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EUROTRACE Installation instructions

Installation on a pipe

These instructions give general notes on installing and handling self-limiting BACAB heating tapeswhen assembling on a pipe. For other forms of installation (container, roof and/or eave heating), pleaseask forspecific instructions.

Safety instructions

To ensure that the heating tapes operate reliably and efficiently, the installation should be carried outby a qualified electrician. All Installation instructions, e.g. for the connection system, must be adheredto. The installation must conform to all national and local regulations.

The following points must be observed in installation:

Never connect the heating tapes two live conductors together. This wouldresult in a short circuit.

Do not allow water or moisture to penetrate the heating tape. Avoid any possible formation of sparksor the risk of fire. All electrical connections and heating tape ends must be provided with waterproo fsealing with specified connection and termination systems.

The heating tapes may never be heated at temperatures over the specified service temperature(switched on and off). Overheating can damage the heating element and accordingly reduce theservice life of the heating tape.

Avoid any excessive mechanical strain on the heating tape during installation and use. Excessivemechanical strain can damage the adhesion between the conductors and the heating element and that

will reduce heating power. Do not step on the heating tape.

Special use

The installation in classified areas (e. g. potential explosive gas atmospheres in chemical plants)requires specially approved tapes and electrical components.

Only approved components and systems may be used.

Non-conformance with this requirement can lead to serious accidents.

The connection and termination parts must be installed in conformance to applicable standards:

e. g.: VDE 0721 Section 1 and Section 2A3 must be complied with in Germany.


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Storage

The heating tapes must be stored in dry and clean places. The storage temperature should be between-40 C and +50 C. If storing for longer, the beginnings and ends of the tape should be protected againstmoisture.

Handling

Avoid excessive pulling or bending of the tape when winding and unwinding, during transport andassembly. To avoid damaging the insulation, exercise care if there are any sharp corners and edges,such as for example on flanges or holding devices. They could harm the insulating protection sleeve.

Bending Never bend the high edge of the tape and never exceed the specified bending radius.

General rules on handlingheating cables

The self-limiting effect allows the tape to overlap without local overheating or indeed burningoccurring. To install the tape correctly, it is necessary to observe the following instructions.

Installation

Before installation

The following points must be checked:

1. The surface of the pipe must be dry and clean.

2. Check the voltage in the power supply. A deviation from the nominal voltage (e. g. AC 200 V insteadof AC 230 V) will change the heating power Correction factors are available on request. Themaximum voltage for the tapes amounts are:

< AC 253 V for AC 230 V classified tape

< AC 132 V for AC 120 V classified tape

3. Check the size of the protective equipment. This may not be larger than the heating tapespecifications. Furthermore, the size of the protective equipment must agree with the length of tapeto be installed. Fuses of type C in conformance with the BS EN 60898 standard are recommended.

4. Ensure that there is a residual current device (rcd). As a rule a nominal value of 30 mA isdemanded or recommended: The tin-plated copper braiding of a BACAB heating tape can be usedas an earth conductor, especially as the electrical resistance is less than 18.2 /km.

5. Only use connection systems that protect the electrical connection and the cable ends against thepenetration of moisture.

6. Only carry out the installation at temperatures above the specified, minimum installation temperatures.

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ationInstructions


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Provide additional heating tape loops for valves, flanges, holding devices, pumps and other pipe

accessories to

ease repairs or replacement of these parts and to reduce the risk of mechanical forces caused bythermal expansion.

Assembly at special parts

The flat side of the heating tape should be affixed as flush as possible onto the pipe to ensure effectiveheat transmission

The spacing between two fastenings should not exceed 200 mm.

The heating tape should be attached with total surface contact but excessive tension, pressure or twistingmust be avoided.

Use temperature-resistant adhesive tape , e. g. fibreglass tape that has the same or better temperatureresistance as the heating tape.

Never use adhesive tapes that contain plasticisers.

Never use adhesive tapes made of PVC.

Never use cable ties made of metal or nylon.

Attachment to the pipe

Attachment to plastic pipes

When heating plastic pipes, aluminium-adhesive tape or foil should be provided under or under and overthe heating tape for better heat transmission and distribution.

example of spacing

max. 200 mm

aluminium foil for plastic pipes

The heating circuit length depends on the voltage and the circuit breaker for the power supply and thecut-in temperature of the heating tape. The maximum heating circuit length must be adhered to inconformance with the technical specifications of the corresponding heating tape type.

The following heating tape pieces must be taken into account when determining the correct heating tape

length, without exceeding the maximum installation length:

add more length (approx. 500 mm) at the beginning and end for the connection and/or thetermination

add heating tape to heat valves, holding devices, flanges and other accessories

more heating tape will be needed if it is to be wound around the pipe in spiral form.

In installation in a straight line on the pipe, we recommend an arrangement in the 4 and/or 8 oclock

position. As a basic rule, the heating tape should always be laid straight on the pipe. The heating tapemay only be laid in spiral form if expressly prescribed in the project planning.

Installation length

usual installation

example of winding

usual arrangement


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Examples

EUROTRACE

Installa

tionInstructions

On a valve

On a flange

On a pipe bend

Avoid clamping the heating tape; e.g. between a pipe attachment and the pipe

wrong right


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Maintenance The self-limiting heating tape does not require any maintenance.

Periodical inspections are recommended, nevertheless:

Visual inspection

Check all enclosures, connections and terminations for the penetration of moisture or water.

Ensure that the thermal insu lation and enclosures are not damaged. There may be a risk that the heatingtape might also be affected.

Checking electrical resistance

This test serves to check the effect of the heating tapes electrical insulation.

Equipment: High-voltage source, as an insulation tester use DC Megger or an equivalentinstrument (min. DC 500 V, resistance 0-20 G).

Procedure for installing heating tape:

Always protect heating tape ends from the penetration of water or moisture, particularly whenthe heating tape is being stored or left for a lengthy time without connections.

Installation instructions

1. Unwind the heating tape from the roll in a straight line. Avoid excessive pulling forces and do notbend or squeeze the heating tape.

It is recommendable to use a roll holder.

2. Begin to attach the heating tape onto the pipe and/or other elements, with due consideration to thefollowing points:

Additional heating tape lengths for assembling the tape (connection/termination, branches)

Heating tape loops wherever necessary

Do not exceed the maximum heating circuit length. Do not cut heating tape until installation and

attachment are finished.3. Mount the connection and/or termination in conformance with the instructions from the manufacturer

of the connection systems.

Never connect the heating tapes two live conductors together. This would result in a shortcircuit.Connect the protective braiding to the earth conductor.

4. Check the electrical resistance between the conductors and the protective braiding (earth conductor)before the thermal insulation is assembled (consult inspection instructions in the section onupkeep)

5. Only mount the thermal insulation if the electrical test has been passed. The thermal insulationshould be dry and all connections should be sealed tightly so that no water can penetrate. Take carethat none of the thermal insulation fastenings are in contact with the heating tape or can damage it,

e.g. screws or terminals.6. Repeat the test for electrical resistance. This provides evidence that the heating tape was not

damaged at assembly.

7. Fill in the installation report . Mark the installation. This makes maintenance easier.


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EUROTRACE

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tionInstructions

Defective heating tapes should not be repaired! Repairs are not recommended for the following reasons:

A fault often causes faulty currents, which gradually destroy the contact surface between the

conductors and the heating element.

If the penetration of water is the reason for the fault, there is a possibility that sparks might occuragain after the repairs.

Always replace the entire length of a defective heating tape!

Repairs

Procedure

Danger! Incorrect handling of the high-voltage source (DC 500 to 2000 V) can cause seriousinjuries. For that reason, this test may only be conducted by qualified personnel.

1. Detach the heating tape from the power supply.

2. Connect the two conductors of the heating tape to the testing devices positive terminal (+).

3. Connect the negative terminal (-) to the heating tapes braiding/earth conductor.

4. Apply test voltage of at least DC 500 V (max. DC 2000 V) for 1 minute and read the resistance inmegaohms (M~) on the device.

5. Make a note of the displayed resistance and keep as a comparison for when other measurements aredue later.

6. The electrical resistance must be measured at all feeding points along the installed heating tape.

Result

The resistance should be at least 20 M. If less, the source of the fault must be found andeliminated. Otherwise the heating tape must be replaced because it is possible that there is a defectin the insulation.

Any information given here is to be understood as a guideline without any legal obligation. Technicaldata are subject to alteration without notice.

Disclaimer of liability

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