM-H57548-HWATsystem-EN 16/08
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
HWAT-R2 heating cables, RayClic connection kits,
and the HWAT-ECO or ACS-30 controllers. It is
important to review this manual and the following
documents with the installing contractor:
• HWAT System Product Selection & Design Guide
(H57538)
• HWAT-ECO Data Sheet (H57339)
• ACS-30 Mulitpoint Commercial heat-tracing
Control System Data Sheet (H58261)
• HWAT Heating Cable Data Sheet (H57512)
• RayClic Connection System Data Sheet (H57545)
• HWAT-ECO Installation and Operation Manual
(H57340)
• ACS-30 Programming Guide (H58692)
For additional information, contact:
Pentair Thermal Management
7433 Harwin Drive
Houston, TX 77036
USA
Tel: [phone]
Tel: [phone]
Fax: [phone]
Fax: [phone]
[e-mail]
www.thermal.pentair.com
Important: For the Pentair Thermal Management
warranty and agency approvals to apply, the instruc-
tions that are included in this manual and product
packages must be followed.
1
General Information1 General Information

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Raychem-IM-H57548-HWATsystem-EN 16/08
1.2 Safety Guidelines
The safety and reliability of any heat-tracing system
depends on the quality of the products selected, and
on proper design, installation, and maintenance.
Incorrect design, handling, installation, or mainte-
nance of any of the system components can cause
underheating or overheating of the pipe, or dam-
age to the heating cable system, and may result in
system failure, electric shock, or fire. The guide-
lines and instructions contained in this guide are
important. Follow them carefully to minimize these
risks and to ensure that the HWAT System performs
reliably.
Pay special attention to the following:
• Instructions marked Important
• Warnings marked WARNING
1.3 Typical HWAT System
A typical HWAT System is shown is Figure 1. The
heating cable is cut to length in the field and is
attached to the pipe with glass tape. A power con-
nection kit connects the heating cable bus wires to
power in a junction box. RayClic tees and splices
accommodate pipe branches to connect two or three
heating cables together. An end seal kit is used to
terminate the end of the heating cable. A controller
is used to set the maintain temperature and improve
energy savings.
1
General Information

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Raychem-IM-H57548-HWATsystem-EN 16/08
Splice
To power
distribution
panel
Note: Partial pipe insulation
shown here for clarity.
All pipes must be fully
insulated
End
seal
Tee
Thermal
insulation
Heating
cable
Pipe
temperature
sensor
Temperature
sensor
Heating
cable
Insulation
Glass
tape
Power
connection
Controller
To BMS
ETL
label
180°
Figure 1: Typical HWAT heating cable system
1.4 Electrical Codes
Section 427 of the National Electrical Code (NEC),
and Part 1, Section 62 of the Canadian Electrical
Code (CEC), in particular, govern the installation of
electrical heat-tracing systems used on hot water
pipes. All installations must be in compliance with
this and any other applicable national or local codes.
1.5 Approvals
HWAT-R2 heating cable and RayClic connection kits,
are UL Listed and CSA certified for use in non-haz-
ardous locations. The HWAT-ECO controller is c-UL-
us Listed and the ACS-30 controller is c-CSA-us cer-
tified (ACS-UIT) and c-UL-us Listed (ACS-PCM2-5) to
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General Information

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Raychem-IM-H57548-HWATsystem-EN 16/08
US and Canadian standards for us in non-hazardous
locations. Refer to the specific product data sheets
for details.
1.6 Warranty
Pentair Thermal Management standard limited war-
ranty applies to all products.
An extension of the limited warranty period to ten
(10) years from the date of installation is available
if a properly completed on-line warranty form is
completed within (30) days from the date of installa-
tion. The extension is valid for the HWAT-R2 heating
cable, RayClic connection kits and accessories, but
not the HWAT-ECO or ACS-30 controllers. You can
access the complete warranty on
www.thermal.pentair.com.
1.7 Trade Coordination
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 instal-
lation of the heating cable and connections must be
properly scheduled, along with the scheduling of the
risers and insulation installation.
This guide will assist the installer throughout the
installation process and must be reviewed by all
affected trades before installation of the HWAT
System begins. In a fast-track job, the HWAT System
must be considered a critical path item: the pipe,
heating cable, insulation, and wallboard must all be
installed in the proper order, since the heating cable
cannot be installed later. If, for example, the walls
go up before the heating cable commissioning tests
have been completed, it may be necessary to remove
the walls 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.
1
General Information

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Raychem-IM-H57548-HWATsystem-EN 16/08
1.8 General Installation Notes
Read and observe the instructions in this guide
to insure that the HWAT System is installed
successfully.
• Accidental damage to the system can be minimized
during construction by installing thermal insulation
on the pipe immediately after the pipe has been
traced and the heating cable has been tested.
• Read all installation documentation to familiarize
yourself with the system components.
• Read and follow all warnings and recommenda-
tions. All involved trades should review this entire
guide and assess the recommendations applicable
to their scope of work.
• All heat-traced pipes and equipment must be ther-
mally insulated. Insulation is an important part
of the HWAT System. For an effective system, the
fiberglass insulation must be a specific thickness
for each specific pipe size as detailed in Table 2 on
page17.
• Do not install the HWAT System below the mini-
mum installation temperature.
– The minimum installation temperature for HWAT
heating cables is 0°F (–18°C)
– The minimum installation temperature for HWAT-
ECO is 40°F (5°C).
• Ensure that your water heater temperature is set
at your desired pipe maintain temperature.
• Do not energize cable when it is coiled or on the
reel.
• Never use metal tie wire or pipe straps to secure
heating cables to pipes.
Important: Exceeding 185°F (85°C) for HWAT-R2
will decrease the power output of the heating cables
over time.
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General Information

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Raychem-IM-H57548-HWATsystem-EN 16/08
1.9 Tools Required
For installing cable and connection kits:
• Utility knife
• Diagonal cutters
• Cable cutters
• Tape measure
• Screwdriver
• Heat gun or propane torch
For testing the heating cable:
• Megohmmeter 2500 Vdc
• Multimeter (voltage, resistance and capacitance)
1
General Information

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2
Heating Cable Verification and
Selection
Raychem-IM-H57548-HWATsystem-EN 16/08
2.1 Heating Cable
The HWAT System includes HWAT-R2 heating cable
designed to maintain the piping at specific tempera-
ture settings with the use of the HWAT-ECO or ACS-
30 controllers. Figure 2 shows the construction of
the heating cable.
Nickel-plated copper bus wires
Self-regulating conductive core
Polymer-coated aluminum wrap
Tinned-copper braid
Modified polyolefin
outer jacket
Modified polyolefin inner jacket
Figure 2: HWAT-R2 heating cable
The minimum control setpoint for HWAT-R2 is 105°F
(40°C). The maximum control setpoint for HWAT-R2
is 140°F (60°C).
2 Heating Cable Verification and
Selection

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
3.1 Heating Cable Storage
• Store the heating cable in a clean, dry location.
Temperature range: 0°F (–18°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 the
heating cables and connection kits received to
confirm that the proper materials are on site. The
heating cable type is printed on its jacket.
• The HWAT System is limited to 208 V or 240 V ser-
vice when using the HWAT-ECO controller. When
using the ACS-30 controller the voltage range is
208–277 V. Ensure that the service voltage avail-
able is correct.
• Inspect the heating cable and connection kits to
ensure there is no in-transit damage.
• Verify that the heating cable jackets are not dam-
aged by conducting the insulation resistance test
(refer to Section 9) on each reel of cable. Do not
power the heating cable when it’s on the reel.
Check piping to be traced:
• Make sure all mechanical pipe testing (i.e. hydro-
static testing/purging) is complete and the system
has been cleared by the client for tracing.
• Walk the system and plan the routing of the heat-
ing cable on the pipe.
• Inspect the piping and remove any burrs, rough
surfaces or sharp edges.
3.3 Installation
• 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.
• Install HWAT heating cable in straight runs along
the pipe. Spiraling the heating cable is not
necessary.
3 Heating Cable Installation

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
• 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.
• When installing the heating cable, the cable
must not be compressed or pinched between
two objects. Wall and floor penetrations and pipe
hangers are particular areas of concern.
Figure 3: Protecting the heating cable in floor
penetrations
• Run insulation through the pipe hanger ensuring
that the pipe is not resting on the heater.
Figure 4: Pipe hanger with heating cable
• When making floor or wall penetrations, make
sure the hole is large enough to accommodate
the pipe and the thermal insulation. When sealing
around pipes at floor penetrations, avoid damag-
ing or cutting the heating cable, or pinching it
between the pipe and the concrete.

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
• The heating cable must not be embedded directly
in the sealing material; the pipe should have ther-
mal insulation over it (if allowed by local codes) or
the heating cable should be run through the pen-
etration in a tube or conduit. If the conduit must be
sealed, use a pliable fire-resistant material (Dow
Corning Fire Stop, 3M Fire Barrier, or T&B Flame-
Safe) that can be removed if necessary.
Figure 5: Multiple pipe floor penetration
• On vertical piping groups, run the heating 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 penetration. Run the heating cable over
the outside of the pipe support. Do not clamp the
heating cable to the pipe with the pipe support.
• In high-rise construction it may be necessary to
install the HWAT System 10 or 12 floors at a time
to fit into the construction schedule. If so, the
end of the heating cable should be sealed with a
RayClic-E end seal and placed in an accessible
location. This allows testing of one part of the
heating cable at a time, and allows splicing it to
another section when the system is complete.
Paying out the cable:
• Use a reel holder that pays out smoothly with little
tension. If the 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 cable length.

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
• Protect all heating cable ends from moisture, con-
tamination and mechanical damage.
Figure 6: HWAT cable layout
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. Connection kits 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 or 8 o’clock positions, as
shown below, to protect it from damage.
Figure 7: Cable positioning

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
Attaching the heating cable
Starting from the end opposite the reel, tape the
heating cable to the pipe every 2 feet. Work back to
the reel. Leave extra heating cable at the power con-
nection, at all sides of splices and tees to allow for
future servicing. See Table 1 on page15.
• Install heating cable connection kits immediately
after attaching the heating cable. If immediate
installation is not possible, protect the heating
cable ends from moisture.
Bending the cable
When positioning the heating cable on the pipe, do
not bend tighter than 1/2” radius. The heating cable
does not bend easily in the flat plane. Do not force
such a bend, as the heating cable will be damaged.
1/2"
Figure 8: Bending technique
Crossing the cable
HWAT heating cables are self-regulating and may be
overlapped whenever necessary without overheating
or burning out.
Cutting the cable
Cut the heating cable to the desired length after it
is attached to the pipe. HWAT can be cut to length
without affecting the heat output per foot.
Attachment tapes
To ensure that the heating cable is in full contact
with the pipe, use tape to attach the heating cable
to the pipe every 2 ft (.6 m). Use Raychem GT-66
attachment tape. One roll will handle approximately
50 ft (15 m) of cable.

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3
Heating Cable Installation
Raychem-IM-H57548-HWATsystem-EN 16/08
Figure 9: Attaching the heating cable
To ensure sufficient heat transfer AT-180 aluminum
tape must be used to install the heating cable on
plastic pipes as shown in Figure 10.
WARNING: Do not use metal attachments such
as pipe straps or tie wire. Do not use vinyl-based
electrical or duct tape. Use only Pentair Thermal
Management approved tapes.
Raychem HWAT
heating cable Continuous AT-180
alluminum tape
over heating cable
Rigid plastic pipe
Thermal
insulation
Figure 10: Installed on plastic pipe with aluminum tape
Raychem GT-66 glass tape
2 ft.

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4
Heating Cable Components
Raychem-IM-H57548-HWATsystem-EN 16/08
4.1 General Connection Kit Information
Raychem RayClic connection kits must be used with
HWAT-R2 heating cable. A complete circuit requires
a power connection and an end seal. Splices and
tees and other connection kits are used as needed.
Use the HWAT System Design Guide (H57510) to
select appropriate connection kits. Installation
instructions are included with every connection kit.
Steps for preparing the heating cable and installing
connection kits must be followed. HWAT connection
kit locations should be noted on “As Built” drawings.
Connection kit locations should be marked on the
outside of the insulation cladding with the labels
provided in the kits.
RayClic-PT
powered
tee
RayClic-PC
powered connection
RayClic-S
splice
RayClic-X
cross tee
RayClic-T
tee
RayClic-PS
powered
splice
RayClic-LE
lighted end seal
RayClic-E
end seal
Alternate
lighted end seal
Alternate
connection kits
HWAT
heating cable
Figure 11: RayClic connection system
Connection Kit Installation
• When practical, mount the connection kits on top
of the pipe. All heating cable connections must be
mounted above grade level.
• Leave excess cable to serve as a service loop at
all connection kits (power, splice, cross or tee) for
future maintenance, as detailed in Table 1. The
additional heating cable will easily pay for itself in
time savings if it becomes necessary to check or
replace a connection kit after installation. Splices
and tees should have a service loop on each of the
heating cables entering the connection kit.
4 Heating Cable Components

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4
Heating Cable Components
Raychem-IM-H57548-HWATsystem-EN 16/08
TABLE 1: SERVICE LOOPS FOR EACH CONNECTION KIT
RayClic-PC 1 2.0 ft (0.6 m) 2 ft (0.6 m)
RayClic-S 2 1.0 ft (0.3 m) 2 ft (0.6 m)
RayClic-T 3 1.0 ft (0.3 m) 3 ft (0.9 m)
RayClic-X 4 1.0 ft (0.3 m) 4 ft (1.2 m)
RayClic-PS 2 1.5 ft (0.5 m) 3 ft (0.9 m)
RayClic-PT 3 1.3 ft (0.4 m) 4 ft (1.2 m)
RayClic-E 1 NA NA
RayClic-LE 1 2.0 ft (0.6 m) 2.0 ft (0.6m)
Connection # of cable Cable length/ Total cable length
kit name connections/kit connection (Service loop)
• All power connection kits must be installed in
accessible locations. Access to splices, tee kits
and end seals is recommended for future modifi-
cation or maintenance but is not required.
• 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.
WARNING: The black heating cable core is elec-
trically conductive and can short. It must be proper-
ly insulated and kept dry. Damaged bus wires can
overheat or short.
WARNING: Fire and shock hazard. Raychem
brand specified components must be used. Do not
substitute parts or use vinyl electrical tape.

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5
Control and Monitoring
Raychem-IM-H57548-HWATsystem-EN 16/08
5.1 HWAT-ECO and ACS-30 Controllers
The Raychem HWAT-ECO controller is designed for
use only with HWAT-R2 heating cables and must be
used to ensure proper water temperature.
Refer to the HWAT-ECO Installation and Operation
Manual (H57340) for the installation and operation
instructions of the controller.
Figure 12: HWAT-ECO controller
The ACS-30 Control System is also approved for use
with HWAT-R2 heating cable. Refer to the ACS-30
Programming Guide (H58692) for the installation and
operating instructions of the control system.
Heat-tracing system
ACCS-UIT2
(Optional)
RMM2
COMMON
ALARM
POWERCONTROL
MODULE
ACCS-PCM-5
COMMON
ALARM
POWERCONTROL
MODULE
ACCS-PCM-5
ACCS-PCM2-5 ACCS-PCM2-5
Figure 13: ACS-30 Control System
5 Control and Monitoring