Industrial Heat

Tracing

Installation and maintenance manual for

mineral insulated cable systems applied
to pipes and vessels
 Important Safeguards and Warnings
WARNING: FIRE AND SHOCK HAZARD.
nVent 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 nVent
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.

• Approvals and performance of the heat-tracing

systems are based on the use of approved
components and accessories.

• Cable terminations must be kept dry before, during,

and after installation.

• Damaged heating cable can cause electrical arcing or

fire. Use only RAYCHEM approved pipe straps or tie
wire to secure the cable to the pipe.

• Damaged heating cable or terminations must be

repaired or replaced. Contact factory for assistance.

• 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 autoignition temperature of
the gases in the area. For further information, see the
design documentation.

• Heating cables are capable of reaching high

temperatures during operation and can cause burns
when touched. Avoid contact when cables are
powered. Insulate the pipe before energizing the
cable. Use only properly trained personnel.

• Material Safety Data Sheets (MSDSs) are available on

our website: nVent.com

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 Table of Contents

1 General Information 1

1.1 Use of the Manual 1

1.2 Safety Guidelines 2
1.3 Typical System 2
1.4 Electrical Codes 3
1.5 Warranty and Approvals 3
1.6 Heating Cable Construction 4
1.7 Heating Cable Identification 6
1.8 Heating Cable Temperature Information 7
1.9 General Installation Guidelines 7
1.10 Heating Cable Storage 9

2 Pre-Installation Checks 10

2.1 Check Materials Received 10

2.2 Check Piping to be Traced 10
2.3 Check Tools 10

3 Heating Cable Installation 11

3.1 Heating Cable Handling 11

3.2 Heating Cable Installation on Pipes 16
3.3 Temperature Sensor Installation for Pipes 23
3.4 Heating Cable Installation on Tanks and Vessels 24
3.5 Temperature Sensor Installation for Vessels 27

4 Component Installation 28

4.1 General Component Information 28

5 Control and Monitoring 30

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6 Thermal Insulation and Marking 31

6.1 Pre-Insulation Checks 31

6.2 Insulation Installation Hints 31
6.3 Marking 32
6.4 Post-Insulation Testing 32

7 Power Supply and Electrical Protection 33

7.1 Voltage Rating 33

7.2 Electrical Loading 33
7.3 Temperature Controller Wiring 34

8 Commissioning and Preventive Maintenance 35

8.1 Tests 35
8.2 Preventive Maintenance 37

9 Test Procedures 39

9.1 Visual Inspection 39

9.2 Insulation Resistance Test – Test 1 39
9.3 Continuity (Resistance) Test – Test 2 40
9.4 Insulation Resistance and Continuity Test 41

10 Troubleshooting Guide 44

11 Installation and Inspection Records 48

Heating Cable Installation Record 48

Installation Record Required for Class I, Division
1,Hazardous Locations According to IEEE 515 50
Heating Cable Commissioning Record 52
Maintenance Log Record 54

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 1
General Information

1.1 Use of the Manual

This installation and maintenance manual is for
RAYCHEM Mineral Insulated (MI) heat-tracing
systems installed on thermally insulated metal pipes
and vessels only. This includes RAYCHEM XMI-A Alloy
825 sheathed, XMI-L low temperature sheath and
copper sheathed pre-terminated,
series-resistance MI heating cables and components.

This manual assumes that the heating cable designs

have been completed using TraceCalc Pro software
available from nVent or following the design steps in
H56884, Mineral Insulated Heating Cables, found in the
Industrial Heat-Tracing Product Selection and Design
Guide. nVent offers complete integrated service from
original design, to product specification, to installation
of the complete system. We also provide future
maintenance of the installation, if required.

For design assistance, technical support, or

information regarding applications where the
MI heating cable will be used for heat-tracing of
plastic pipes, flexible or expansion joints, or in
submerged environments, please contact your nVent
representative or nVent directly.
nVent
7433 Harwin Drive
Houston, TX 77036
USA
Tel: +1.800.545.6258
Fax: +1.800.527.5703
thermal.info@nVent.com
nVent.com

Important: For the nVent warranty and agency

approvals to apply, the instructions that are
included in this manual and with associated
products must be followed.

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 1 General Information

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 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. The
guidelines and instructions contained in this guide
are important. Follow them carefully to minimize
these risks and to ensure that the MI system
performs reliably.

1.3 Typical System

Junction box

To
power Circuit
supply ID tag

Stainless steel
pipe straps, banding, Cold
or tie wire lead

Pipe to be Drip loop

heated (coil excess cold lead)
Hot-cold joint
Pipe insulation
Heating cable
Tie wire

Electric Heat Trace warning label

Figure 1: Typical Design B system

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 1 General Information

1.4 Electrical Codes

Articles 427 and 500 of the National Electrical Code
and Sections 18 and 62 of the Canadian Electrical
Code, Part 1, in particular, govern the installation of
electrical heat-tracing systems in hazardous and
nonhazardous locations. Installation of heat-tracing
systems must comply with all national and local
codes. In particular, ground-fault equipment protection
is required for all electric heat-tracing installations to
prevent arcing, fire, and shock if the cable is improperly
installed or damaged.

1.5 Warranty and Approvals

Raychem XMI-A Alloy 825 sheath and copper
sheath MI heating cables are approved for use in
nonhazardous locations and Class I, Division 1 & 2
Groups A, B, C, D, Class II, Division 1 & 2, Groups E, F,
G, Class III hazardous locations. Class I Zone 1 AEx eb
IIC T* Gb – for US and Ex 60079-30-1 IIC T* Gb – for
Canada.
Raychem XMI-L low temperature sheath heating cables
are approved for use in Class I, Division 2 Groups
A, B, C, D, Class II, Division 2, Groups E, F, G Class III
hazardous locations and Class I Zone 2 AEx nA IIC T*
Gc – for US and Ex 60079-30-1 IIC T* Gc – for Canada.
Refer to specific product data sheets for details.

Note: T*- refer to design documentation

nVent’s limited standard warranty applies to all

products. You can access the complete warranty
on nVent.com. To qualify for an extended 10-year
warranty, register online within 30 days of
installation at nVent.com

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 1 General Information

1.6 Heating Cable Construction

The heating cables are available as factory-terminated
units in the configurations shown in Table 1.
Table 1: MI HEATING CABLE CONFIGURATION
MI cable Number of
design conductors Configuration

XMI-A Heating Cables

A Single conductor Heated length Cold lead length
(XMI-A61 series)

B Single conductor Cold lead Heated Cold lead

(XMI-A61 series) length length length

D Dual conductor Heated length Cold lead length

(XMI-A32 and
XMI-A62 series)

E Dual conductor Cold lead Heated Cold lead

(XMI-A32 and length length length
XMI-A62 series)

XMI-L Heating Cables

D Dual conductor Heated length Cold lead length
(XMI-L32 and
XMI-L62 series)

E Dual conductor Cold lead Heated Cold lead

(XMI-L32 and length length length
XMI-L62 series)

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1 General Information

A sectional view of a Design D XMI-A Alloy 825

sheath MI heating cable is shown in Figure 2. All
of the cables include both a heating section and
a non-heating cold lead section. These sections
are joined in the hot-cold joint where the heating
element is spliced into larger bus wires. A final
transition at the end of the cold lead section
provides an environmental seal and tails for the
electrical connection. At the opposite end of the
cable, the conductors of Design D cables are joined
and hermetically sealed within an end cap. XMI-L
low temperature sheath cables have an additional
corrugated sheath over the heated section as
shown in Figures 3 and 4.

Heated length Cold lead

(length as ordered)
Pot

End Hot-cold Bus wires Gland Tails

cap joint connector (standard length
Heating
12 in (30 cm)
element

Figure 2: Sectional view of Design D XMI-A MI cable

Heated length Cold lead

(length as ordered)
Pot

End cap Heating Hot-cold joint Gland

cable connector
Conduit plug Corrugated sheath

Figure 3: Sectional view of Design D XMI-L MI cable

Heated length
Cold lead (length as ordered) Cold lead
Pot

Gland Hot-cold Heating Hot-cold joint

connector joint cable
Corrugated sheath

Figure 4: Sectional view of Design E XMI-L MI cable

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 1 General Information

1.7 Heating Cable Identification

Each MI heating cable is supplied with an
identification tag on which the heating cable catalog
number is permanently printed. In addition to its
identification purposes, the catalog number provides
information regarding the heating cable length,
power output, and operating voltage. Also printed
on the tag are the designer’s circuit identification
number, serial number and the maximum
temperature the cable sheath may attain along with
other design information.
If the cable has been designed for a hazardous
location, the area classification is printed in the ‘Haz.
Locations’ section of the tag.

Figure 5: Typical MI identification tag (front)

The heating cable catalog number may be broken

out as follows:

D/32SA2200/35/200/120/7/LS23A/X/N12
Gland size (NPT)
Hot/cold joint type
X - use for XMI-A Alloy 825 sheath
C - use for XMI-L low temperature sheath
Y - use for copper sheath
Cold lead code
Cold lead length (in feet)
Metric: 2.1M = 2.1 meters
Heating cable voltage
Heating cable wattage
Heating cable length (in feet)
Metric: 10.7M = 10.7 meters
Heating cable reference
Heating cable design
configuration (A, B, D, E)

Figure 6: MI heating cable catalog number

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 1 General Information

WARNING: Fire or explosion hazard. Ensure that

the information provided in the Haz. Locations and
Temp. Code [Max. Sheath Temp.] fields comply with
the area in which the heating cable will be installed.

1.8 Heating Cable Temperature Information

MI heating cables are available for a variety of
applications, with several sheath materials to suit
different temperature requirements. The maximum
maintain and exposure temperatures for these sheath
materials is shown in Table 2.

Table 2: MAXIMUM CABLE TEMPERATURE

Maximum
Maximum continuous Maximum continuous
maintain exposure exposure temperature for
Product family temperature temperature hot/cold joints and end cap

XMI-A 1022°F (550°C) 1200°F (650°C) 1022°F (550°C)

XMI-L (Note 1) 752°F (400°C) 1022°F (550°C) 1022°F (550°C)

Copper 300°F (150°C) 392°F (200°C) 300°F (150°C)

LSZH jacketed 158°F (70°C) 194°F (90°C) 194°F (90°C)
copper

Note 1: 842°F/450°C if corrosives are present

1.9 General Installation Guidelines

These guidelines are provided to assist the installer
throughout the installation process and should be
reviewed before the installation begins.
Avoid damage to the MI heating cable as follows:
• Do not repeatedly bend and straighten the cable.
• Do not bend within 6 inches (15 cm) of a splice,
the hot-cold joint, or the end cap.
• Do not bend the cold lead within 6 in (15 cm) of
the termination pot seal.
• Do not alter cable length.
• Do not energize before installation is complete.
• Do not use screw type adjustable pipe straps/
banding.
• Avoid crushing and excessive bending or pulling
of cold leads during installation, testing and
commissioning

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 1 General Information

• Do not install so that cables are crossed,

overlapped, or grouped. Grouped cables can cause
localized overheating with a risk of fire or cable
failure.
• Keep welding torches well clear of cable and
protect against slag falling on cables below.

Important: When welding, the ground clamp must

be kept as close to the welding area as possible.
• Ensure all pipes, tanks, etc., have been released
by the client for tracing prior to heating cable
installation.
• Heating cables must be spaced at least 1/2 in
(13 mm) from any combustible surface.
• The metal sheath of XMI-A and XMI-L heating
cables shall be bonded to the circuit bonding
conductor, but shall not be used as the bonding
means. Metallic structures or materials used for
the support of, or on which the heating cables are
installed, must be bonded to ground in accordance
with CSA Standard C22.1, Section 10, or the
National Electrical Code as applicable.
• In case of multiple tracing or spiraling, space cable(s)
at least 1 inch (2.5 cm) apart, if possible (Figure 17).
• Install cable in a manner that permits removal of
serviceable equipment such as valves, pumps,
filters, and so on, with minimum disruption to the
surrounding heating cable.
• Use stainless steel pipe straps, stainless steel
banding, or 16 AWG or larger stainless steel tie wire to
fasten XMI-A and XMI-L heating cables to pipes. Use
stainless steel pipe straps, stainless steel banding,
or 16 AWG or larger copper tie wire to fasten copper
sheathed heating cables to pipes.
• Avoid bending cable to an inside radius less than
6 times the outside diameter of the cable, when
installing on valves, pumps, and other irregularly
shaped surfaces. On small flanges and joints
where it is impractical to bend the cables tightly,
metal foil or metal bridging pieces can be used to
fill gaps between the heating cable and the surface
to be heated.

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 1 General Information

• Ensure heating cable sheath material is suitable

for the maintain and continuous exposure
temperatures shown in Table 2. If the anticipated
maximum continuous exposure temperature of
the hot-cold joint or end cap of the cable to be
installed exceeds the values in Table 2, install as
shown in Figure 26.
• Apply thermal insulation as soon as possible after
heat-tracing to prevent mechanical damage to
the heating cables. Waterproof cladding must be
installed immediately after insulation is applied to
prevent the insulation from becoming wet.
• Make all connections to supply cables in above
grade junction boxes and keep covers on junction
boxes when not working on them.
• To maintain the integrity of the epoxy seal
termination, avoid the application of excessive heat
to the epoxy during installation, commissioning
and operation of the heating units
• The minimum installation temperature is –76°F
(–60°C).
• Use a temperature controller suitable for the
process temperature. nVent supplies a wide range
of temperature controllers including the RAYCHEM
series electronic monitoring controllers.

Important: DO NOT remove metal tags from

cold lead.

Important: Repair or assembly of field-fabricated

units shall be done by a person qualified to do so and
in accordance with the nVent requirements.

1.10 Heating Cable Storage

• Store heating cables in a clean dry location and
protect them from mechanical damage.
• Temperature range –40°F to 140°F
(–40°C to 60°C)
• Store heating cables in their shipping container
until they are installed.

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 2 Pre-Installation Checks

2.1 Check Materials Received

Review the heating cable design drawings/schedules
and compare the list of materials to the catalog
numbers of heating cables and components received
to confirm that proper materials are on site. If in
doubt, measure the conductor resistance and check
against that of the schedule. The heating cable
voltage, wattage, and length are printed on the metal
tag attached to the cold lead.
• Ensure that the heating cable voltage rating is
suitable for the source voltage available.
• Inspect the heating cable and components for
in-transit damage.
• Perform continuity and insulation resistance
testing (minimum 100 MΩ) on each cable as
detailed in Section 9 and record the results on the
Heating Cable Installation Record in Section 11.

2.2 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.
• Verify that the actual pipe length, routes, and location
of pipe fittings such as valves, pipe supports,
hangers, and other components match the design
drawings.
• Inspect the piping for burrs, rough surfaces or
sharp edges that may damage the heating cable.
Remove if necessary.
• Verify that any surface coatings are dry to the touch.

2.3 Check Tools

The following tools are recommended for installing
MI heat-tracing systems:
• Lineman’s pliers
• Screwdriver
• Adjustable wrench
• Deadblow mallet

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 3 Heating Cable Installation

3.1 Heating Cable Handling

• Handle heating cable with care. Take care when
bending the cable around pumps, valves, and
flanges.
• Protect cold lead tails from damage by threading
a short section of PVC pipe on to the gland
connector as shown.

Threaded
PVC end

Heating Cold PVC pipe

cable lead Gland connector

Figure 7: Protecting cold lead tails

• Avoid damaging heating cables by cutting or
crushing.
• Uncoil heating cables along a floor or surface
to avoid kinking or twisting. DO NOT pull out
into a spiral.
• Handle the hot-cold joint carefully. Support the
joint on both sides when moving and positioning
the cold lead.
• Do not bend the cold lead using a length of pipe,
placed over the tails and pot, as a fulcrum to
facilitate the bend. The cold lead and/or pot will be
damaged. Bend the cold lead using a bending tool
designed to bend cable or conduit.
• Keep cables clean and dry.
• To prevent galling of threads when using stainless
glands, a thread lubricant should be applied to the
male thread mating with the female backnut.

Heating cable allowances

All parts of a heat traced system which increase the
surface area of the normally insulated pipe/ vessel
(e.g. valves or flanges) or metallic fins that protrude
out of the insulation (e.g. supports), will increase
the overall heat loss. These areas of increased heat
loss require compensation, either by using higher
overall design safety factors or by the addition of
extra cable length. The heating cable allowances are
specified in design software and documentation.
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 3 Heating Cable Installation

In such cases sufficient cable should be added

in such a way to at least enable removal of
instruments, valves etc (“maintenance loop”). For
pipes requiring more than one run of heating cable,
apply the full allowance for each run of cable on
each fitting or support as long as space allows.
However, MI heating cables must not touch or
overlap and the minimum spacing between the
heating cables must be observed. The minimum
spacing between cables is 1” (2.5cm). Contact
nVent if more than two runs are needed or if
cable spacing is less than 1” (2.5 cm). For some
applications, it may be physically impossible to
install all of the recommended allowance directly on
the fitting or support. In this case, install the excess
heating cable on the pipe on either side of the
fitting or support, or distribute the additional heater
length along the entire circuit length if a lower local
temperature is acceptable.

This constraint may be difficult for small pipes and/

or multiple cable runs. If required, contact nVent for
assistance.

For further details on individual allowances please

refer to the design documentation or the nVent
design software (e.g. TraceCalc Pro reports).

For NPS sizes 2" and smaller (in outdoor

applications where wind may be significant) it
is recommended that all components are fully
insulated as there is a risk of a lower maintain
temperature on the components due to heat
losses.

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3 Heating Cable Installation

Positioning heating cables

Install cables around the bottom section of pipe,
avoiding bottom dead center (Figure 8).
For two cable runs, install between 30° and 45° on
either side of bottom dead center (Figure 8).

For three cable runs (as in a three phase

installation) install bottom cable about 10° to
one side of bottom dead center (Figure 8). On
a vertical pipe, space cables evenly around
circumference of pipe.

Weatherproof Temperature Temperature

jacket (typ) sensor sensor

Pipe

Insulation
Cable ‘A’ (typ) Cable ‘A’ Cable ‘B’

One heating cable Two heating cables

Cable ‘C’ Temperature

Sensor

Cable ‘A’ Cable ‘B’

Three heating cables

Figure 8: Cable positioning—typical cross section

Care must be taken at joints, flanges, valves or any

obstructions on the pipe line to prevent damage to
the heating cables during installation.

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 3 Heating Cable Installation

Attaching cold leads

Attach the hot/cold joint to the pipe or vessel
ensuring that it is firmly anchored to the heated
surface and check that the hot/cold joint is not
damaged during installation.

Important: In some instances it is not permitted to

have a hot-cold joint or end cap anchored to the heated
surface because of the risk of exceeding the maximum
recommended exposure temperature (see Table 2). In
such instances, follow the installation detail shown in
Figure 26.

Cold leads should always emerge from the thermal

insulation in such a way that the resultant hole
in the insulation cannot admit water or other
contaminants. Coil excess length of cold lead as it
exits the insulation (Figure 16) and ensure that cold
leads can accommodate any movement of the pipe
work.

Bending the cable

6X heating cable O.D.

Heating cable O.D.

Figure 9: Minimum bend radius

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 3 Heating Cable Installation

When positioning the heating cable on the pipe, do

not bend to an inside radius less than 6 times the
outside diameter of the heating cable. For XMI-L
cables, note that the heating cable is contained
within the corrugated outer sheath, and the
heating cable outside diameter should be used
for calculation of the minimum bending radius
rather than the outside diameter of the corrugated
sheath. Refer to the XMI-L heating cable data sheet,
H59079, for information on heating cable bending
radius.

Crossing the cable

Do not cross, overlap, or group the heating cables.

Figure 10: Crossing, overlapping, and grouping

3.2 Heating Cable Installation on Pipes

nVent recommends that you complete the Heating
Cable Installation Record during the installation of
the heating cable and thermal insulation and keep
this record for future reference.

Important: The FM Required Installation Record

for Class I, Division 1, Hazardous Locations (Section
11) must be completed and submitted to nVent to
complete the FM approval process.
• If mounting junction boxes or other ancillary
equipment onto pipe via brackets, install brackets
on pipe before installing heating cables. This will
avoid damage to the heating cable, as the tension
required to secure the banding for the bracket is
greater than the tension required to secure the
cable banding.

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 3 Heating Cable Installation

• Where feasible, uncoil the single heating cable

and lay it alongside the pipe section to be traced.
For shorter Design B single conductor cable
which is to be installed in the form of a “hairpin,”
it may be advantageous to unroll the heating
cable, loop it, and then lay it alongside the pipe
section so that both runs of cable can be installed
simultaneously.

End
cap

Figure 11: Uncoiling heating cable

• Attach hot-cold joint to end of pipe nearest the

power supply point, and other end of heating cable
to the other end of the pipe. Support hot-cold joint
by attaching cable with pipe straps/banding at
a distance of 6 inches (15 cm) on either side of
joint. Secure joint itself to pipe with a pipe strap/
band as shown in Figure 16.
• Fasten middle of heating cable to the halfway
point of pipe leaving equal slack on either side.

End
cap

Figure 12: Attaching hot-cold joint and end cap

• Attach heating cables to pipe with pipe straps/

banding, or tie wire, at intervals of 18 inches (45
cm) or less. Tie wire should be snug, but should
not cut or indent the sheath. When installing
copper sheathed heating cables using tie wire, use
only 16 AWG or larger copper tie wire to prevent
cutting into the cable sheath.
• Allow extra cable per design specifications and
drawings at all pipe fixtures.

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3 Heating Cable Installation

Stainless steel pipe strap,

banding, or tie wire

Leave large
bending radii (typ)

Figure 13: Allowances for valves, flanges, and pipe

supports

• Use tie wire to hold cable to irregularly shaped

components such as valves or pipe supports.
• In hazardous locations, when attaching heating
cable to irregular shaped components such as
flanges and valves, use pipe straps on either side
of the component to secure the cable to the pipe.

Figure 14: Installing cable on valves and pipe supports

• Allow cable to wave along pipe as per Figure 16

and Figure 17. This allows for expansion and
contraction of the heating cable as it heats up and
cools down. Use up excess cable by waving along
pipe and increasing amount used at each pipe
support.

Important: Do not use up excess cable at one

location. Distribute equally along pipe.

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 3 Heating Cable Installation

Hot-cold joint

Tie wire

Figure 15: Completed MI heating cable installation

Important: For hazardous area installations any

reapportioning of cable should be verified by those
responsible for the system design.

Important: If tensioning tools are used, avoid

over-tightening pipe straps, banding, or tie wire used
to attach heating cable as this can damage the heating
cable. This permits movement of heating cable during
its heating cycle, as restricted movement can lead to
cable failure due to fatigue.

WARNING: Fire and shock hazard. Do not install

damaged cable. Heating cable must be repaired or
replaced before installation.

Typical pipe installation details

The following illustrations show general installation
methods. Actual installation configurations will vary
depending on the number of heating cables being
installed and the shape of the components being
traced.

Junction box

Cold Hot-cold Stainless steel pipe straps,

lead joint banding, or tie wire

6" Insulation
18" max
(15 cm)
6" (45 cm)
(15 cm)
Drip loop

Figure 16: Pipe strap spacing

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3 Heating Cable Installation

18" max
(45 cm)

1/2" (13 mm) wide s/s banding

(tighten with hand-tensioner only)
Prepunched s/s strapping
Wave cables 1" (2.5 cm) to 2" (5 cm) along pipe
Note: Where several runs of cable are required
on one pipe, prepunched strapping may aid in
the installation and spacing of cables.

Figure 17: Fastening several runs of cable

For valve sizes 3-1/2" (9 cm) or smaller

Stainless steel pipe straps,

banding, or tie wire

Pipe Valve body

MI heating cable Apply stainless

See design drawing MI steel tie wire to
for specific heating heating hold MI heating
cable length needed. cable cable in place.

For valve sizes larger than 3-1/2" (9 cm)

Stainless steel pipe straps,

banding, or tie wire

Pipe Valve body

Apply stainless
MI steel tie wire to
heating hold MI heating
MI heating cable cable cable in place.
See design drawing
for specific heating
cable length needed.

Figure 18: Valves

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 3 Heating Cable Installation

Steel pipe

Stainless steel pipe straps,

banding or tie wire (typical)
MI heating cable

MI heating cable is applied to

outside radius of elbow.

Figure 19: Installation at 90° elbow

3" (8cm) max

from strap to
edge of flange

Flange

Heating cable

Stainless steel
pipe straps,
banding, or
tie wire

Apply stainless steel

tie wire to hold heating
cable in place. Notes:
1. Heating cable must maintain contact with
flange when bending the cable around the pipe flanges.
2. In hazardous areas, secure the cable to the pipe on
either side of the flange using pipe straps.
Figure 20: Flanges

Bar hanger
Pipe

MI heating Stainless steel pipe straps,

cable 3” (8 cm)
banding, or tie wire
maximum

Notes: In hazardous areas, secure the cable to the pipe on

either side of the pipe support using pipe straps
Figure 21: Hanger type pipe support

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3 Heating Cable Installation

See design drawings for specific

heating cable length needed.

MI heating cable Pipe

Stainless steel pipe straps,

banding, or tie wire (typical)

Note: Minimum 1" (2.5 cm) spacing, if possible.

Figure 22: Shoe and sleeve type support

Stainless steel pipe straps,

banding, or tie wire

Dummy leg

Pipe
shoe
Insulation

Heating
cable
Notes:
1. Minimum 1" (2.5 cm) spacing.
2. Check drawings for dummy leg insulation.

Figure 23: Dummy supports

nVent.com | 21
 3 Heating Cable Installation

Pumps should have their own heating cable,

separate from the connecting pipe.

Stainless steel pipe straps, Junction box

banding, or tie wire (series connect)

Pump
body

Motor
Heating Stainless steel tie wire is
cable required on both sides to
hold heating cable in place.

Notes:
1. Minimum 1" (2.5 cm) spacing, if possible.
2. Cover heating cable with metal foil or equal before
applying insulation to ensure the cable does not
become trapped in the insulation.

Figure 24: Pumps

Notch insulation
2' max (60 cm) spacers to clear
6" (15 cm) Insulating heating cable
spacers (approx 3/8" (9.5 mm)
‘A’ ‘A’ x 3/8" (9.5 mm))

8' max (2.5 m)

6" (15 cm) Insulating

2' max (60 cm) spacers

Section ‘A’ – ‘A’

Notes:
1. When using oversize insulation to allow space for heat tracing,
use insulating spacers at intervals not exceeding 8 ft (2.5 m)
to reduce chimney effect between the pipe and insulation.
2. Insulating spacers to be same material as oversize insulation.

Figure 25: Risers

22 | nVent.com
 3 Heating Cable Installation

Hot-cold joint Stainless steel pipe straps,

(keep off pipe) banding, or tie wire

Split metal sleeve Insulation

over hot-cold joint
partially exiting Heating cable
insulation (see detail)

Detail

Figure 26: When maximum pipe temperature exceeds

cold lead or hot-cold joint and end cap capability

Pipe

Stainless steel
pipe straps,
banding,
or tie wire Heating cable

Figure 27: Pressure gauge

3.3 Temperature Sensor Installation for Pipes

Secure the temperature sensor to the pipe using
pipe straps or banding. Position the sensor element
parallel to the pipe and in a location where it will not
be affected by the heating cable (Figure 28). In all
cases it is essential that the temperature sensor

nVent.com | 23
 3 Heating Cable Installation

be positioned in accordance with the designer’s

instructions.

Important: The temperature sensor must be

installed so that it senses the temperature conditions
within the heating zone. For example, where flow and
static conditions occur within one heating zone, the
temperature sensor should be located at a point of no
flow and away from the end of the pipe or a component
such as a pipe support.

Temperature Stainless steel Temperature

sensor pipe straps, sensor
or banding
‘A’

‘A’
Heating cable Sensor
hot section lead Pipe Heating cable
Section ‘A’ – ‘A’

Figure 28: Pipe-mounted temperature sensor

The temperature sensor should be strapped in good

thermal contact with the pipe and protected so that
insulating materials cannot become trapped between
it and the heated surface. Install temperature sensor
with care as damage may cause a calibration error.

3.4 Heating Cable Installation on Tanks and

Vessels
On vessels, tanks, or large surfaces, the heating
cable is worked onto the area to form a heating
mat. Prepunched strapping, where allowable, may
be spot welded to the surface of the vessel to be
heated and the heating cable attached to it. When
using prepunched strapping, bend the tabs on the
prepunched strapping backwards over the cable as
shown in Figure 29. Note that prepunched strapping
will not accommodate XMI-L cables due to the larger
diameter of the outer corrugated sheath. In this case,
wire mesh and tie wire may be used.
For irregular shaped vessels, or when installing

24 | nVent.com
3 Heating Cable Installation

XMI-L heating cables, the surface can be covered

with a wire mesh and the heating cable fastened
to the wire mesh using tie wire. Alternatively, the
heating cable may be fastened to the wire mesh
and the mesh applied to the vessel.
Consult design schedule for limits, proportions and
spacing when marking out the surface area and
ensure that the prepunched strapping or wire mesh
is suitably located. This can be best achieved by
marking out the cable run for spacing and extremities
of the cable loops (Figure 29).

Use the following formula to determine cable

spacing:
Cable spacing (in) = A
 rea to be heated (ft2) x 12
Length of heating cables (ft)

Or if metric:
Cable spacing (mm) = Area to be heated (m2) x 1000
Length of heating cables (m)

Locate termination end of heating cable and

attach to vessel, usually near electrical supply point.
Trace over space marking and secure to vessel
using previously attached prepunched strapping
(Figure 29). Pay attention to minimum bending
radius and heating cable spacing when forming
loops.

nVent.com | 25
 3 Heating Cable Installation

Space Radius Prepunched

markings of loops strapping

Loop
positions

Tab – bend
Prepunched Heating cable backwards over
strapping cable so smooth
edge holds cable
(sharp edge up)

Figure 29: Cable layout using prepunched strapping

Install stainless steel banding over heating cable

and strapping as shown in Figure 30. This prevents
cable runs from becoming loose if they slip out
from the “clip” on the strapping.

26 | nVent.com
 3 Heating Cable Installation

Prepunched Heating cable

strapping

Banding

Temperature
sensor
Temperature Cold Junction
controller leads box

Notes:
1. Prepunched strapping can be cut to desired
circumference and spot welded to tank to
suit. Bands to be equally spaced on small
vessels.
2. The heating cable can be fastened to wire
mesh and then applied to the bottom and
sides of the vessel.

Figure 30: Typical vessel/tank installation

Important: Heating cable should be installed

longitudinally on the vessel. Never spiral wrap the MI
heating cable around the circumference of the vessel.

Important: Cover cable with metal foil if foamed-

in-place insulation is used. This will prevent the cable
from becoming trapped in the insulation.

3.5 Temperature Sensor Installation for Vessels

Secure the temperature sensor to the vessel using
pipe straps or banding, or where the temperature
permits it, metal foil tape. Position the temperature
sensor on the vessel between two runs of cable
(Figure 30).

nVent.com | 27
 4 Component Installation

4.1 General Component Information

RAYCHEM heating cables must be terminated in a
junction box suitable for the area classification.
Select appropriate components from nVent literature
number H56884, Mineral Insulated Heating Cables,
found in the Industrial Heat-Tracing Product
Selection and Design Guide, or by using TraceCalc
Pro software.

Component installation tips

• Ensure that the heating cable cold lead angles
downward as it exits the insulation to prevent
water ingress (Figure 16).
• Plan the location of the power connection junction
box so that the excess cold lead can be coiled
before entering the box, then mount the box firmly
to a beam, stanchion, or pipe using appropriate
mounting brackets. For series connected heating
cables, junction boxes may be installed in a similar
manner.
• Cable or conduit leading to junction boxes,
temperature controllers, and transformers must
be installed so that water does not enter the
enclosure.
• Side entries are preferred to avoid condensation in
bottom of junction box.
• Do not bend the cold lead within 6 in (15 cm) of
the termination pot seal.
• Perform visual inspection of glands for scratches
or damage, including threads
• Ensure surface of cable where gland will seal to
sheath is clean
• If gland is contaminated: disassemble, clean, and
visually inspect contaminated parts
• In CID1 hazardous locations glands must have a
minimum of 5 threads engaged.

28 | nVent.com
4 Component Installation

Gland
connector

Pot

When possible
extend pot inside FM note:
junction box
When installing FM certified
units, the pot must be fully
Gland recessed inside the gland body.
connector

Figure 31: Junction box connection

• If necessary, remove the hole plug where the cold

lead will enter the junction box. Screw a reducer
into the junction box conduit hub if required, then
insert the tails and screw the gland connector
tight. Tighten the compression nut.

Important: Make sure that the tails do not

become trapped between the pot and gland connector
or reducer bushing, if used.

Important: The compression nut must be

tightened to the torque setting indicated on the tag
attached to the gland connector. This ensures that
the cable sheath is properly grounded and prevents
moisture from entering the junction box.

• Perform visual inspection of gland after tightening

back nut and check for cracks, deformation /
out-of-round.
• The torque tag on glands should not be removed
(ensuring information available for future
maintenance)
• Connect the cold lead tails and distribution power
wires to the terminal block.
• Position the terminal block and wiring in the
junction box and install the box lid. Make sure lid
is watertight. Check to make sure that hole plugs
are firmly tightened into any unused conduit hubs.

nVent.com | 29
 5 Control and Monitoring

RAYCHEM control and monitoring products are

designed for use with Mineral Insulated 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
nVent representative.

Refer to the installation instructions supplied with

control and monitoring products. Control and
Monitoring systems should be installed by a certified
electrician.

Table 3: RAYCHEM CONTROL AND MONITORING PRODUCTS

Thermostats Controllers

RAYCHEM Series
Multiple Options Elexant
(visit www.nvent. 4010i/
com/raychem) 4020i 920 NGC-30 NGC-40

Control
Ambient sensing • • • •
Line-sensing • • • •
PASC • • • •
Monitoring
Ambient temperature • • • •
Pipe temperature • • • •
Ground fault • • • •
Current • • • •
Location
Local • • • •
Remote • • • •
Hazardous E507S & ETS-05 only • • • •
Communications
Local display • • • •
Remote display • • • •
Network to DCS • • • •

• Indicates an optional component

30 | nVent.com
 6 Thermal Insulation and
Marking

6.1 Pre-Insulation Checks

Visually inspect the heating cable and components
for possible damage or incorrect installation.
Damaged cable must be repaired or replaced.

Perform continuity and insulation resistance tests

on each cable following the procedure in Section 9.
Confirm the results meet the minimum requirement
stated in Test 1 and Test 2 and record them on the
Heating Cable Installation Record in Section 11.

6.2 Insulation Installation Hints

• Make sure all of the piping is insulated according
to the design specification, including valves,
flanges, pipe supports, and pumps.
• Ensure thermal insulation is suitable for the
temperatures involved and for the location of the
pipe (i.e. outdoors or below grade).

Important: Some types of insulation may be

damaged by the high operating temperature reached by
some MI cables.
• Ensure that heating cable does not become
trapped in the joint between the two half shells
of insulation. In some cases, it may be necessary
to cover the heating cable with metal foil to avoid
this problem.
• 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 waterproof cladding, be sure
drills, screws and sharp edges do not damage
the heating cable. The cladding must be installed
immediately after insulation is applied to prevent
the insulation from becoming wet.

nVent.com | 31
 6 Thermal Insulation and
Marking

• To weatherproof the insulation, seal around all

fixtures that extend through the cladding. Check
around valve stems, support brackets, and
thermostat capillaries and sensor leads.
• To minimize “chimney effect” on vertical lengths
of piping when using oversized insulation, install
baffles between the thermal insulation and
the pipe at maximum 8-foot (2.5 m) intervals
(Figure 25).
• To prevent localized overheating, do not allow
thermal insulation or other material to become
lodged between the cable and the pipe. If urethane
foam insulation is applied over heating cable,
special care must be taken to ensure that the
urethane does not get between the MI heating
cable and the pipe. This can be accomplished by
banding the cable to the pipe, and applying a strip
of metal foil longitudinally to the pipe over the
cable.

WARNING: Use only fire-resistant insulation

such as fiberglass, mineral wool or calcium silicate.

6.3 Marking
Install “Electrically Traced,” or similar, warning
labels along piping at 10-foot (3 m) intervals on
alternate sides, and on equipment requiring periodic
maintenance, such as valves, pumps, filters, and so
on, to indicate presence of electric heating cables.

6.4 Post-Insulation Testing

After the insulation is complete, perform a
continuity and insulation resistance test on each
circuit to confirm that the cable has not been
damaged (refer to Section 9).

32 | nVent.com
 7 Power Supply and Electrical
Protection

7.1 Voltage Rating

Verify that the source voltage corresponds to the
heating cable voltage rating printed on the cable
tag. For circuits where the heating cables are series
connected, the sum of the voltages shown on the
cable tags should equal the source voltage.

7.2 Electrical Loading

Size the over-current protective devices according
to the design specification. If devices other than
those identified are used, refer to the current rating
(amps) on the heating cable tag to determine the
electrical load.

Ground-fault protection
Use circuit breakers with 30-mA ground-fault
protection on all heating cable circuits.
nVent, 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.
RAYCHEM series electronic monitoring controllers
incorporate adjustable ground-fault protection,
eliminating the need for separate ground-fault
breakers.

WARNING: To minimize the danger of fire from

sustained electrical arcing if the heating cable is
damaged or improperly installed, and to comply
with nVent 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. (See code for
exceptions.)

WARNING: Disconnect all power before making

connections to the heating cable.

Important: Contact nVent for installation details

for low voltage applications where a step-down
transformer is used to provide power to the heating
cable.

nVent.com | 33
 7 Power Supply and Electrical
Protection

7.3 Temperature Controller Wiring

Wiring diagrams for typical temperature controllers
are supplied with the controller. A contactor may
be used to switch loads greater than the maximum
current or voltage rating of the controller. Contact
nVent for details.

Contactor current ratings: Always ensure that

current ratings of the switch contacts are not
exceeded. Inrush current may be higher than
normal operating current, particularly with copper
conductor heating cables.

34 | nVent.com
 8 Commissioning and Preventive
Maintenance
nVent 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. Record and
maintain results for the life of the system, utilizing
the Heating Cable Commissioning Record (refer to
Section 11).

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 in
junction boxes, 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
repaired or replaced.

Continuity and insulation resistance

Continuity and insulation resistance testing
are recommended at four stages during the
installation process, and as part of regular system
inspection, and after any maintenance or repair
work. Continuity testing checks the integrity of
the resistive heating element inside the heating
cable. IR testing checks the integrity of the
electrical insulating barrier between the resistive
heating element and the cable sheath. IR testing
is analogous to pressure testing a pipe and
detects damage to the heating cable sheath or
terminations. 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
Line-sensing controlled systems
Check circuit breaker sizing and the supply voltage
to make sure that it is suitable for the heating cable
voltage rating and amperage printed on the heating
cable identification tag.

nVent.com | 35
 8 Commissioning and Preventive
Maintenance
• Turn on the main circuit breaker.
• Turn on the branch circuit breakers.
• Set the temperature controller or 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.
• Allow the system to reach the control point and the
current to stabilize. This may take several hours for
some circuits.
• Measure the voltage and pipe temperature for each
circuit and record the values in the Heating Cable
Commissioning Record (refer to Section 11). This
information is needed for future maintenance and
troubleshooting.
• Measure the circuit current using a clamp-on or
panel ammeter. The measured value should be
approximately the number shown under “Amps”
on the heating cable identification tag. Variations
of 10% to 20% are possible due to deviations in
measurement equipment, supply voltage, and
cable resistance. Record the values in the Heating
Cable Commissioning Record in Section 11.
• When the system is completely checked out,
reset the temperature controller to the proper
temperature.

The heating cable power (wattage) can be

calculated by multiplying the measured voltage by
the measured current using the following formula:

Power (W) = Volts (Vac) x Current (A)

The calculated wattage can be compared to the

wattage indicated on the heating cable tag at
the temperature of operation. This gives a good
indication of heating cable performance.

Control and monitoring systems

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

Important: The current and resistance of some

MI heating cables can vary with temperature. Higher
maintain temperatures may result in higher cable
resistances and decreased current.
36 | nVent.com
 8 Commissioning and Preventive
Maintenance

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

8.2 Preventive Maintenance

Recommended maintenance for nVent heat-tracing
systems consists of performing the commissioning
tests on a regular basis, preferably at least once a
year, unless a RAYCHEM series electronic monitoring
controller is used. These controllers automatically
exercise and monitor the heating cable circuit
for faults. Systems that use electro-mechanical
thermostats for control should be checked before
each winter.
If the heat-tracing system is found to be defective,
refer to Section 10 for troubleshooting assistance.
Make the necessary repairs and replace any part of
the heat-tracing system if it has been found to be
defective.

De-energize all circuits that may be affected by

maintenance.

Protect the heating cable from mechanical or

thermal damage during maintenance work.

The recommended cable installation methods allow

for extra cable at all pipe fixtures (such as valves,
pumps, and pressure gauges) so that cable does
not have to be cut when performing maintenance
work.

Maintenance records
nVent recommends that the Maintenance Log
Record (refer to Section 11) be completed during all
inspections and kept for future reference.

nVent.com | 37
 8 Commissioning and Preventive
Maintenance

Repairs
Use only RAYCHEM MI cable and components when
replacing any damaged cable. Repairs should be
performed only by qualified personnel and to nVent
requirements. 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
energize cables that have been damaged. Damaged
heating cable or terminations must be repaired or
replaced. Damaged cable should be repaired by a
qualified person.

WARNING: Heating cables are capable of

reaching high temperatures during operation and
can cause burns when touched. Avoid contact when
cables are powered. Insulate the pipe before energiz-
ing the cable. Use only properly trained personnel.

38 | nVent.com
 9 Test Procedures

nVent recommends that the Heating Cable

Installation Record be completed during testing and
kept for future reference.

9.1 Visual Inspection

• Visually inspect the pipe and connections to the
heating cable for physical damage. Damaged
heating cable must be repaired or replaced.
• Check that electrical connections are tight and
grounded.
• Check that the heating cable sheath temperature
is appropriate for the area classification and
Temperature Class (T-code).
• Ensure that the heating cable carries the correct
circuit identification and that there have been no
unauthorized modifications to the heating cables.
• Verify that all junction boxes are appropriate for
the area classification and correctly sealed with
no moisture inside. Ensure that the cable gland
connectors are tight and correctly fitted into
junction boxes.
• Check for damage to cold lead and inspect glands
for worn or galled threads. The use of a thread
lubricant on threads between gland backnut and
body is recommended with stainless steel glands.
• Check for damaged or wet thermal insulation,
damaged, missing or cracked lagging and
weather-proofing.
• Check control and monitoring systems for
moisture, corrosion, setpoint, switch operation,
sensor or capillary damage, and ensure that they
are operational and properly set.
• Check circuit breaker sizing and the supply voltage
to make sure that it is suitable for the heating
cable voltage rating printed on the cable tag.

9.2 Insulation Resistance Test – Test 1

Insulation resistance is measured between
the heating cable sheath and the tails. nVent
recommends that the insulation resistance test
be conducted using a test voltage of 1000 Vdc,
however in the absence of equipment with this
capability, a 500 Vdc test is suitable to detect most
installation related concerns.
nVent.com | 39
 9 Test Procedures

Frequency
Insulation resistance testing is recommended at
four stages during the installation process and as
part of regularly scheduled maintenance.
• Before installing the cable – minimum 100
megohms
• Before installing the thermal insulation –
minimum 20 megohms
• After installing the thermal insulation – minimum
20 megohms
• Prior to initial start-up (commissioning) –
minimum 10 megohms *including branch
circuit wiring.
• As part of the regular system inspection
• After any maintenance or repair work
* Under adverse weather conditions, or when the
tails or connections have evidence of moisture,
lower insulation resistances may be encountered.
Refer to Section 10 for corrective actions.
Test Criteria
The minimum insulation resistance for a clean, dry,
properly installed circuit should reflect the values
shown above, regardless of the heating cable length.

9.3 Continuity (Resistance) Test – Test 2

Continuity testing is conducted using a standard
Digital Multimeter (DMM) and measures the
resistance between the cold lead tails.
Test Criteria
Measure the resistance of the MI heating cable with
the DMM. Most MI heating cable resistances are
less than 100 ohms. The approximate resistance
can be calculated using the formula: Resistance
(ohms) = Volts2 / Watts. Voltage and wattage can
be found on the heating cable identification tag.

Important: This measured value is the resistance

at 20°C; the calculated value is the resistance at the
operating temperature and may be higher than the
measured value.

40 | nVent.com
 9 Test Procedures

9.4 Insulation Resistance and Continuity Test

1. De-energize the circuit.
2. Disconnect the temperature controller or
thermostat if installed.
3. Disconnect tails from terminal block, if installed.
4. Set megohmmeter test voltage at 0 Vdc.
5. Connect the positive (+) lead to the heating
cable sheath.
6. Connect the negative (-) lead to both heating
cable tails simultaneously.
7. Turn on the megohmmeter and set the voltage to
1000 Vdc; apply the voltage for 1 minute. Meter
needle should stop moving. Rapid deflection
indicates a short. Record the insulation
resistance value in the Heating Cable Installation
Record (Section 11).
8. Turn off the megohmmeter.
9. If the megohmmeter does not self-discharge,
discharge phase connection to ground with
a suitable grounding rod. Disconnect the
megohmmeter.
10.Check the continuity (resistance) of the heating
cable between the two tails. Record the
resistance value in the Heating Cable Installation
Record.
11.Disconnect the multimeter.
12.Reconnect heating cable tails to terminal block.
13.Reconnect the temperature controller or
thermostat.

If the heating cable fails the insulation resistance

test, stop and follow the troubleshooting
instructions in Section 10. If it fails the continuity
(resistance) test, it is most likely defective and must
be repaired.

WARNING: Fire hazard in hazardous locations.

Insulation resistance tests can produce sparks. Be
sure there are no flammable vapors in the area before
performing this test.

nVent.com | 41
 9 Test Procedures

Tails Tails

Test 1 Test 2
Insulation Resistance Continuity

Figure 32: Connecting the megohmmeter and

multimeter

42 | nVent.com
9 Test Procedures

nVent.com | 43
10 Troubleshooting Guide

Symptom Probable Causes

Insulation resistance less 1. Rain, high humidity or adverse

than expected weather conditions.

2. Nicks or cuts in heating cable sheath,

with moisture present.

3. Kinked or crushed heating cable.

4. Arcing created by damage to the

heating cable.

5. Physical damage to heating cable is

causing a direct short.

6. Presence of moisture in terminations

or connections.

7. Damaged termination.

Symptom Probable Causes

Circuit breaker trips 1. Circuit breaker undersized.

2. Defective circuit breaker.

3. Short circuit in electrical

connections.

4. Excessive moisture in connection

boxes.

5. Nicks or cuts in heating cable

sheath, moisture present.

6. Kinked or crushed heating cable.

7. Ground-fault protection device

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

Note: If the corrective actions above do not resolve the problem, verify
that the installation is as per design.

44 | nVent.com
10 Troubleshooting Guide

Corrective Action

(1) Dry tails and face of seal. Inspect power connection box for
moisture or signs of tracking. Dry out connections and retest.

(2, 3, 4) Visually inspect cable for damage, especially at elbows,

flanges, and around valves. If damaged, repair or replace heating
cable. Inspect power connection box for moisture or signs or
tracking. Dry out connections and retest.

(5) 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 along the pipe. Replace
damaged sections of heating cable.

(6) Dry out cold lead and/or connections and replace termination if
necessary.

(7) Replace termination

Corrective Action

(1) Recalculate circuit load current. Resize breaker as required.

(2) Repair or replace breaker.

(3, 4) Eliminate short circuit. Thoroughly dry connections. Install

conduit drains as required.

(5, 6) Repair damaged section or replace heating cable.

(7) Replace undersized GFPD with 30mA GFPD. Check the GFPD
wiring instructions.

nVent.com | 45
10 Troubleshooting Guide

Symptom Probable Causes

Power output appears 1. Wet or missing insulation.

correct but pipe temperature
is below design maintain 2. Insufficient heating cable on valves,
temperature. flanges, supports, pumps, and other
components.

3. Temperature controller set

incorrectly.

4. Improper thermal design used.

5. Temperature sensor in wrong

location.

6. Low fluid temperature entering pipe.

Symptom Probable Causes

Power output is zero or 1. No input voltage.

incorrect
2. Temperature controller wired in the
normally open (N.O) position.

3. Broken or damaged heating

element, hot-cold joint, end cap, or
broken tail.

4. Wrong cable used.

5. Improper voltage used.

Note: If the corrective actions above do not resolve the problem,

verify that the installation is as per design.

46 | nVent.com
10 Troubleshooting Guide

Corrective Action

(1) Remove wet insulation and replace with dry insulation and
secure it with proper weather-proofing.

(2) Confirm compliance with system design. (If valve, flange, and
pipe support types and quantities have changed, additional
heating cable may be required.)

(3) Reset temperature controller.

(4) Contact your nVent representative to confirm the design and

modify as recommended.

(5) Confirm that sensor is in the correct location.

(6) Verify temperature of fluid entering pipe.

Corrective Action

(1) Repair electrical supply lines and equipment.

(2) Confirm wiring using the normally closed (N.C.) terminals so

that contacts close with falling temperature.

(3) Repair or replace heating cable.

(4) Verify installation as per design and replace cable if

necessary.

(5) Verify voltage and connect to proper voltage if necessary.

nVent.com | 47
11 Installation and Inspection
Records

Heating Cable Installation Record

Location Ref. drawings(s)
Line number Heating cable number
Panel number Breaker number
Heating cable manufacturer Heating cable model
Heating cable wattage unit length / voltage rating

Megohmmeter manufacturer / model

Megohmmetter date of last calibration
Multimeter manufacturer / model

TESTING:
Note: Minimum acceptable insulation resistance shall be 20 megohms.
Recommended test voltage is 1000 Vdc.
1. Receipt of material
Continuity test
Insulation resistance test
2. Before installing cable on pipe
Continuity test
Insulation resistance test
3. After installation
Continuity test
Insulation resistance test
4. Visual inspection before installing thermal insulation
Heating cable correctly installed on pipe, vessel or equipment
Heating cable correctly installed at valves, pipe supports, other components
Junction boxes correctly installed and cable terminated
Installation agrees with manufacturers instructions and circuit design
5. Thermal insulation installation complete
Continuity test
Insulation resistance test
6. Tagging and identification complete (panel, field components, pipe decal)
7. Heating cable effectively grounded
8. Temperature controls properly installed and setpoints verified
9. Thermal insulation weather tight (all penetrations sealed)
10. Covered hot-cold joints and end caps marked on insulation outer cladding
11. Drawings, documentation marked as–built
Performed by
Witnessed by
Accepted by
Approved by

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Project number Temp. code (from tag)

Area classification Auto ignition temp.
Circuit number Circuit amp/ voltage
Source voltage

Voltage setting Accuracy / full scale

Ohm setting Accuracy / full scale

Test Value / Remarks Date Initials

Company Date
Company Date
Company Date
Company Date

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Installation Record Required for Class I, Division 1,

Hazardous Locations According to IEEE 515

Location System/Project number

CIRCUIT ID #
Area:
Auto ignition temperature
Group classification
HEATING CABLE CIRCUIT:
Heating cable type
Supply voltage
Circuit length
Design maximum pipe temperature
Heating cable temp code/sheath temp. (from tag)
(T-rating)
COMPONENTS:
Junction boxes
GROUND-FAULT PROTECTION:
Make & model
Ground leakage
Trip level (ma)
INSTALLATION INSTRUCTIONS:
Correct components per manufacturer's specification
Ground-fault protection device tested
INSULATION RESISTANCE TESTING: Instrument used
Calibration date
Megohmmeter test voltage
(1000 Vdc recommended)
Insulation resistance reading before thermal insulation installed
(minimum insulation resistance shall be 20 megohms)
Insulation resistance reading after thermal insulation installed
(minimum insulation resistance shall be 20 megohms)

CIRCUIT READY TO COMMISSION:

Prepared by
Approved by

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Reference drawing(s)

Test Value / Remarks Date Initials

Company Date
Company Date

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Heating Cable Commissioning Record

Location System
Heating cable number Line number
Panel number Location
Heating cable manufacturer Heating cable model

DESIGN INFORMATION:
Total design length
Thermal insulation type
Normal pipe temperature
HEATING CABLE TESTING:
Continuity/Resistance value (Ohms)
Insulation Resistance value (10 megohms minimum)
Test ambient temperature

PERFORMANCE DATA: Volts AC

Panel Field

Startup
Second test
Third test
Ambient temperature at time of test
Pipe temperature at beginning of test
Calculated watts per unit length (Volt x Amp / Length)
TEMPERATURE CONTROL: type
Controller Ambient sensing
High limit controller Type
Controls calibrated
Controls operation verified
ALARMS / MONITORING: type
Temperature High setting
Current High setting
Ground-fault current
Loss of voltage
Other
GROUND-FAULT PROTECTION: type
Setting Measured current
Performed by
Witnessed by
Accepted by
Approved by

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Project number Reference (drawing(s)

Area classification Autoignition temp.
Circuit number Circuit amp/ voltage
Heating cable wattage unit length / voltage rating

Total installed length

Thermal insulation thickness
Maintain pipe temperature

Current in Amperes
1 phase 3 phase
Line A phase B phase C phase Neutral

After final test

After final test

Pipe sensing Temperature setpoint

Location Temperature setpoint

Low setting Operation verified

Low setting Operation verified
Setting Operation verified
Operation verified
Operation verified

Tested for operation

Company Date
Company Date
Company Date
Company Date

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Maintenance Log Record

Location System
CIRCUIT INFORMATION
Heating cable catalog. No.
Breaker panel number Breaker number
Ground-fault protection (type)
Controller
VISUAL
Panel Number Circuit No.
Date
Initial
Thermal insulation
Damaged insulation/lagging
Water seal good
Insulation/lagging missing
Presence of moisture
Heating system components
Enclosures, boxes sealed
Presence of moisture
Signs of corrosion
Heating cable lead discoloration
Heating and/or high-limit controller
Operating properly
Controller setpoint
ELECTRICAL
Insulation resistance testing (bypass controller if applicable)
Test voltage
Insulation resistance value (10 megohms minimum)
Heating cable supply voltage
Value at field connection
Heating cable circuit current reading
Amp reading at first test
Amp reading after second test
Test ground fault
Comments and actions:

Prepared by Company
Approved by Company

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Reference drawing(s)

Circuit length
Cable voltage
Ground-fault trip setting

Date
Date

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North America
Tel +1.800.545.6258
Fax +1.800.527.5703
thermal.info@nvent.com
Asia Pacific
Tel +86.21.2412.1688
Fax +86.21.5426.3167
cn.thermal.info@nvent.com
Europe, Middle East, Africa
Tel +32.16.213.511
Fax +32.16.213.604
thermal.info@nvent.com
Latin America
Tel +1.713.868.4800
Fax +1.713.868.2333
thermal.info@nvent.com

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