Raychem XL-Trace User manual

XL-Trace System
InstallatIon and operatIon manual for
pIpe freeze protectIon and flow
maIntenance
THERMAL MANAGEMENT WWW.PENTAIRTHERMAL.COM

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Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01
Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD.
Raychem heat-tracing systems must be installed cor-
rectly 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 Thermal Management
requirements, agency certifications, and national elec-
trical 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
Thermal Management-specified 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 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 cable can cause electrical arcing or
fire. Do not use metal attachments such as pipe straps
or tie wire. Use only Thermal Management approved
tapes and cable ties to secure the cable to the pipe.
•Do not attempt to repair or energize damaged heating
cable. Remove damaged sections at once and replace
them with a new length using the appropriate Raychem
splice kit. Replace damaged connection kits.
•Use only fire-resistant insulation materials such as
fiberglass wrap or flame-retardant foams.
Note: Pipes are shown without insulation for illustrative
purposes only. All pipe installations must be fully cov-
ered with thermal insulation.

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Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01
Table of Contents
1 General Information 1
1.1 UseoftheManual 1
1.2 XL-TraceApplications 2
1.3 SafetyGuidelines 2
1.4 Approvals 3
2 Installation Guidelines 4
2.1 HeatingCableStorage 4
2.2 Pre-InstallationChecks 4
2.3 HeatingCableInstallation 5
2.4 HeatingCableConnections 17
3 Thermal Insulation 25
3.1 InsulatingtheSystem 25
3.2 InsulationInstallation 25
4 Power Supply and Electrical Protection 28
4.1 VoltageRating 28
4.2 CircuitBreakerSizing 28
4.3 ElectricalLoading 28
4.4 Ground-FaultProtection 28
4.5 ImportantPowerSupplySafeguards 29
5 Control, Monitoring and Power Distribution 30
5.1 ControlSystems 30
5.2 PowerDistribution 33
6 Commissioning and Preventive Maintenance 36
6.1 Tests 36
7 Test Procedures 38
7.1 SystemTests 38
7.2 FaultLocationTests 43
8 Troubleshooting Guide 48
9 Appendix 50
10 Installation and Inspection Records 56

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General Information
1.1 Use of the Manual
ThismanualcoverstheinstallationofRaychem
XL-Traceself-regulatingheatingcablesandcon-
nectionsforcommercialconstructionpipesystems
inordinary(nonhazardous)areas.Themanualcov-
ersgeneralheatingcableinstallationprocedures
andspecificinstallationdetailsandshowsavailable
connectionkitsforthedifferentapplications.The
manualalsodiscussescontrols,testing,andperiodic
maintenance.
Thismanualassumesthattheproperheat-tracing
designhasbeencompletedaccordingtothePipe
FreezeProtectionandFlowMaintenanceDesign
Guide(H55838).Onlytheapplicationsdescribedin
Section1.2areapprovedbyThermalManagement
forXL-Tracesystemswhenusedwithapproved
Raychemconnectionkits.Theinstructionsinthis
manualandtheinstallationinstructionsincluded
withtheconnectionkits,controlsystems,powerdis-
tributionsystems,andaccessoriesmustbefollowed
fortheThermalManagementwarrantytoapply.
ContactyourThermalManagementrepresentative
forotherapplicationsandproducts.
Foradditionalinformation,contact:
Thermal Management
7433HarwinDrive
Houston,TX77036
USA
Tel: +1.800.545.6258
Tel: +1.650.216.1526
Fax: +1.800.527.5703
Fax: +1.650.474.7711
[e-mail]
www.pentairthermal.com

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General Information
1.2 XL-Trace Applications
XL-Traceheat-tracingsystemsareapprovedand
qualifiedfortheapplicationslistedbelow.
Freeze protection
• General water piping.Freezeprotection(40°F
(4°C)maintain)ofinsulatedmetallicorplastic
waterpiping.
• Sprinkler piping systems.Freezeprotection(40°F
(4°C)maintain)ofinsulatedmetallicstandpipes
andsupplypipingupto20".
Flow maintenance
• Greasy waste lines.Flowmaintenance(110°F
(43°C)maintain)ofinsulated-greasedisposal
lines.
• Fuel lines.Flowmaintenance(40°F(4°C)main-
tain)forinsulatedmetallicpipingcontaining#2
fueloil.
Forheatingcableapplicationsotherthanthoselisted
above,pleaseseeyourThermalManagementrepre-
sentativeorcallusat(800)545-6258.
1.3 Safety Guidelines
Aswithanyelectricalequipment,thesafetyandreli-
abilityofanysystemdependsonthequalityofthe
productsselectedandthemannerinwhichtheyare
installedandmaintained.Incorrectdesign,handling,
installation,ormaintenanceofanyofthesystem
connectionkitscoulddamagethesystemandmay
resultininadequateperformance,overheating,
electricshock,orfire.Tominimizetheserisksand
toensurethatthesystemperformsreliably,read
andcarefullyfollowtheinformation,warnings,and
instructionsinthisguide.
Payspecialattentiontothefollowing:
• Importantinstructionsaremarked Important
• Warningsaremarked WARNING

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General Information
1.4 Approvals
XL-Traceheat-tracingsystemscarryagency
approvalsforthedifferentapplicationsshownin
Section1.2.Fordetailedinformationonwhich
approvalsarecarriedforthespecificapplica-
tion,refertothePipeFreezeProtectionandFlow
Maintenancedesignguide(H55838).
Warranty
ThermalManagementstandardlimitedwarranty
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onlinewarrantyformissubmit-
tedwithinthirty(30)daysfromthedateofinstalla-
tion.Youcanaccessthecompletewarrantyonour
websiteatwww.pentairthermal.com.

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Installation Guidelines
2.1 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.
2.2 Pre-Installation Checks
Check materials received
Catalog number: 5, 8 or 12 XL — 1 or 2 -CR -CT
Power output (W/ft)
Product family
Voltage 1 = 120 Vac (only available for 5 or 8)
2 = 208–277 Vac (available for 5, 8, or 12)
Jacket type: Polyolefin or
Fluoropolymer
(Required for grease and fuel lines)
Figure 1: XL-Trace catalog number
• 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.
• Ensurethattheservicevoltageavailableiscorrect
fortheXL-Traceheatingcableselection.
• Inspecttheheatingcableandconnectionkitsto
ensurethereisnoin-transitdamage.
• Verifythesystemdesigndoesnotexceedthemax-
imumexposuretemperatureoftheheatingcable
5XL/8XL:150°F(65°C)12XL:185°F(85°C)
• Verifythattheheatingcablejacketsarenotdam-
agedbyconductingtheinsulationresistancetest
(refertoSection7)oneachreelofheatingcable.
Donotpowertheheatingcablewhenit’sonthe
reel.

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Installation Guidelines
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.
2.3 Heating Cable Installation
Minimuminstallationtemperatureof:0°F(–18°C).
Heatingcableinstallationinvolvesthreebasicsteps:
1. Payingouttheheatingcable
2. Attachingtheheatingcabletothepipe
3. Wrappingheatsinks
Paying out the heating cable
Mountthereelonaholderandplaceitneareither
endofthepiperuntobetraced.Useareelholder
thatpaysoutsmoothlywithlittletensionasshown
inFigure2.Avoidjerkingtheheatingcablewhile
pulling.
Payouttheheatingcableandlooselystringitalong
thepipe,makingsuretheheatingcableisalways
nexttothepipewhencrossingobstacles.Iftheheat-
ingcableisonthewrongsideofacrossingpipeor
I-beam,youwillhavetoreinstallitorcutandspliceit.

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Installation Guidelines
Figure 2: Paying out the heating cable
When paying out the heating cable, AVOID:
• Sharpedges
• Excessivepullingforceorjerking
• Kinkingorcrushing
• Walkingonorrunningovertheheatingcablewith
equipment
WARNING: Fire and shock hazard. Do not install
damaged heating cable. Connection kits and heat-
ing cable ends must be kept dry before and during
installation.
Attaching the heating cable
Oncetheheatingcablehasbeenrunfortheentire
section,beginfasteningittothepipe.Startatthe
endandworktowardthereel.Theadditionalheat-
ingcablerequiredforvalvesandotherheatsinksis
showninTable1andTable2.RefertoTable3forthe
additionalheatingcablerequiredforconnectionkits.
Theheatingcablemaybeinstalledinsingleorin
multiplerunsasrequiredbythedesign.

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Installation Guidelines
Figure 3: Attaching the heating cable

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Installation Guidelines
TABLE 1:
ADDITIONAL HEATING CABLE FOR VALVES
Pipe diameter (IPS)
Heating cable in feet (meters)
1/2  0.8 (0.24)
3/4  1.3 (0.4)
1 2.0 (0.6)
1-1/4  3.3 (1.1)
1-1/2  4.3 (1.3)
2 4.3 (1.3)
3 4.3 (1.3)
4 4.3 (1.3)
6 5.0 (1.5)
8  5.0 (1.5)
10  5.6 (1.7)
12  5.9 (1.9)
14  7.3 (2.2)
18  9.4 (2.9)
20  10.5 (3.2)
TABLE 2:
ADDITIONAL HEATING CABLE FOR PIPE SUPPORTS
AND FLANGES
Support
Additional heating cable
Pipehangers(insulated) Noadditionalheatingcable
Pipehangersnoninsulatedand
U-boltsupports:
Add2xpipediameter
Weldedsupportshoes Add3xthelengthoftheshoe
Flanges Add2xpipediameter
Note:Forapplicationswheremorethanoneheatingcableis
requiredperfootofpipe,thiscorrectionfactorappliesforeach
heatingcablerun.

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Installation Guidelines
• Runinsulationthroughthepipehangerensuring
thatthepipeisnotrestingontheheater.
Heating cable
Heating cable
beneath
insulation
and pipe hanger
Heating cable
over pipe hanger
Pipe hanger
under insulation
Pipe hanger
over insulation
Insulation over
pipe hanger
Heating cable
Figure 4: Pipe hanger with heating cable
Figure 5: Single pipe floor penetration
• 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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Installation Guidelines
• 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pene-
tration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 6: 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XL-Trace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.
• WhenXL-Traceisinstalledbehindwalls,the
powerconnectionkitmustbeaccessible.
Wheneverpossible,positiontheheatingcableon
thelowersectionofthepipeasshowninFigure7to
protectitfromdamage.

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Installation Guidelines
One heating cable
45°
Two heating cables
45° 45°
Figure 7: Positioning the heating cable
Securing the heating cable
WARNING: Damage to the heating cable can
cause electrical arcing or fire. Do not use metal
attachments such as pipe straps or tie wire. Use only
Thermal Management-approved tapes or plastic
cable ties.
Important: Before taping the heating cable to
the pipe, make sure all heat-tracing allowances for
flanges, valves, supports, and other connection kits
have been verified.
Useoneofthefollowingattachmentmethodsto
securetheheatingcableontothepipe:GT-66or
GS-54glassclothtape,AT-180aluminumtape,or
plasticcableties.
Glass clotH adHesiVe tape
• GT-66(66-footroll)general-purposetapefor
installationat40°F(4°C)andabove.Applyat
1-footintervals.
• GS-54(54-footroll)general-purposetapefor
installationbelow40°F(4°C).Applyat1-foot
intervals.
at-180
aluMinuM tape
• Requiredforplasticpipeapplicationstoensure
properpoweroutputofheatingcable.

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• Tapelengthwiseovertheheatingcableas
requiredbythedesigndrawingorspecification
(seeFigure8).
• Recommendedforheat-tracingpumpbodiesor
odd-shapedequipment,orascalledoutinthe
designdrawingasaheat-transferaid.
• Installattemperaturesabove32°F(0°C).
Heating cable
1 ft (0.3 m)
Pipe
Thermal insulation
Weather proofing
Glass cloth tape
AT-180 aluminum tape
over heating cable
(Required for proper
output for plastic
pipe applications)
Heating
cable
PipeAT-180
aluminum tape
Figure 8: Attaching the heating cable
ca Ble ties
• Recommendedinapplicationswherethepipesur-
facepreventspropertapeadhesion.
• Useplasticcabletiesonly.
• Cabletiesmustbehand-tightenedonlytoprevent
damagetoheatingcable!
Bending/Crossing/Cutting the Heating Cable
BendinG tH e HeatinG 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.

13
Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01
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1/2"
Figure 9: Bending technique
crossin G tHe HeatinG caBle
XL-Traceheatingcablesareself-regulatingandmay
beoverlappedwhenevernecessarywithoutover-
heatingorburningout.
cuttinG tH e HeatinG caBle
Cuttheheatingcabletothedesiredlengthafteritis
attachedtothepipe.XL-Tracecanbecuttolength
withoutaffectingtheheatoutputperfoot.
Wrapping the Heat Sinks
Oncethestraightsectionsaresecuredtheheating
cablecanbesecuredtotheheatsinks.Attachthe
heatingcabletotheheatsinksaccordingtoFigure
10below.Thelengthofheatingcableinstalledis
determinedinthedesign.

14 Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01
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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.
Figure 10: Valve
Glass tape
(typical)
Heating cable Loop length is twice
the diameter of the pipe
Figure 11: Flange

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Raychem-IM-H58033-XLTracePipeFreezeProtectionCOM-EN 18/01
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Installation Guidelines
Heating cable
Glass tape
Pipe
Figure 12: Pressure gauge
Glass tape
Pump discharge
Pump body
Heating cable
Pump
suction
Use AT-180
tape
Motor
To power connection
Pump body
Pump body
Figure 13: Split case centrifugal pump

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Installation Guidelines
Heating cable secured to pipe
Glass tape
Heating cable loop
Support shoe Pipe
Figure 14: Pipe support shoe
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.
Figure 15: Elbow