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Maintenance and
Operation Manual
Polymer Insulated (PI)
Series Constant Wattage
Heating Cable Systems
EN-RaychemPI-IM-DOC517 R8
1
2
3
4
5
6
7
8
9
10
General information
15
16
18
20
System testing
21
22
Trouble Shooting
23
PI heating cable
Splice kit
Junction box
1 General information
Use of the manual
This Installation and Maintenance manual is for Pentair series
resistance heating cable systems on thermally insulated pipes, vessels
and associated equipment only. In particular it refers to polymer
insulated (PI) series heating cable systems, which feature a specific
power output, varying with design parameters, mostly with cable length
and voltage. This manual provides general information and shows an
overview of the most common installations and applications off PI.
In any case, the information provided for specific projects will take
precedence over this manual.
Cable gland
Cold leads
Heating cable
Connection leads
Important
For the Pentair warranty to apply, the instructions that are included in
this manual and product packages must be followed. The installation
must also be in accordance with local National requirements
applicable to electrical heat tracing systems, as well as the
requirements of other International Standards, such as IEC 60079.
Approvals coding
XPI (system)
PTB 08 ATEX 1102X
II 2G Ex e II T2...T6
II 2D Ex tD A21 IP65 T290...T80C
Ex e II T2...T6
Ex tD A21 PI65 T290...T80C
II 2G Ex e II
II 2D tD A21
Ex e II
Ex tD A21
XPI-S (system)
PTB 08 ATEX 1102X
II 2G Ex e II T2...T6
II 2D Ex tD A21 IP65 T290...T80C
Ex e II T2...T6
Ex tD A21 PI65 T290...T80C
II 2G Ex e II
II 2D tD A21
Ex e II
Ex tD A21
XPI-NH
XPI
XPI-S
Maximum voltage
U /U (V AC)
300/500
500/750
500/750
Maximum Withstand
Temperature (C)
260
260
260
260
300
300
Temperature Classification
n/a
T2-T6
T2-T6
20
20
20
n/a
Minimum Installation
Temperature (C)
60
70
70
2,5 x
6x
high
high
poor contact
10
30
25
+ 11...30
25
20
+ 31...50
21
18
+ 51...75
18
15
+ 76...100
15
12
+ 101...125
12
10
+ 126...150
10
+ 151...200
sharp edges
excessive pulling force
kinking and crushing
walking on it, or running over it with equipment.
Sensor
Pipe
Heating cable
Pipe
Heating cable
Prepunched
strapping
Temperature
sensor
Heating cable
Temperature
controller
Junction box
Cold leads
9
tracing allowances.
Any change to designed circuit length will change power
output and design must be reconfirmed.
Cut the heating cable to length after it is attached to the pipe.
10
See design
documentation for
specific heating cable
length needed
Pipe
11
Pipe
PI heating cable
Heating cable
Glass tape
General note:
Trace pipe fittings as shown to allow easy maintenance.
Alternatively wire mesh cages might be used.
12
6x
Cable > 6 mm
2,5 x
Cable 6 mm
13
14
glass tape
15
Warning
As with any temperature measurement equipment,
possible falsification of true temperatures due to
increased heatloss caused by the sensor itself might
lead to inaccurate temperature readings or unsafe
tripping of safety limiters. The setpoint might need to be
adjusted accordingly
Contact Pentair or the supplier of the limitation device
in order to obtain detailed information concerning
offsetting of limitation devices.
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17
6.3 Marking
Install Electric Traced signs on the insulation cladding along
piping at suitable intervals (3-5 m intervals recommended) on
alternate sides as a warning.
Mark on outside of insulation the location of any heating cable
components like connection points, splices etc.
18
19
8 System testing
warning: Fire hazard in hazardous locations.
Megger tests can produce sparks. Be sure there are no flammable
vapors in the area before performing this test (hot work permit).
20
21
10 Trouble Shooting
warning: Damage to cables or components can cause
sustained electrical arcing or fire. Do not energize heating cables
that have been damaged. Damaged heating cable, splices or
connections must be repaired or replaced. Damaged cable should
be repaired by a qualified person.
It should be carefully evaluated, whether the severity of the
damage allows on-site repair or whether the entire
heating cable needs to be replaced.
22
23
24
Area name:
Cable type:
Drawing no.:
P & ID -no.:
Installation company:
Date:
25
> 20 M
2500 Vdc
Vdc
yes:
*
mm*
yes:
yes:
Signature
yes:
3a Cables entries are sealed and cable protected at entries into insulation cladding
2d Cable covered with aluminium foil at flanges & cable on valves with wire mesh cages
2c Cable resistance:
yes:
1d Sensor of temperature limiter properly installed and set according to design specification
mm
mm
yes:
mm*
Actual value
1c Temperature sensor properly installed on the pipe/vessel & control temperature is set
mm*
Visual inspection
Required value
26
> 20 M
General note: Local / national rules and standards need to be respected where applicable.
Vac L-L*
Vac L-N*
Remarks:
> 20 M
2500 Vdc
C*
C*
2500 Vdc
Vac L-L
Vac L-N
Vdc
Vdc
every 5 m/ at components
yes:
yes:
27
Area name:
Configured in:
Cable type:
Drawing no.:
P & ID -no.:
Required value
DELTA / STAR
Installer:
Date:
Actual value
Installation company:
triphased
INSTALLATION RECORD SHEET
Signature
28
Segment 3 resistance:
mm* yes:
2500 Vdc
Vdc
* yes:
3a Cables entries are sealed and cable protected at entries into insulation cladding yes:
2d Cable covered with aluminium foil at flanges & cable on valves with wire mesh cages yes:
> 20 M
Segment 2 resistance:
> 20 M
> 20 M
2c Segment 1 resistance:
2500 Vdc
Vdc
Sensor of temperature limiter properly installed and set according to design specification yes:
mm
Temperature sensor properly installed on the pipe/vessel & control temperature is set yes:
mm*
mm
Visual inspection
mm*
29
General note: Local / national rules and standards need to be respected where applicable.
Vac L-L*
3 x Vac L-N*
3 x Vac L-N*
Remarks:
> 20 M
> 20 M
> 20 M
2500 Vdc
C*
C*
Vac L-L
3 x Vac L-N
3 x Vac L-N
Vdc
> 20 M
> 20 M
> 20 M
Circuit oversized
Defective RCD
30
Corrective actions
1 Investigate and remedy
2 Resize or redesign
3 Replace
4 a redesign for lower startup temperatures.
b preheat pipe from alternative heat source to
temperatures considered in electrical design
c employ soft start techniques of control system to
smoothly heat up system.
Corrective actions
1 Investigate and remedy
3 Redesign
4 Replace
5 Redesign distribution
31
2 Loss of supply voltage due to:
a overcurrent protection or residual current
protection operating
b loose terminals in junction box, bad splice
c loss of supply cable continuity (open circuited
from damage)
Design error
Note:
Locate faults by the following steps:
1 Visually inspect the power connections and splices for correct
installation.
2 Look for signs of damage at:
a) Valves, pumps, flanges and supports.
b) Areas where repairs or maintenance work has been
carried out recently.
3 Look for crushed or damaged insulation and cladding along
the pipe.
32
Corrective actions
1 Investigate causes, restore normal conditions and re-arm
2 Restore supply voltage
a following A and B
b re-tighten terminals, replace splice connection
NB: If excessive heating has occured due to high
resistance, replace terminals or crimps
c locate damage and repair
3 Investigate causes, replace equipment
Corrective Actions
1 Remove and replace with dry insulation of correct
specification and ensure complete weatherproofing
2 Repair or reset to correct level of operation
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sterreich
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Sverige
Lietuva/Latvija/Eesti
Trkiye
Magyarorszg
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EN-RaychemPI-IM-DOC517 R8
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