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Industrial Heat-Tracing
Installation and
Maintenance Manual

Self-Regulating and Power-Limiting
Heating Cable Systems

Table of Contents
WARNING: Fire and shock hazard.
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 Tyco Thermal Controls requirements, agency
certifications, and the 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 Tyco Thermal Controls 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.

1
2
3
4
5
6
7
8
9
10
11

General Information

1–2

Heating Cable Selection

Heating Cable Installation

3–15

Heating Cable Components

Control and Monitoring

17–18

Thermal Insulation

Power Supply and Electrical Protection

Commissioning and Preventive Maintenance

21–22

Test Procedures

23–31

Troubleshooting Guide

32–35

Installation and Inspection Records

36–41

• 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 from the
Tyco Thermal Controls Customer Service Center.

iii

1.1

General Information

Use of the Manual
This installation and maintenance manual is for Raychem
Self-Regulating and Power-Limiting heat-tracing systems
on thermally insulated pipes and vessels only. This includes
Raychem BTV, QTVR, XTV, and VPL heating cables and the
appropriate Raychem components.
For information regarding other applications, design assistance or technical support, contact your Tyco Thermal
Controls representative or Tyco Thermal Controls directly.
Tyco Thermal Controls
2415 Bay Road
Redwood City, CA 94063-3032
USA
Tel (800) 545-6258
Tel (650) 216-1526
Fax (800) 527-5703
Fax (650) 474-7711
info@tycothermal.com
www.tycothermal.com
Important: For the Tyco Thermal Controls 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.

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 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

General Information

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

Heating Cable Selection

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 Tyco Thermal Controls web site,
www.tycothermal.com, to select the proper heating cable
for your application.

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 (Tyco Thermal Controls 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).

3.1

Heating Cable Storage

3.3 Installation

• 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

Heating Cable Installation

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 are no holes in the heating cable jackets
by conducting the insulation resistance test (refer to
Section 9) on each reel of cable.

Heating Cable 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

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.

Pipe
Multiple cables
from two reels

Pipe

Multiple cables
from a single reel

Heating Cable Installation

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.

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.

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

• Special application tape for stainless steel pipes
• For installations at –40°F (–40°C) and above
• Use in applications below 356°F (180°C)

GT-66 fiberglass tape

• General purpose tape for installation at 40°F (5°C) and
above
• Use in applications below 266°F (130°C)
GS-54 fiberglass tape

WARNING: Fire and shock hazard. Do not install
damaged cable. Components and cable ends must be
kept dry before and during installation.

GT-66 or GS-54 glass tape
across heating cable

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.
One heating cable

Two heating cables

AT-180 aluminum tape

• Heat-transfer tape for plastic pipes, pump bodies, and
odd-shaped equipment
• Install above 32°F (0°C)
• Use in applications below 300°F (150°C)
• Tape lengthwise over the heating cable as required by
the design

AT-180 aluminum tape
over heating cable

WARNING: 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.

Heating Cable Installation

Attaching the heating cable

Heating Cable Installation

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.

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” 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.

Heating Cable Installation

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.

Heating Cable Installation

The heating cable does not bend easily in the flat plane.
Do not force such a bend, as the heating cable may be
damaged.

10 feet
Glass tape
Heating
(typical)
cable

Wrap loops
in opposite
directions

Apply glass
tape before Pull heating cable loop length
spiraling
heating cable
on pipe

Tape after spiraling
heating cable on
pipe

Self-regulating
minimum bend radius

Power-Limiting cable, VPL, allows for a single overlap of
the heating cable per zone.
For VPL heating cable only:

Bending the cable

1/2"

Crossing the cable
Self-Regulating cables, BTV, QTVR, XTV, allow for multiple
overlapping of the heating cable.

3/4"

Power-limiting
minimum bend radius

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.

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.

Heating Cable Installation

Typical installation examples

Heating Cable Installation

Pipe support shoe

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.

Heating cable loop

Valve

Support shoe
Glass tape
Valve body
Glass tape

Pipe

Heating cable
Multiple crossovers allowed
for self-regulating cables

Note: Cable loop length
varies depending on
heat loss.

Heating cable secured to pipe

Elbow

Pipe

Heating cable

Flange

Pipe

Single crossover only, allowed
for power-limiting cables

Heating cable
Glass tape
(typical)

Glass tape
(typical)
For pipe diameters of 2"
and larger, the heating
cable should be installed
on the outside (long)
radius of the elbow.
Heating cable

Loop length is twice
the diameter of the pipe.

Heating Cable Installation

Pressure gauge

Heating Cable Installation

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

Pipe
Pipe hanger

Glass tape
Heating cable
Heating cable

Split case centrifugal pump
To power connection

Glass tape

Pump discharge

Do not clamp heating
cable with support

Heating cable
Glass tape
Pump body
Pump
suction

Motor

Use AT-180
tape

4.1

Heating Cable Components

General Component Information
Raychem components must be used with Raychem selfregulating and power-limiting heating cables. A complete
circuit requires a power connection and an end seal.
Splices and tees are used as needed.

Heating Cable Components

Raychem Components for Nonhazardous, CID2 and Zone
1 Hazardous Locations
Power Connection

Splice

Tee

End Seal

JBM-100-A

PMKG-LS

PKMG-LT

E-150

JS-100-A

S-150

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.

E-100-L
T-100
E-100

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.
• All power connections, splices, tees, and end seals in
a Division 1 location must use the HAK-C-100 connection kit and an HAK-JB3-100 or a Division 1 Nationally
Recognized Testing Lab (NRTL) approved junction box.
WARNING: The black heating-cable core and fibers
are electrically 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
stripping the heating cable.

T-100

JBS-100-A

PMKG-LE

Raychem Components for CID1 Hazardous Locations
Splice
HAK-JB3-100
junction box
HAK-C-100
connection kit
Tee

End seal

Power connection
UMB
Junction box, connection
kit, and mounting bracket
sold separately

WARNING: Fire and shock hazard. Raychem brand
specified components must be used. Do not substitute
parts or use vinyl electrical tape.

Control and Monitoring

Tyco Thermal Controls DigiTrace® control and monitoring
products are designed for use with Self-Regulating and
Power-Limiting heat-tracing systems. Thermostats, controllers and control and monitoring systems are available.
Compare features of these products in the table below.
For additional information on each product, refer to the
Industrial Product Selection and Design Guide or contact
your Tyco Thermal Controls representative.

6.1

Refer to the installation instructions supplied with control
and monitoring products. Control and Monitoring systems
may require installation by a certified electrician.

AMC-F5
AMC-1A
AMC-1H

AMC-F5
AMC-1B
AMC-2B-2
E507S-LS
E507S-2LS-2
Raystat-EX03-A

Perform insulation resistance testing, known as a Megger™
test (refer to Section 9), prior to covering the pipe with
thermal insulation.

6.2

DigiTrace Series 1, 2

920

200N

T2000

NGC-30

Ambient temperature

Pipe temperature

Ground fault

Control
Ambient sensing

Line-sensing

PASC

6.3

Monitoring

Continuity
P

Local display

Remote display

Network to DCS

Location
Local

Remote
Hazardous

AMC-1H

E507S

Communications

Marking
Apply “Electric Traced” labels on outside of the cladding at
10-foot intervals on alternate sides to indicate presence of
electric cables.
Other labels, which identify the location of splices, tees,
and end connections installed beneath the thermal insulation, are supplied with those components and must also
be used.

Current

Insulation Installation Hints
• Insulation must be properly installed and kept dry.
• Check insulation type and thickness against the design
specification.
• To minimize potential heating cable damage, insulate as
soon as possible after tracing.
• Check that pipe fittings, wall penetrations, and other
irregular areas have been completely insulated.
• When installing cladding, be sure drills, screws, and
sharp edges do not damage the heating cable.
• To weatherproof the insulation, seal around all fixtures
that extend through the cladding. Check around valve
stems, support brackets, and thermostat capillaries.

CONTROLLERS

910

Pre-Insulation Checks
Visually inspect the heating cable and components for
correct installation and damage. Damaged cable must be
replaced.

Tyco Thermal Controls Control and Monitoring Products
THERMOSTATS

Thermal Insulation

6.4

Post-Insulation Testing
After the insulation is complete, perform an insulation
resistance test on each circuit to confirm that the cable has
not been damaged (refer to Section 9).
WARNING: Use only fire-resistant insulation, such
as fiberglass, mineral wool, or calcium silicate.

1 DigiTrace controllers used in CID1 areas require the use of appropriate hazardous

area enclosures or Z-purge systems.

2 480V VPL must use DigiTrace 920, 200N, T2000 or NGC-30 controllers only.

7.1

Power Supply and
Electrical Protection

Voltage Rating

Tyco Thermal Controls requires a series of tests be performed on the heat-tracing system upon commissioning.
These 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).

Verify that the source voltage corresponds to the heatingcable rating printed on the cable jacket and specified by the
design.

7.2

Electrical Loading
Overcurrent devices are selected according to the heating cable type, source voltage, and circuit length to allow
start-up at the designed ambient temperatures. The design
specifies the size and type of overcurrent device.

7.3

Ground-Fault Protection
If the heating cable is improperly installed, or physically
damaged to the point that water contacts the bus wires,
sustained arcing or fire could result. If arcing does occur,
the fault current may be too low to trip conventional circuit
breakers.
Tyco Thermal Controls, the U.S. National Electrical Code,
and the Canadian Electrical Code require both ground-fault
protection of equipment and a grounded metallic covering on all heating cables. All Raychem products meet the
metallic covering requirement. Following are some of the
ground-fault breakers that satisfy this equipment protection
requirement: Square D Type GFPD EHB-EPD (277 Vac),
Cutler Hammer (Westinghouse) Type QBGFEP.
480 V VPL must use DigiTrace 920, 200N, T2000, or
NGC-30 controllers only, which provide ground-fault
protection at 480 volts.
WARNING: To minimize the danger of fire from
sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Tyco
Thermal Controls 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.

WARNING: Disconnect all power before making
connections to the heating cable.

Commissioning and Preventive
Maintenance

8.1

Tests
A brief description of each test is found below. Detailed test
procedures are found in Section 9.

Visual inspection
Visually inspect the pipe, insulation, and connections to the
heating cable for physical damage. Check that no moisture
is present, electrical connections are tight and grounded,
insulation is dry and sealed, and control and monitoring
systems are operational and properly set. Damaged heating
cable must be replaced.

Insulation Resistance
Insulation Resistance (IR) testing is used to verify the
integrity of the heating-cable inner and outer jackets. IR
testing is analogous to pressure testing a pipe and detects
if a hole exists in the jacket. IR testing can also be used to
isolate the damage to a single run of heating cable. Fault
location can be used to further locate damage.

Power check
The heating-cable power per foot (meter) is calculated by
dividing the total wattage by the total length of a circuit.
The current, voltage, operation temperature, and length
must be known. Circuit length can be determined from “as
built” drawings, meter marks on cable, or the capacitance
test.
Power (w/ft or m) = Volts (Vac) x Current (Amps)

Length (ft or m)
The watts per foot (meter) can be compared to the heatingcable output indicated on the product data sheet at the
temperature of operation. This gives a good indication of
heating-cable performance.

Ground-fault test
Test all ground-fault breakers per manufacturer’s
instructions.

8.2

Commissioning and Preventive
Maintenance

Preventive Maintenance

9.1

Recommended maintenance for Tyco Thermal Controls
heat-tracing systems consists of performing the commissioning tests on a regular basis. Procedures for these tests
are described in Section 9. Systems should be checked
before each winter.

De-energize all circuits that may be affected by
maintenance.

The recommended cable installation methods allow for
extra cable at all pipe fixtures (such as valves, pumps, and
pressure gauges) that are likely to incur maintenance work.

Maintenance records
The “Installation and Inspection Record,” (refer to Section
11), should be filled out during all maintenance and repair
work, and kept for future reference.

Repairs
Use only Raychem cable and components when replacing
any damaged heating cable. Replace the thermal insulation to original condition or replace with new insulation, if
damaged.
Retest the system after repairs.
WARNING: Damage to cables or components can
cause sustained electrical arcing or fire. Do not attempt
to repair damaged heating cable. Do not energize cables
that have been damaged by fire. Replace damaged cable
at once by removing the entire damaged section and
splicing in a new length using the appropriate Raychem
splice kits. Do not reuse grommets. Use new grommets
whenever the heating cable has been pulled out of the
components.

Visual Inspection
• Check inside heating cable components for proper
installation, overheating, corrosion, moisture, and loose
connections.
• Check the electrical connections to ensure that ground
and bus wires are insulated over their full length.
• Check for damaged or wet thermal insulation; damaged,
missing or cracked lagging and weather-proofing.
• Check that end seals, splices, and tees are properly
labeled on insulation cladding.
• Check control and monitoring system for moisture, corrosion, set point, switch operation and capillary damage.

If the heat-tracing system fails any of the tests, refer to
Section 10 for troubleshooting assistance. Make the necessary repairs and replace any damaged cable immediately.

Protect the heating cable from mechanical or thermal damage during maintenance work.

Test Procedures

9.2

Insulation Resistance (Megger™) Test
Frequency
Insulation resistance testing is recommended at five stages
during the installation process and as part of regularly
scheduled maintenance.
• Before installing the cable
• Before installing components
• Before installing the thermal insulation
• After installing the thermal insulation
• Prior to initial start-up (commissioning)
• As part of the regular system inspection
• After any maintenance or repair work

Procedure
Insulation resistance testing (using a megohmmeter)
should be conducted at three voltages; 500, 1000, and
2500 Vdc. Significant problems may not be detected if testing is done only at 500 and 1000 volts.
First measure the resistance between the heating cable bus
wires and the braid (Test A) then measure the insulation
resistance between the braid and the metal pipe (Test B).
Do not allow test leads to touch junction box, which can
cause inaccurate readings.

Test Procedures

1.
2.
3.
4.
5.

De-energize the circuit.
Disconnect the thermostat or controller if installed.
Disconnect bus wires from terminal block, if installed.
Set test voltage at 0 Vdc.
Connect the negative (–) lead to the heating-cable
metallic braid.
6. Connect the positive (+) lead to both heating-cable bus
wires simultaneously.
7. Turn on the megohmmeter and set the voltage to 500
Vdc; apply the voltage for 1 minute. Meter needle
should stop moving. Rapid deflection indicates a short.
Record the insulation resistance value in the Inspection
Record.
8. Repeat Steps 4–7 at 1000 and 2500 Vdc.
9. Turn off the megohmmeter.
10. If the megohmmeter does not self-discharge, discharge
phase connection to ground with a suitable grounding
rod. Disconnect the megohmmeter.
11. Repeat this test between braid and pipe.
12. Reconnect bus wires to terminal block.
13. Reconnect the thermostat.
Note: System checkout and regular maintenance
procedures require that Megger™ testing be performed
from the distribution panel unless a control and monitoring system is in use. If no control system is being used,
remove both power feed wires from the breaker and
proceed as if testing heating-cable bus wires. If a control
and monitoring system is being used, remove the control
equipment from the circuit and conduct the test directly
from the heating cable.

Test Procedures

All insulation resistance values should be greater than
1000 megohms. If the reading is lower, consult Section 10,
Troubleshooting Guide.
Note: Insulation resistance values for Test A and B;
for any particular circuit, should not vary more than 25
percent as a function of measuring voltage. Greater variances may indicate a problem with your heat-tracing system; confirm proper installation and/or contact Tyco
Thermal Controls for assistance.
Test A

Test B

WARNING: Fire hazard in hazardous locations.
Megger™ test can produce sparks. Be sure there are no
flammable vapors in the area before performing this test.

Insulation resistance criteria
A clean, dry, properly installed circuit should measure
thousands of megohms, regardless of the heating-cable
length or measuring voltage (0–2500 Vdc). The following
criteria are provided to assist in determining the acceptability of an installation where optimum conditions may not
apply.

9.3

Test Procedures

Power Check
The power output of Self-Regulating and Power-Limiting
cable is temperature-sensitive and requires the following
special procedure to determine its value.
1. Power the heating cable and allow it to stabilize for 10
minutes, then measure current and voltage at the junction box. If a thermostat or controller is used, refer to
details below.
2. Check the pipe temperature under the thermal insulation at several locations.
3. Calculate the power (watts/ft) of the heating cable by
multiplying the current by the input voltage and dividing
by the actual circuit length.

Power (w/ft or m) = Volts (Vac) x Current (Amps)
Length (ft or m)

Ambient-sensing controlled systems
If the actual ambient temperature is higher than the desired
thermostat setting, turn the thermostat setting up high
enough to turn on the system, or (with some models)
manually set the selector switch to the ON position.
• Turn on the main circuit breaker.
• Turn on the branch circuit breakers.
• After a minimum of ten minutes, measure the voltage,
amperage, ambient temperature, and pipe temperature for
each circuit and record the values in the “Installation and
Inspection Record” (refer to Section 11). This information
is needed for future maintenance and troubleshooting.
• When the system is completely checked out, reset the
thermostat to the proper temperature.

Test Procedures

• When the system is completely checked out, reset the
thermostat to the proper temperature.

Control and monitoring systems
Refer to the installation instructions supplied with the product for commissioning tests and records.

9.4

Fault Location Tests
Fault location
There are three methods used for finding a fault within a
section of heating cable: the ratio method, 1/R method, and
the capacitance method. The capacitance method can also
be used to determine total heating-cable length.
Ratio test method
The ratio method uses resistance measurements taken at
each
the location
A end of the heating cable to approximate
B
of a bus wire short. A shorted heating cable could result
in a tripped circuit breaker or a cold section of pipe. If
the resistance can be read on a standard ohm meter this
method can also be used to find a fault from a bus wire to
the ground braid. This type of short would trip a GFPD and
show a Braid
failed Megger™ reading.
A

Measure the bus-to-bus heating-cable resistance from the
front end (measurement A) and the back end (measurement B) of the suspected section.

Line-sensing controlled systems
Set the thermostat to the desired control temperature, or
to a setting high enough to turn the circuit on if the pipe
temperature is above the control temperature.
• Turn on the main circuit breaker.
• Turn on the branch circuit breakers.
• Allow the system to reach the control point. This may
take up to four hours for most circuits. Large, liquid-filled
pipes may take longer.
• Measure the voltage, amperage, and pipe temperature for
each circuit and record the values in the “Installation and
Inspection Record” (refer to Section 11). This information
is needed for future maintenance and troubleshooting.
26

Test Procedures

The approximate location of the bus wire short, expressed
as a percentage of the heating-cable length from the front
end, is:
Fault location: D = A x 100

(A + B)
Example:

A = 1.2 ohms
B = 1.8 ohms

Test Procedures

I/R method
The I/R method uses the core resistance of the heating
cable to approximate the location of a fault when the heating cable has been severed and the bus wires have not
been shorted together. A severed cable may result in a cold
section of pipe and many not trip the circuit breaker.
Measure the bus-to-bus heating cable resistance from the
front end (measurement A) and the back end (measurement B) of the suspect section. Since self-regulating cables
are a parallel resistance, the ratio calculations must be
made using the conductance (1/R) of the cable.

Fault location: D = 1.2 / (1.2 + 1.8) x 100

= 40%
The fault is located 40% into the circuit as measured from
the front end.
A

To locate a low resistance ground fault, measure between
bus and braid.

The approximate location of the fault, expressed as a percentage of the heating-cable length from the front end is:

Braid
A

Braid

Fault location: D =
1/A
x 100
A
(1/A + 1/B)

The approximate location of the fault, expressed as a percentage of the heating-cable length from the front end, is:

Example:

Fault location: D = A x 100
A
(A + B)

Fault location: D = (1/100) / (1/100 + 1/25) x 100

= 20%

Example:

A = 1.2 ohms
B = 1.8 ohms

A = 100 ohms
B = 25 ohms

The fault is located 20% from the front end of the circuit.

Fault location: D = 1.2 / (1.2 + 1.8) x 100

= 40%
The fault is located 40% into the circuit as measured from
the front end.

Test Procedures

Capacitance test method
This method uses capacitance measurement (nF) to
approximate the location of a fault where the heating cable
has been severed. It also gives an estimate of total heating-cable length in a non-severed circuit. This reading must
be taken at the power connection and will only work when
the heating cable has passed IR testing. This information is
used to calculate the heating-cable output per linear foot or
to determine if the maximum length has been exceeded.
Record the capacitance reading from one end of the heating cable. The capacitance reading should be measured
between both bus wires twisted together (positive lead)
and the braid (negative lead).
Multiply the measured capacitance with the heating-cable’s
capacitance factor as listed in the following table.
Example:
20XTV2-CT
Recorded capacitance = 16.2 nF
Capacitance factor
= 10.1 ft/nF
Fault location
= 16.2 x 10.1 nF

= 164 ft (50 m)

from reading location
As an alternative, capacitance values from both the front
and back end can be used. The ratio of one capacitance
value taken from one end (A) divided by the sum of both
A and B (A + B) and then multiplied by 100 yields the distance from the first end, expressed as a percentage of the
heating circuit length.

Test Procedures

Heating cable capacitance factors
Cable catalog
number
3BTV1-CR

Capacitance
factor
7.5

Cable catalog
number
15QTVR1-CT

Capacitance
factor
3.3

3BTV2-CT

20QTVR1-CT

3BTV1-CR

20QTVR2-CT

3BTV2-CT

5XTV1-CT-T3

10.8

5BTV1-CR

5XTV2-CT-T3

11.1

5BTV2-CT

10XTV1-CT-T3

10.3

5BTV1-CR

10XTV2-CT-T3

10.7

5BTV2-CT

15XTV1-CT-T3

9.7

8BTV1-CR

7.5

15XTV2-CT-T3

9.9

8BTV2-CT

20XTV1-CT-T2

9.3

8BTV1-CR

20XTV2-CT-T2

10.1

8BTV2-CT

5VPL1-CT

10BTV1-CR

5.5

10VPL1-CT

10BTV2-CT

15VPL1-CT

10BTV1-CR

20VPL1-CT

10BTV2-CT

5VPL2-CT

10QTVR1-CT

4.7

9.4

10VPL2-CT

10QTVR2-CT

15VPL2-CT

15QTVR2-CT

20VPL2-CT
5VPL4-CT
10VPL4-CT
15VPL4-CT
20VPL4-CT

Troubleshooting Guide

Symptom

Probable Causes

Corrective Action

Low or inconsistent
insulation resistance

Nicks or cuts in the heating cable.
Short between the braid and heatingcable core or the braid and pipe.

Check power, splice, tee, and end connections for cuts, improper
stripping distances, and signs of moisture. If heating cable is not
yetinsulated, visually inspect the entire length for damage, especially
at elbows and flanges and around valves. If the system is insulated,
disconnect heating cable section between power kits, splices, etc.,
and test again to isolate damaged section.

Arcing due to damaged heating-cable
insulation.

Replace damaged heating-cable sections and restrip any improper or
damaged connections.

Moisture present in the components.

If moisture is present, dry out the connections and retest. Be sure
all conduit entries are sealed, and that condensate in conduit cannot
enter power connection boxes. If heating-cable core or bus wires
are exposed to large quantities of water, replace the heating cable.
(Drying the heating cable is not sufficient, as the power output of the
heating cable can be significantly reduced.)

Test leads touching the junction box.

Clear the test leads from junction box and restart.

High pipe temperature may cause low IR
reading.

Retest at ambient, if necessary.

Reference tests:

Insulation Resistance Test, Visual Inspection

Symptom

Probable Causes

Corrective Action

Circuit breaker trips

Circuit breaker is undersized.

Recheck the design for startup temperature and current loads. Do
not exceed the maximum circuit length for heating cable used. Check
to see if existing power wire sizing is compatible with circuit breaker.
Replace the circuit breaker if defective or improperly sized. Visually
inspect the power connections, splices, and end seals for proper
installation; correct as necessary.

Start-up at too low a temperature.
Connections and/or splices are shorting
out.

Physical damage to heating cable is
causing a direct short.

Check for visual indications of damage around the valves, pump, and
any area where there may have been maintenance work. Look for
crushed or damaged insulation lagging along the pipe. Replace damaged sections of heating cable.

Bus wires are connected at the end.

Check the end seal to ensure that bus wires are properly terminated
per installation instructions. If a dead short is found, the heating
cable may have been permanently damaged by excessive current and
may need to be replaced.

Nick or cut exists in heating cable or
power feed wire with moisture present or
moisture in connections.

Replace the heating cable, as necessary. Dry out and reseal the
connections and splices. Using a megohmmeter, retest insulation
resistance.

GFPD is undersized (5mA used instead
of 30mA) or miswired.

Replace undersized GFPD with 30mA GFPD. Check the GFPD wiring
instructions.

Reference tests:

Insulation Resistance Test, Fault Location Test, Visual Inspection

Troubleshooting Guide

Symptom

Probable Causes

Corrective Action

Low pipe temperature

Insulation is wet, or missing.

Remove wet insulation and replace with dry insulation, and secure it
with proper weatherproofing.

Insufficient heating cable was used on
valves, supports, and other heat sinks.

Splice in additional heating cable but do not exceed maximum circuit
length.

Thermostat was set incorrectly.

Reset the thermostat.

Improper thermal design used.

Contact your Tyco Thermal Controls representative to confirm the
design and modify as recommended.

Improper voltage applied.
Thermocouple is not in contact with pipe.

Reinstall the thermocouple on the pipe.

Reference tests:

Power Check, Visual Inspection

Symptom

Probable Causes

Corrective Action

Low or no power output

Low or no input voltage applied.

Repair the electrical supply lines and equipment.

The circuit is shorter than the design
shows, due to splices or tees not being
connected, or the heating cable having
been severed.

Check the routing and length of heating cable (use “as built” drawings to reference actual pipe layout).

Improper component connection causing
a high-resistance connection.

Check for loose wiring connections and rewire if necessary.

Control thermostat is wired in normally
open position.

Rewire the thermostat in the normally closed position.

Pipe is at an elevated temperature.

Check the pipe temperature. Verify heater selection. Check the power
output of the heating cable per the design vs. actual. Reduce pipe
temperature if possible or contact your Tyco Thermal Controls representative to confirm design.

The heating cable has been exposed
to excessive temperature, moisture or
chemicals.

Replace damaged heating cable. Check the pipe temperature. Check
the power output of heating cable.

Reference tests:

Power Check, Fault Location Test, Visual Inspection

Connect all splices or tees. Locate and replace any damaged heating
cables. Then recheck the power output.

Installation and Inspection
Records

Tyco Thermal Controls Heat-Tracing Installation and Inspection Record

Facility
Circuit number
Heating cable type
Circuit length
Commission

Visual Inspection
Visual inspection inside connection boxes for signs of
overheating, corrosion, moisture, loose connections
and other problems.
Proper electrical connection, ground, and bus wires
insulated over full length.
Damaged or wet thermal insulation; damaged, missing, cracked lagging or weather-proofing; gaps in
caulking.
Covered end seals, splices, and tees properly labeled
on insulation cladding.
Control and Monitoring system checked for moisture,
corrosion, set point, switch operation, capillary damage, and protection.
Insulation resistance (Megger™) test
Test A

Ohms

500 Vdc

(bus to braid)

1000 Vdc
2500 Vdc

Test B

500 Vdc

(braid to pipe)

1000 Vdc
2500 Vdc

Power check
Circuit voltage
Panel

(Vac)

Circuit end*

(Vac)

Circuit amps after 10 min

(Amps)

Pipe temperature

(°F)

Power = Volts x amps/ft

(watts/ft)

* Commissioning only
36

Installation and Inspection
Records

Tyco Thermal Controls Heat-Tracing Installation and Inspection Record

Facility
Circuit number
Heating cable type
Circuit length
Commission

Inspection date:
Visual Inspection
Visual inspection inside connection boxes for signs of
overheating, corrosion, moisture, loose connections
and other problems.
Proper electrical connection, ground, and bus wires
insulated over full length.
Damaged or wet thermal insulation; damaged, missing, cracked lagging or weather-proofing; gaps in
caulking.
Covered end seals, splices, and tees properly labeled
on insulation cladding.
Control and Monitoring system checked for moisture,
corrosion, set point, switch operation, capillary damage, and protection.
Insulation resistance (Megger™) test
Test A

Ohms

500 Vdc

(bus to braid)

1000 Vdc
2500 Vdc

Test B

500 Vdc

(braid to pipe)

1000 Vdc
2500 Vdc

Power check
Circuit voltage
Panel

(Vac)

Circuit end*

(Vac)

Circuit amps after 10 min

(Amps)

Pipe temperature

(°F)

Power = Volts x amps/ft

(watts/ft)

* Commissioning only
38

FM Required Installation Record for Class I,
Division 1, Hazardous Locations
To complete the FM approval process, this complete form must be
returned to the Tyco Thermal Controls Customer Service Center (fax
number (800) 527-5703)
Company name

Purchase order no.

Circuit ID no.

Ref. drawing(s)

Area
Autoignition temp. (AIT):

Group classification:

Heater circuit
Heater type:
Supply voltage:

Circuit length:

Maximum pipe temp:

Temp ID (T-rating)

Components
Power connection

Splice:

Tee

End seal:

Ground-fault equipment
Make and model:

Device trip level:

Installation instructions
Correct components per manufacturer’s specification:
Seal fittings opened and inspected (properly poured):
Ground-leakage device tested:
Insulation resistance testing
Use 2500 Vcd for Self-Regulating and Power-Limiting cables
Instrument used:

Calibration date:

As measured on the pipe before insulation installed*

Test value

Date

Initials

Test value

Date

Initials

Insulation resistance between conductor and braid (Test A)
Insulation resistance between braid and pipe (Test B)
As measured after insulation installed*
Insulation resistance between conductor and braid (Test A)
Insulation resistance between braid and pipe (Test B)
* Minimum insulation resistance must be 1000MΩ
Circuit ready to commission
Prepared by

Company

Date

Approved by

Company

Date

Important: All information, including illustrations, is believed to be reliable.
Users, however, should independently evaluate the suitability of each product
for their particular application. Tyco Thermal Controls makes no warranties as
to the accuracy or completeness of the information, and disclaims any liability
regarding its use. Tyco Thermal Controls' only obligations are those in the Tyco
Thermal Controls Standard Terms and Conditions of Sale for this product, and in
no case will Tyco Thermal Controls or its distributors be liable for any incidental,
indirect, or consequential damages arising from the sale, resale, use, or misuse
of the product. Specifications are subject to change without notice. In addition,
Tyco Thermal Controls reserves the right to make changes—without notification
to Buyer—to processing or materials that do not affect compliance with any
applicable specification.

Worldwide Headquarters
Tyco Thermal Controls
2415 Bay Road
Redwood City, CA 94063-3032
USA
Tel (800) 545-6258
Tel (650) 216-1526
Fax (800) 527-5703
Fax (650) 474-7711
info@tycothermal.com
www.tycothermal.com

Canada
Tyco Thermal Controls
250 West St.
Trenton, Ontario
Canada K8V 5S2
Tel (800) 545-6258
Fax (800) 527-5703

H57274 9/06
Printed in USA

Megger is a trademark of Megger Limited.

Tyco, DigiTrace, Raychem. TraceCalc Pro, BTV, QTVR, XTV and VPL are
trademarks of Tyco Thermal Controls LLC or its affiliates.

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