raychem electromelt system installation and operation ...€¦ · electromelt system installation...

ElectroMelt System

INSTALLATION AND OPERATION MANUAL FOR SURFACE SNOW MELTING AND ANTI-ICING SYSTEMS

WWW.PENTAIRTHERMAl.COMTHERMAl MANAGEMENT

ii Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01

Important Safeguards and Warnings

WARNING: FIRE AND SHOCK HAZARD.

Raychem heat-tracing systems must be installed cor-rectly to ensure proper operation and to prevent shock and fire. Read these important warnings and carefully follow all the installation instructions.

•To minimize the risk of fire from sustained electrical arcing if the heating cable is damaged or improperly installed and to comply with Thermal Management requirements, agency certifications, and national 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 are based on the use of Raychem parts only. Do not substitute parts or use vinyl electrical tape.

•Bus wires will short if they contact each other. Keep bus wires separated.

•Connection kits and heating cable ends must be kept dry before and during installation.

•The black heating cable core is 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 scoring the jacket or core.

•Damaged heating cable can cause electrical arcing or fire. Use only plastic cable ties to secure the heating cable to the reinforcement. Do not use metal attach-ments such as tie wire.

•Do not attempt to repair or energize damaged heat-ing cable. Remove damaged sections at once and replace them with a new length using the appropriate Raychem splice kit. Replace damaged connection kits.

•Megohmmeters operate at high voltage. This voltage is hazardous and possibly lethal. Read and follow all instructions included with the instrument you are using.

iiiRaychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01

Table of Contents

1 General Information 11.1 UseoftheManual 11.2 ElectroMeltApplications 21.3 SafetyGuidelines 21.4 Approvals 21.5 Warranty 3

2 Pre-Installation Checks 42.1 BeforeYouStart 42.2 CheckMaterials 42.3 ReviewtheDesign 52.4 ProjectCoordinationMeeting 62.5 HeatingCableandConnectionKitStorage 62.6 GeneralInstallationGuidelines 6

3 Heating Cable Installation 83.1 ProtecttheHeatingCable 83.2 HeatingCableInstallation 8

4 Power Supply and Electrical Protection 154.1 VoltageRating 174.2 CircuitBreakerSizing 174.3 Ground-FaultProtection 184.4 ImportantPowerSupplySafeguards 19

5 Installation 205.1 ManualOn/OffControl 205.2 SlabSensingThermostat 205.3 AutomaticSnowController 215.4 Controllers 215.4 PowerDistribution 24

6 Commissioning and Preventive Maintenance 266.1 ElectroMeltSystemStartup 266.2 Tests 28

iv Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01

7 Test Procedures 297.1 SystemTests 297.2 FaultLocationTests 33

8 Troubleshooting Guide 36

9 Installation and Inspection Records 40

1

1 General Information

Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01

1.1 Use of the ManualThismanualcoverstheinstallationofElectroMeltself-regulatingheatingcablesandconnectionkitsforcommercialsurfacesnowmeltingforconcretepave-mentorinconcreteunderpavingstones;andforanti-icinginconcretepavement.Themanualcoversgeneralheatingcableinstallationproceduresandspecificinstallationdetailsandprovidesinformationonavailableconnectionkitsandaccessories.Themanualalsoprovidesinformationoncontrols,test-ing,andperiodicmaintenance.

Thismanualassumesthatthepropersnow-meltingoranti-icingdesignhasbeencompletedaccordingtotheSurfaceSnowMeltingandAnti-Icing−ElectroMeltDesignGuide(H53393).OnlytheapplicationsdescribedinSection1.2ofthismanualareapprovedbyThermalManagementforElectroMeltSurfaceSnowMeltingandAnti-IcingsystemswhenusedwithapprovedRaychemconnectionkits.Theinstruc-tionsinthismanualandtheinstallationinstructionsincludedwiththeconnectionkits,controlsystems,powerdistributionsystems,andaccessoriesmustbefollowedfortheThermalManagementwarrantytoapply.ContactyourThermalManagementrepresen-tativeforotherapplicationsandproducts.

Foradditionalinformation,contact:Thermal Management7433HarwinDriveHouston,TX77036USATel: +1.800.545.6258Tel: +1.650.216.1526Fax: +1.800.527.5703Fax: [email protected]

Important: For the Thermal Management war-ranty and agency approvals to apply, the instructions that are included in this manual and with associated products must be followed.

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1.2 ElectroMelt Applications

Surface Snow MeltingSurfacesnowmeltingsystemspreventtheaccu-mulationofsnowonramps,slabs,driveways,side-walks,platformscales,andstairsundermostsnowconditions.

Anti-IcingAnti-icingsystemskeepthesurfacetemperatureabovefreezingatalltimestopreventiceformation.Anti-icingapplicationsrequireahigherwattdensityandlongerhoursofoperationthanasurfacesnowmeltingsystem.

1.3 Safety GuidelinesThesafetyandreliabilityofanyheat-tracingsystemdependsonthequalityoftheproductsselectedandthemannerinwhichtheyareinstalledandmain-tained.Incorrectdesign,handling,installation,ormaintenanceofanyofthesystemcomponentscoulddamagethesystemandmayresultininadequatesnowmelting,de-icing,electricshock,orfire.Tominimizetheserisksandtoensurethatthesystemperformsreliably,readandcarefullyfollowtheinfor-mation,warnings,andinstructionsinthisguide.

Payspecialattentiontothefollowing:

• Importantinstructionsaremarked Important

• Warningsaremarked WARNING

1.4 Approvals TheElectroMeltsurfacesnowmeltingandanti-icingsystemisULListedandCSACertifiedforuseinnon-hazardouslocations.

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1.5 WarrantyThermalManagement'standardlimitedwarrantyappliestoallproducts.Anextensionofthelimitedwarrantyperiodtoten(10)yearsfromthedateofinstallationisavailableifaproperlycompletedonlinewarrantyformissubmittedwithinthirty(30)daysfromthedateofinstallation.Youcanaccessthecompletewarrantyonourwebsiteatwww.pentairthermal.com.

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2 Pre-Installation Checks


2.1 Before You StartTheElectroMeltsurfacesnow-meltingandanti-icingsystemisanengineeredsystemthathasbeendesignedforyourapplication.Toensureanefficientinstallationandstartup,obtainalloftherelevantengineeringinformationbeforeyoustart.Contactthegeneralcontractor,owner,orowner’srepresentativetoobtainastatementoftheprojectdesignbasis,projectspecifications,andtheheatingcablelayoutdrawings.

2.2 Check MaterialsBeforebeginninginstallationwork,verifythatallmaterialrequiredfortheinstallationisonhandoronorder.Itisespeciallyimportanttohavethepropermegohmmeter,propanetorchandcrimptoolavailable.

Heating cable • Reviewtheheatingcabledesignandcompare

thelistofmaterialstothecatalognumbersoftheheatingcablesandconnectionkitsreceivedtoconfirmthatthepropermaterialsareonsite.Theheatingcablecatalognumberisprintedonitsjacket.

• EnsurethattheservicevoltageavailableiscorrectfortheElectroMeltheatingcableselection(seeTable1).Inspecttheheatingcableandconnectionkitstoensurethereisnoin-transitdamage.

• Verifythattheheatingcablejacketsarenotdam-agedbyconductingtheinsulationresistancetest(refertoSection7)oneachreelofcable.Donotpowertheheatingcablewhenit’sonthereel.

TABlE 1: ElECTROMElT SElF-REGUlATING HEATING CABlE

Supply voltage Catalog number

208V,240V,277V EM2-XR

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Thefollowingtoolsarerecommendedtoperformthevariousinstallationtasks.ElectroMeltconnectionkitandaccessoriesinstructionsincludeamoredetaileddescriptionofthetoolsrequiredtoassembleeachkit.

Stripping ElectroMelt heating cable • Utilityknife• Diagonalcutters• Pliers(long-nosed)• Ruler• Diagonalcutters

Shrinking tubing • Propanetorchorelectricheatgun• Metallicflameshield

Assembling power connection and splice • Alltoolslistedabove• Appropriatecrimptool

Testing heating cable• 2500VdcMegohmmeter• Voltmeter

2.3 Review the DesignToensurethattheinstallationprogressessmoothlyandmeetsthedesignobjectives,answerthefollow-ingquestions:• Whatistheexactareatobeheated?• Howistheconcretereinforced?Howwilltherein-

forcementbesupported?• Wherearetheconcreteconstructionjoints,expan-

sionjoints,andcrackcontroljointslocated?• Whatistheheatingcablespacing?• Whatisthedepthofburialoftheheatingcable?• Wherearetheheatingcablepowerconnections

andendsealterminationslocated?

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2.4 Project Coordination MeetingHoldaprojectcoordinationmeeting.Atthismeetingreviewthedesign.Duringthemeetingdiscusstheroleofeachtradeandcontractor.

Heatingcableinstallationstartsaftertheconcretereinforcementhasbeeninstalled.Theheatingcablewillbeattachedtothereinforcementusingplas-ticcabletiestomaintainthedesignspacing.Thereinforcementisnecessarytoensurethatthepave-mentisstructurallysound.Paverapplicationsalsousereinforcementssuchasrebarandwiremeshtosecuretheheatingcable.Itisimportantthatthedesignheatingcabledepthandspacingintheconcretebemaintainedforproperoperationofthesystem.

2.5 Heating Cable and Connection Kit Storage TopreventdamagetotheElectroMeltsystembeforeinstallation,thefollowingprecautionsshouldbeobserved:1. Storetheheatingcableinacleandryplace.2. Storagetemperaturerange:–40°F(–40°C)to

140°F(60°C).3. Protecttheheatingcableandconnectionkits,

accessories,andcontrollersfrommechanicaldamage;keepthemoutofhightrafficareaswheretheymaybewalkedonoraccidentallydamaged.

2.6 General Installation GuidelinesTheseguidelinesareprovidedtoassisttheinstallerthroughouttheinstallationprocessandshouldbereviewedbeforetheinstallationbegins.

AvoiddamagetotheElectroMeltheatingcableasfollows:• Donotenergizecablesbeforeinstallationis

complete.• Donotinstallcablesifthetemperatureisbelow

30°F(–1°C).• Donotrepeatedlybendandstraightenthecable.

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• Ensureheatingcableisnotincontactwithaninsulatingmaterial.

• Installheatingcableatthedesignedspacingtoensurecorrectwattdensity.

• Forslopingramps,suchastoanundergroundparkinggarage,laytheheatingcableacrossthewidthoftheramp.

• Useaplanktotipwheelbarrowon.• Theheatingcabledoesnotbendeasilyintheflat

plane.Donotforcesuchabend,astheheatingcablemaybedamaged.

• Donotusesharpobjectssuchasrakes,shovels,etc.wheninstallingcable,orwalkonthecablewithhardboots.

• Makeallconnectionstocablesinabovegradejunctionboxesandkeepcoversonjunctionboxeswhennotworkingonthem.

8

3 Heating Cable Installation


Thissectionprovidesinstructionsforinstallingtheheatingcablesinpavementorslabs.Readandfol-lowtheseinstructionstoensurethattheElectroMeltsystemperformsreliablyandasintended.

3.1 Protect the Heating Cable Onmanyprojectsthereisadelaybetweeninstalla-tionoftheheatingcableandplacementofthecon-crete.Ifthereisanydelayatall,takethefollowingprecautionstoprotecttheinstallationuntilconcretecanbepoured:• Preventtrafficfromcrossingtheareawherethe

heatingcableisinstalled.• Installtemporaryendsealssuchasvinylelectri-

caltape,heatshrinktubing,orothersuitablematerialsonallexposedheatingcableendstopreventwaterentry.Alltemporaryendsealsmustberemovedbeforeinstallation.

• Mechanicallyprotecttheheatingcablesothatitcannotbedamagedbybeingwalkedon,runover,painted,sandblasted,welded,cut,orotherwisecut,abraded,burned,orcontaminated.

3.2 Heating Cable Installation

1. locate Structural FeaturesElevatethereinforcementfromtheground,measureandmarkthedesignedheatingcablespacingonthereinforcementandmarkthelocationofallpave-mentjoints.Thereinforcementshouldbeelevatedfromthegroundsothattheheatingcableattachedtoitwillbe11/2to2inches(4to6cm)fromthesurfaceofthefinishedconcrete.Forpaverapplica-tions,concreteshouldbe2inches(6cm)thicktoallow11/2inches(4cm)betweenheatingcableandsurfaceofconcrete.Notetheplannedlocationofstructuressuchasflagpoles,railposts,benchesorparkingmeters.Thesearetypicallyinstalledafterconcretecuresandtheirinstallationrequirescutting

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intotheconcrete.Heatingcableshouldbelaidouttoavoidareaswherefollowonconstructionwillbecompleted.AnEMK-XEJexpansionjointkitmustbeusedtocrossexpansionjointsasshowninFigure1.Thekitincludesaprotectivesleevethatmustbeslippedovertheheatingcableasitispaidoutfromthereel.

Expansionjoint

Expansionjoint

Figure 1: Expansion joint

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2. layout Heating CableMounttheheatingcablereelonaholderandplaceitnearthejunctionboxwherethecircuitwillbeterminated.Planforbothendsoftheheatingcablecircuittoresideinthejunctionbox.Useareelholderthatpaysoutsmoothlywithlittletensionandavoidjerkingthecablewhilepulling.Ensurethecorrectnumberofexpansionjointkitsforthecircuityouareinstallingareslippedovertheheatingcablebeforepayingoutthecable.

Laytheheatingcableonthereinforcementinaserpentinepatternatthedesignspacingpreviouslymarked.Ensureheatingcableisatleast4inches(10 cm)fromtheedgeofthepavementandfromobstaclessuchaspipes,drains,andanchors.

AnEMK-XSsplicekitmayberequiredtoconnectlengthsofheatingcableintoadesignedcircuitlength.Protecttheendsoftheheatingcableagainstwaterdamagewithtemporaryendsealsuntiltheterminationkitsareinstalled.

Theheatingcablemustbeinstalledbetweenthepavementandjunctionboxina1inchrigidmetalconduit(Figure2).Theconduitmustnotpenetratebuildingwallsorfloorsandmustnotbeinsulated.Extendtheconduitatleast6inchesintotheconcreteoftheapplicationareaandprovideprotectivebush-ingsateachendoftheconduit.

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6" min.

Heating cableRigidconduit

Junction box

Concrete Rebar

Figure 2: ElectroMelt installation

3. Secure Heating CableExpansionjointkitsshouldbeplacedattheplannedexpansionjointpriortosecuringheatingcabletothereinforcement.Secureheatingcabletothereinforce-mentwithplastictiewraps(notwire)atapproxi-mately12inch(30cm)intervals,asshowninFigure3.Handtightenplastictiewrapstopreventdamagetotheheatingcable.

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Heating cable spacing

Rebar

Heating cable

Rebar or mesh chair

Top of finished surface

Figure 3: ElectroMelt installed on rebar

4. Perform Insulation Resistance TestAftertheheatingcablehasbeenplaced,butbeforeanyterminationsorspliceshavebeenmade,testtheinsulationresistanceofeachlengthofheatingcableusingtheelectricalresistancetestingprocedureinSection7.Iftheinsulationresistanceislessthan1000megohmswhentestedat2500Vdc,consultSection8,troubleshootingguide.

5. Install SplicesInstallanysplicesthatmayberequired.Markthelocationofsplicesontheheatingcableinstallationdrawingforfuturereference.

RepeattheinsulationresistancetestprocedureinSection7at2500Vdc.

6. Terminate the Heating CableTerminatetheheatingcableusinganEMK-XPpowerconnectionandendsealkitbeforeconcreteispoured.Worksuchasdraininstallation,placement

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ofanchorbolts,andcuttingofcrackcontroljointsisoftendoneaftertheinitialconcretepour.Itisadvisabletotesttheheatingcablefordamagebyperforminganinsulationresistancetestafteranyconstructionisperformedontheconcrete.

Installthesnowmeltingandanti-icingequipmentlabelssuppliedwiththeEMK-XPpowerconnectionandendsealkittothecoverofthejunctionboxandtothepowerdistributionpanelboardtocomplywithULrequirements.

PerformaninsulationresistancetestofthebranchcircuitconductorsusingtheproceduresinSection 7beforeinstallingthepowerconnectionkit.Subsequenttestingoftheheatingcablemaybedonefromthepowerdistributionpanel.Testingthepowerwiringwith2500Vdcwillrevealanywiredamagethatmightlaterbemistakenforlowheatingcableinsulationresistance.

7. Pour the ConcreteCoordinateplacementoftheconcretewiththecon-tractor.Concreteshouldbepouredsothatheatingcableis11/2to2inches(4to6cm)fromsurface.Allprecautionsshouldbetakenduringthepourtoprotecttheheatingcable.Donotusesharptoolssuchasshovelsandrakesduringthepour.Donotstriketheheatingcablewithtools,walkontheheat-ingcable,ordoanythingelsethatwilldamagethecablejacket.Donotenergizetheheatingcablesdur-ingtheconcretecuringperiod.Donotallowtrafficonthenewcompletedsurfaceuntiladequatestabil-ityhasbeenattainedandthematerialhascuredsuf-ficiently.Setpaverspermanufacturersinstructionsaftersatisfactoryinsulationresistancetest.

AtleastoneSMCSSnowMeltingCautionSignshouldbeinstalledwitheachsnowmeltingsysteminordertoreducetheriskofdamagetotheembeddedheat-ingcableduringfuturealterationsoradditionstotheheatedsurface.Forconcreterampapplications,oneSMCSisrecommendedatthetopoftherampandanotheratthebottom,installedintherampitself.

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ConducttheinsulationresistancetestinSection7at2500Vdccontinuouslyduringtheconcretepour.Ifdamagetotheheatingcableissuspected,stoptheconcretepourimmediatelyandinspectheatingcablefordamage.Ifnecessary,replacedamagedportionsofheatingcablebysplicinginanewlengthofheat-ingcableusingtheEMK-XSsplicekitorreplacethedamagedcircuitentirely.

ConducttheinsulationresistancetestinSection7at2500Vdcaftertheconcretepouriscomplete.

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4 Power Supply and Electrical Protection



Catalog number DescriptionHeating cable allowance1

Connection Kits

Power connection EMK-XP

End seal EMK-XP

EMK-XP

Powerconnectionandendsealkit;use1percircuitStandard pkg:1

3ft(1m)forconnectionplusconduitlengthforpowercon-nectionandconduitlengthforendseal

EMK-XS

Splicekit;useasneededStandard pkg: 1Note: Heatingcablewillbedeliveredwithouttheneedtoinsertasplice.However,repairandinstallationissuesinyourspecificapplicationmayrequiredtheuseofasplicekit.

1ft(30cm)

Accessories

EMK-XJR

Jacketrepairkit,useasneededStandard pkg: 1

NA

EMK-XCT

Nyloncableties;1perfootofcableusedStandard pkg: 100perpack

NA

EMK-XT

CrimpingtoolStandard pkg:1

NA

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Catalog number DescriptionHeating cable allowance1

Continued

CT-CABLE-TIE

UV-resistantcabletie;useasneededStandard pkg:100perbox

NA

SMCS

SnowmeltcautionsignDimensions6x4in(150x100mm);1minimumpersystemStandard pkg:1

0.3ft(0.1m)

EMK-XEJ

Expansionjointkit;1perexpansionjointcrossingStandard pkg:1

11/2ft(45cm)

EMK-XJB

JunctionboxDimensions151/2x113/4x75/8in(394x299x194mm)Standard pkg:1

1–2ft(30–60cm)foreachendinthejunctionbox.Maximumof2circuitsperEMK-XJB

1Allowextraheatingcableforeaseofcomponentinstallation.

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4.1 Voltage RatingVerifythatthesupplyvoltageiseither208,240,or277voltsasspecifiedbytheElectroMeltsystemdesignandthattheheatingcableisappropriatelyrated(refertoTable1).

4.2 Circuit Breaker SizingCircuitbreakersmustbesizedusingthecablelengthsshowninTable3forautomaticsnowcontrolsystemorTable4formanualsnowcontrolsystem.Donotexceedthemaximumcircuitlengthshownforeachbreakersize.Usecircuitbreakersthatincor-porate30-mAground-faultcircuitprotection,orpro-videequivalentlevelsofground-faultprotection.

TABlE 3: MAxIMUM HEATING CABlE CIRCUIT lENGTH FOR STARTUP AT 20°F (–7°C) IN FT (M) USING AN AUTOMATIC SNOW CONTROl SYSTEM

Heating cable supply voltage

Circuit breaker 208 V 240 V 277 V

15Amp 80 (24) 85 (26) 100 (31)

20Amp 105 (32) 115 (35) 130 (40)

30Amp 160 (49) 170 (52) 195 (59)

40Amp 210 (64) 230 (70) 260 (79)

50Amp 265 (81) 285 (87) 325 (99)

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TABlE 4: MAxIMUM HEATING CABlE CIRCUIT lENGTH FOR STARTUP AT 0°F (–18°C) IN FT (M) USING A MANUAl CONTROl SYSTEM

Heating cable supply voltage

Circuit breaker 208 V 240 V 277 V

15Amp 75 (23) 80 (24) 90 (27)

20Amp 100 (31) 110 (34) 120 (37)

30Amp 145 (44) 160 (49) 180 (55)

40Amp 200 (61) 210 (64) 240 (73)

50Amp 245 (75) 265 (81) 300 (91)

4.3 Ground-Fault ProtectionIftheheatingcableisimproperlyinstalledorphysi-callydamagedtothepointthatwatercontactsthebuswires,sustainedarcingorfirecouldresult.Ifarcingdoesoccur,thefaultcurrentmaybetoolowtotripconventionalcircuitbreakers.ThermalManagementandnationalelectricalcodesrequirebothground-faultprotectionofequipmentandagroundedmetalliccoveringonallheatingcables.Ground-faultprotectionmustbeprovidedbytheinstaller.

WARNING: To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with Thermal Management requirements, agency certifi-cations, 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.

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4.4 Important Power Supply Safeguards• Makesurethattheheatingcableloadyouarecon-

nectingiswithintheratingofthecontrolsystemselected.Checkthedesigndrawingsfortheheat-ingcableload.

• Theelectricalconduitthatfeedswiringtothecon-troldevicemusthavealow-pointdrainsoconden-sationwillnotentertheenclosure.

• Makesurethatthelinevoltageyouareconnectingtothecontrolsystemiscorrect.Forproperwiring,followtheinstallationinstructionsenclosedwiththecontroldevice.

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5 Control, Monitoring and Power Distribution


Controlsystemsareselectedfromthefollowingthreeoptions.Allareeffectiveandapproved;how-ever,anautomaticsnowcontrolleroffersthehighestsystemefficiencyandthelowestoperatingcostandismoststronglyrecommended.1. Manualon/offcontrol2. Slabsensingthermostat3. Automaticsnowcontroller

Ifthecurrentratingofthecontrolmeansisexceed-ed,allthreemethodswillrequirecontactorssizedtocarrytheload.Eachmethodoffersatrade-offbalancinginitialcostversusenergyefficiencyandabilitytoprovideeffectivesnowmelting.Ifthesystemisnotenergizedwhenrequired,snowwillaccumulate.Ifthesystemisenergizedwhenitisnotneeded,therewillbeunnecessarypowerconsump-tion.Choosethecontrolmethodthatbestmeetstheprojectperformancerequirements.Foradditionalinformation,contactyourThermalManagementrepresentative.

5.1 Manual On/Off ControlAmanuallycontrolledsystemisoperatedbyaswitchthatcontrolsthesystempowercontactor.Thismethodrequiresconstantsupervisiontoworkeffectively.Amanualsystemcanbecontrolledbyabuildingmanagementsystem.

5.2 Slab Sensing ThermostatAslabsensingthermostatcanbeusedtoenergizethesystemwhenevertheslabtemperatureisbelowfreezing,butisnotenergyefficientwhenusedasthesolemeansofcontrol.Theslabsensingthermostatisrecommendedforallsurfacesnowmeltingandanti-icingapplications,evenwhenanautomaticsnowcontrollerisused,andisrequiredforallasphaltandpaverinstallations(forasphalt,itpreventssurfacedamageduetooverheating).

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5.3 Automatic Snow ControllerWithanautomaticsnowcontroller,thesnowmelt-ingsystemisautomaticallyenergizedwhenbothprecipitationandlowtemperaturearedetected.Whenprecipitationstopsortheambienttempera-turerisesabovefreezing,thesystemisde-ener-gized.Inaddition,aslabsensorde-energizesthesystemaftertheslabreachestheslabsensingsetpointeveniffreezingprecipitationisstillpresent.Usinganautomaticsnowcontrollerwithaslabsen-soroffersthemostenergy-efficientcontrolsolu-tion.Foradditionalinformation,refertoFigure4.

CIT-1snow sensor

APS-4C (shown) with SC-40C satellite contactor or APS-3C snow controller

OptionalSC-40Csatellite contactor

To additionalSC-40C satellitecontactors

Optional RCU-3 or RCU-4remote control unit

SIT-6E pavement mounted sensor

RCU-1

Figure 4: Automatic snow melting control system

5.4 ControllersForareaswherealargenumberofcircuitsarerequired,theRaychemACS-30canbeused.TheSurfaceSnowMeltingcontrolmodeintheACS-30includesanExternalDevicecontroloption.ThisoptionallowsaSnow/Moisturesensingcontroller(fromTable5.10)tobeintegratedintotheACS-30system.Notethatsensors(snoworgutter)cannotbedirectlyconnectedtotheACS-30system.RefertotheACS-30ProgrammingGuide(H58692)formoreinformationonsystemsetup.

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TABlE 5: CONTROl SYSTEMS

Description

Slab sensing thermostat

EC-TS

ElectronicslabsensingthermostatforsnowmeltingapplicationshousedinaNEMA4Xenclosurewith2x1/2inconduitentriesforpowerand1glandentryforthesensor.ThetemperaturesetpointandLEDindicatorsforalarm,power,andheat-ingcablestatuscanbevisuallycheckedthroughtheclearlid.Electricalratingis30Aat100–277V,50–60Hz,SPSTswitch.TheEC-TSincludesa25ft(7.6m)sensor.

Automatic snow melting controllers

APS-3C

AutomaticsnowmeltingcontrollerhousedinaNEMA3Renclosureprovideseffective,economicalautomaticcontrolofallsnowmeltingapplications.CSACertified,c-UL-usListed,availablein120Vand208-240V,50/60Hzmodels,24-AmpDPDToutputrelay,adjustablehold-ontimer,andintegralhighlimittemperaturesensorwithanadjustablerangeof40°Fto90°F(4°Cto32°C).Enclosuredimensions:11-1/2inx9-1/8inx6-9/16in(292mmx232mmx167mm)

APS-4C

AutomaticsnowmeltingcontrollerhousedinaNEMA3Renclosureprovideseffective,economicalautomaticcontrolofallsnowmeltingapplications.TheAPS-4Coper-atesuptotenSC-40Csatellitecontactorsforlargerloads.CSACertified,c-UL-usListed,availablein277Vsingle-phase,and208/240,277/480,and600Vthree-phasemodels,built-in3-pole50-Ampcontactor(40-Ampcontactorfor277Vsinglephase),integral30-mAground-faultcircuitinterrupter,adjustablehold-ontimer,andintegralhighlimittemperaturesensorwithanadjustablerangeof40°Fto90°F(4°Cto32°C).Enclosuredimensions:11-1/2inx9-1/8inx6-9/16in(292mmx232mmx167mm)

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Description

Automatic snow melting controllers, continued

SC-40C

Satellitecontactorpowercontrolperiph-eralforanAPS-4Csnowmeltingcontrol-ler,housedinaNEMA3Renclosure.CSACertified,c-UL-usListed,availablein277Vsingle-phase,and208/240,277/480,and600Vthree-phasemodels,built-in3-pole50-Ampcontactor(40-Ampcontactorfor277Vsinglephase),integral30-mAground-faultcircuitinterrupter,andinte-gralhighlimittemperaturesensorwithanadjustablerangeof40°Fto90°F(4°Cto32°C).Enclosuredimensions:11-1/2inx9-1/8inx6in(292mmx232mmx152mm)

Snow melting and gutter de-icing sensors and accessories

CIT-1

Overheadsnowsensorthatdetectspre-cipitationorblowingsnowatambienttemperaturesbelow38°F(3.3°C).ForusewitheitheranAPS-3CorAPS-4Cauto-maticsnowmeltingcontroller.

SIT-6E

Pavement-mountedsensorsignalsfortheheatingcabletoturnonwhenthepave-menttemperaturefallsbelow38°F(3.3°C)andprecipitationinanyformispresent.Microcontrollertechnologyeffectivelyelimi-natesicebridgingwhileensuringaccuratetemperaturemeasurement.ForusewitheitheranAPS-3CorAPS-4Cautomaticsnowmeltingcontroller.

RCU-3

TheRCU-3providescontrolandstatusdis-playtotheAPS–3Ccontrollerfromaremotelocation.Ithasa2,4,6or8hourCYCLETIMEadjustment,independentofAPS-3Csetting.

RCU-4

TheRCU-4providescontrolandstatusdisplaytotheAPS-4CcontrollerandSC-40CSatelliteContactorfromaremotelocation.Ithasa2,4,6or8hourCYCLETIMEadjustment,independentoftheAPS-4CorSC-40Csetting.

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Description

NP

NP

NP

NP

NP

NP

NP

SMPG1

Single-phasepowerdistributionpanelthatincludesground-faultprotection,monitor-ing,andcontrolforsnowmeltingsystems.Single-phasevoltagesinclude208and277V.

Ifstandardconfigurationsdonotmeetyourneeds,customSMPGpanelsareavailableandprocessedunderthecatalognumberSMPG-GENERAL,partnumberP000000763.PleasecontactyourThermalManagementrepresentativeforacustomSMPGpanelquotation.

5.5 Power DistributionFigure5showstypicalwiringschematicsforsingleandgroupcontrolsystems.Forlargesystemswithmanycircuits,aSMPGpanelshouldbeused.RefertoFigure6forthetypicalwiringschematic.

Single circuit control

Temperaturecontroller

1-poleGFEP breaker

1N

G

Heatingcable

øø supply

Heating cable sheath, braid or ground

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Group control

C

Temperaturecontroller

Contactor

1-poleGFEP breaker

N

G (Typ 3)

ø2

ø1

ø3

3-phase 4-wiresupply (WYE)

3-pole mainbreaker

ø

ø 1 supply

N

Heating cable sheath, braid or ground

Figure 5: Typical controller wiring—multiple circuits

NG

Three-polemain contactor

Fuse

Main circuit breaker (optional)

Incomingpower

24 V

One-pole with 30 mAground-fault trip (277 V)

Remote annunciation alarm(circuit breakerwith alarm type #3)

GIT-1

CIT-1

Aerialsnow sensor

Gutterice sensor

Hightemperaturesensor

Single Øconnection

SNOW/ICE

SUPPLY

EUR-5A SNOW SWITCHAUTOMATIC SNOW/ICE MELTING CONTROL PANEL

HEATER

HEATERCYCLE

HOURS

0

45°F

50°F

55°F

60°F65°F

70°F

75°F

80°F

85°F

2

4 6

8

10

TEMPERATURE

Control transformer

Heating cablesheath, braid

or ground

Figure 6: SMPG wiring diagram

26

6 Commissioning and Preventive Maintenance


6.1 ElectroMelt System StartupThestartupofanElectroMeltsystemwillbesimpleiftheheatingcablehasbeeninstalledcarefullyandtestedateachstepasrecommendedinSection3.

Before Applying PowerBeforeapplyingelectricalpowertotheElectroMeltheatingcable,consulttheinstallationtestrecordstoverifythattheheatingcableandthebranchcir-cuitwiringinsulationresistancehavebeentestedat2500Vdcfromthedistributionpanelboard.Thisfinalinsulationresistancetestensuresthatnogroundfaultsexistinthepowerwiringortheheatingcableduetoinsulationdamage.

WARNING: Damaged heating cable can cause arcing or fire. Do not energize damaged heating cable. Repair or replace damaged heating cable prior to applying power.

Verify Insulation Resistance TestVerifythattheentirebranchcircuitincludingtheheatingcablehasaninsulationresistanceof1000megohmsminimumwhentestedwitha2500Vdcmegohmmeter.

Verify Electrical Supply VoltageMeasuretheincomingelectricalsupplytoverifythatthepowertobeconnectedtotheheatingcableis208Vacto277VacforEM2-XRheatingcable.

Visually Inspect Electrical System Visuallyinspectallsystemelectricalcomponents.1. Inspectallwiringforconformancetoapplicable

codes.2. Inspectallwiringforconformancetodesign

drawings.3. Verifyproperratingonallovercurrentprotec-

tiondevices.4. Verifythatthecontactorcoiloperatingvoltageis

correctforcontroldeviceused.5. Verifythatallheatingcableterminationsare

closed,andthatthesnow-meltingequipment

27



labelisaffixedtothecoverofthejunctionboxesanddistributionpanel.

Energize the System ControllerApplypowertothecontroldevice(manualswitch,ambientthermostatorautomaticsnowcontroller).Checkforproperoperation.Donotenergizethesnow-meltingsystemuntilthecontrollerisoperat-ingproperly.Turnthecontrolleroffbeforeapplyingpowertotheheatingcable.

Apply Power to Over Current Protection DevicesTurnonthecircuitbreakersorotherovercurrentprotectiondevices.Testinstalledground-faultpro-tectiondevice,followingtheinstructionspackagedwiththedevice.Iftheground-faultdetectionfeaturedoesnotfunctionproperly,replacethedevicebeforeenergizingtheheatingcable.

Energize the Heating Cable Operatethecontroldevicetoenergizetheheat-ingcable.Ifcircuitbreakersorotherovercurrentprotectiondevicestrip,refertotheTroubleshootingSectionofthismanual.Waitonetothreehoursforthepavementtowarmup.Verifythateachheatingcablecircuitisprovidingheatbytouchingthesur-faceofthepavement.Ifanycircuitisnotheating,verifythatpowerispresentatthebranchcircuitdownstreamofthecontactor,ringoutthebranchcir-cuitwiring,thenconsulttheTroubleshootingsectionofthismanual.

Perform Annual Insulation Resistance TestYoursystemmaybesubjecttoconcretecracking,concretemodificationsandrework,orelectricalmaintenancethatmightaffectthesnow-meltingandanti-icingsystem.Performinsulationresis-tancetestingoneachElectroMeltheatingcablebeforethefirstuseofthesystemeachfalltodetectchangesordamagethatmightaffecttheopera-tionofthesystem.RecordtheresultsoftheannualtestontheformsprovidedinSection9.Repairanydamagedetectedduringannualtest.RefertotheTroubleshootingGuidewhenthemegohmmeterreadingisbelow1000megohmsat2500Vdc.

28



6.2 TestsAbriefdescriptionofeachtestisfoundbelow.DetailedtestproceduresarefoundinSection7.

Visual InspectionVisuallyinspecttheheatingcable,powerconnec-tionsandsplicesforphysicaldamage.Checkthatnomoistureispresent,electricalconnectionsaretightandgrounded,andcontrolandmonitoringsystemsareoperationalandproperlyset.Damagedheatingcablemustbereplaced.

Insulation ResistanceInsulationResistance(IR)testingisusedtoverifytheintegrityoftheheatingcableinnerandouterjackets.

Power CheckThepowercheckisusedincommissioningtocon-firmthatthecircuitisfunctioningcorrectly.

Ground-Fault TestTestallground-faultbreakerspermanufacturer’sinstructions.

29

7 Test Procedures


7.1 System TestsThefollowingtestsmustbedoneafterinstallingtheconnectionkits,butbeforetheconcreteispoured:1. Visualinspection2. Insulationresistancetest

Aftertheconcreteispoured:1. Visualinspection2. Insulationresistancetest3. Circuitlengthverification(Capacitancetest)4. Powertest

Alltestproceduresaredescribedinthismanual.Itistheinstaller’sresponsibilitytoperformthesetestsorhaveanelectricianperformthem.RecordtheresultsintheInstallationandInspectionRecordinSection9.

Visual Inspection Test• Checkallpowerconnectionsandsplicekitsfor

properinstallation,overheating,corrosion,mois-ture,orlooseconnections.

• Checktheelectricalconnectionstoensurethatgroundandbuswiresareinsulatedovertheirfulllength.

• Checkthecontrollerforpropersetpointandoperation.Refertoitsinstallationandoperationmanualfordetails.

Insulation Resistance Test

frequency

Insulationresistancetestingisrequiredduringtheinstallationprocessandaspartofregularlysched-uledmaintenance,asfollows:• Uponreceiptofheatingcable• Priortoinstallation• Aftersplicekits,terminationsorendsealsare

installed• Continuouslyduringconcretepour• Afterconcretepouriscomplete

30

7 Test Procedures


• Afteranystructuralworkormaintenanceisper-formedonconcreteinapplicationarea

• Aspartofscheduledmaintenance

procedure

Insulationresistancetesting(usingamegohm-meter)shouldbeconductedatthreevoltages:500,1000,and2500Vdc.Potentialproblemsmaynotbedetectediftestingisdoneonlyat500and1000volts.Measuretheresistancebetweentheheatingcablebuswiresandthebraid.Donotallowtestleadstotouchjunctionbox,whichcancauseinaccuratereadings.

Important: System tests and regular mainte-nance procedures require that insulation resistance testing be performed. Test directly from the controller or the junction box closest to the power connection.

insulation resistance criteria

Aclean,dry,properlyinstalledcircuitshouldmeasurethousandsofmegohms,regardlessoftheheatingcablelengthormeasuringvoltage(500–2500 Vdc).

Allinsulationresistancevaluesshouldbegreaterthan1000megohms.Ifthereadingislower,consultSection8,TroubleshootingGuide.

31

7 Test Procedures


2500 VdcMegohmmeter

Braid pigtail

Buswires

Figure 7: Insulation resistance test

WARNING: The heating cable can store a large electrical charge after the insulation resistance test is performed. To prevent personal injury from electrical shock, fully discharge the cable prior to disconnecting the megohmmeter. The megohmme-ter may discharge automatically. However, it may be necessary to short the cable leads. Contact your supervisor or the instrument manufacturer to verify the safest practice.

insulation resistance test procedure

1. De-energizethecircuit.2. Disconnectthecontrollerifinstalled.3. Disconnectbuswiresfromterminalblock.4. Settestvoltageat0Vdc.5. Connectthenegative(–)leadtotheheating

cablemetallicbraid.6. Connectthepositive(+)leadtobothheating

cablebuswires.

32

7 Test Procedures


7. Turnonthemegohmmeterandsetthevoltageto500Vdc;applythevoltageforoneminute.Meterneedleshouldstopmoving.Rapiddeflectionindicatesashort.Recordtheinsulationresis-tancevalueintheInspectionRecord.

8. RepeatSteps4–7at1000and2500Vdc.9. Turnoffthemegohmmeter.10. Ifthemegohmmeterdoesnotself-discharge,

dischargephaseconnectiontogroundwithasuitablegroundingrod.Disconnectthemegohmmeter.

11. Reconnectbuswirestoterminalblock.12. Reconnectthecontroller.

Circuit length verification (capacitance test)Connectthecapacitancemeternegativeleadtobothbuswiresandthepositiveleadtothebraidwire.Setthemetertothe200nFrange.Multiplythisread-ingbythecapacitancefactorforthecorrectheatingcableshownbelowtodeterminethetotalcircuitlength.Length(ftorm)=Capacitance(nF)xCapacitancefactor (ft/nForm/nF)

TABlE 6: CAPACITANCE FACTORS

Capacitance factor

Heating cable ft/nF (m/nF)

EM2-XR 5.2 (1.6)

Comparethecalculatedcircuitlengthtothedesigndrawingsandcircuitbreakersizingtables.

Figure 8: Capacitance test

33

7 Test Procedures


Power Check1. Powertheheatingcableandallowittostabilize

for30minutes.2. Verifyinputvoltageandcheckforcurrent.3. Ensurecircuitbreakershavenottripped.

7.2 Fault location TestsTherearethreemethodsusedforfindingafaultwithinasectionofheatingcable.1. Ratiomethod2. Conductancemethod3. Capacitancemethod

Ratio MethodTheratiomethodusesresistancemeasurementstakenateachendoftheheatingcabletoapproxi-matethelocationofabuswireshort.Ashortedheatingcablecouldresultinatrippedcircuitbreak-er.Iftheresistancecanbereadonastandardohmmeterthismethodcanalsobeusedtofindafaultfromabuswiretothegroundbraid.ThistypeofshortwouldtripaGFPDandshowafailedinsulationresistancereading.Measurethebus-to-busheatingcableresistanceateachend(measurementAandmeasurementB)ofthesuspectedsection.

A B

A B

A B

Braid

Figure 9: Heating cable resistance measurement test

Theapproximatelocationofthefault,expressedasapercentageoftheheatingcablelengthfromthefrontend,is:

Faultlocation:D= A x100 ________

(A+B)

Example: A= 1.2ohms B= 1.8ohms

34

7 Test Procedures


Faultlocation:D= 1.2/(1.2+1.8)x100 = 40%

Tolocatealowresistancegroundfault,measurebetweenbusandbraid.

A B

A B

A B

Braid

Figure 10: low resistance ground-fault test


Faultlocation:D= A x100 ________

(A+B)

Example: A= 1.2ohms B= 1.8ohms

Faultlocation:D= 1.2/(1.2+1.8)x100 = 40%

Thefaultislocated40%intothecircuitasmeasuredfromthefrontend.

Conductance MethodTheconductancemethodusesthecoreresistanceoftheheatingcabletoapproximatethelocationofafaultwhentheheatingcablehasbeenseveredandthebuswireshavenotbeenshortedtogether.Asev-eredheatingcablemaynottripthecircuitbreaker.Measurethebus-to-busheatingcableresistanceateachend(measurementAandmeasurementB)ofthesuspectsection.Sinceself-regulatingheatingcablesareaparallelresistance,theratiocalcula-tionsmustbemadeusingtheconductanceoftheheatingcable.

A B

A B

A B

Braid

Figure 11: Heating cable resistance measurement

35

7 Test Procedures



Faultlocation:D= 1/A x100 ________

(1/A+1/B)

Example: A= 100ohms B= 25ohms

Faultlocation:D= (1/100)/(1/100+1/25)x100 = 20%

Thefaultislocated20%fromthefrontendofthecircuit.

Capacitance MethodThismethodusescapacitancemeasurement(nF)asdescribedon"Circuitlengthverification(capacitancetest)"onpage32,toapproximatethelocationofafaultwheretheheatingcablehasbeenseveredoraconnectionkithasnotbeenconnected.

Recordthecapacitancereadingfromoneendoftheheatingcable.Thecapacitancereadingshouldbemeasuredbetweenbothbuswirestwistedtogether(positivelead)andthebraid(negativelead).Multiplythemeasuredcapacitancewiththeheatingcable’scapacitancefactoraslistedinthefollowingexample:

Example: EM2-XR=16.2nF

Capacitancefactor= 5.2ft/nF

Faultlocation = 16.2nFx5.2ft/nF=84.3ft(25.7m)

Theratioofonecapacitancevaluetakenfromoneend(A)dividedbythesumofbothAandB(A+B)andthenmultipliedby100yieldsthedistancefromthefirstend,expressedasapercentageofthetotalheatingcablecircuitlength.SeeTable6onpage32,forcapacitancefactors.

Faultlocation:C= A x100 ________

(A+B)

36

8 Troubleshooting Guide


Symptom Probable Cause Corrective Action

Circuitbreakertrips Circuitbreakerundersized.

Circuitoversized.

Start-upattoolowatemperature.

Re-establishwhatthecurrentloadsaregoingtobeandresizethebreakers.

Checktoseeifexistingbuswiresizingiscompatiblewithlargersizebreaker.

Defectivecircuitbreaker Replacecircuitbreaker.

Connectionsandorsplicesmaybeshortingout.

Physicaldamagetotheheat-ingcablemaybecausingashort.

Locateandrepairtheincorrectconnections.Locateandremovedamagedsectionsofheatingcable.Performinsulationresistancetestperinstallationinstructions.

Tolocateshortingproblems,followthesesteps:1. Visuallyinspectthepowerconnectionsandendsealsfor

properinstallation.2. Checkforvisualindicationsofdamagewheretheremay

havebeenmaintenancework.3. Lookforcrackedordamagedconcreteoranyevidenceof

workontheconcrete.4. Ifyouhavenotlocatedtheproblematthispoint,contact

yourThermalManagementrepresentativeforsuggestionsandassistance.

Buswiresconnectedattheendseal.

Removeendseal,disconnectwires,andinstallanewendseal.

Excessivemoistureinconnec-tionboxesorsplices.

Dryoutandresealconnectionsandsplices.Performinsulationresistancetestperinstallationinstructions.

Nickorcutinheatingcableorpowerfeedwirewithmoisturepresent.

Locateandreplacedamagedpowerfeedwire.

37




Circuitbreakertrips Circuitbreakerundersized.

Circuitoversized.

Start-upattoolowatemperature.

Re-establishwhatthecurrentloadsaregoingtobeandresizethebreakers.

Checktoseeifexistingbuswiresizingiscompatiblewithlargersizebreaker.

Defectivecircuitbreaker Replacecircuitbreaker.

Connectionsandorsplicesmaybeshortingout.

Physicaldamagetotheheat-ingcablemaybecausingashort.

Locateandrepairtheincorrectconnections.Locateandremovedamagedsectionsofheatingcable.Performinsulationresistancetestperinstallationinstructions.

Tolocateshortingproblems,followthesesteps:1. Visuallyinspectthepowerconnectionsandendsealsfor

properinstallation.2. Checkforvisualindicationsofdamagewheretheremay

havebeenmaintenancework.3. Lookforcrackedordamagedconcreteoranyevidenceof

workontheconcrete.4. Ifyouhavenotlocatedtheproblematthispoint,contact

yourThermalManagementrepresentativeforsuggestionsandassistance.

Buswiresconnectedattheendseal.

Removeendseal,disconnectwires,andinstallanewendseal.

Excessivemoistureinconnec-tionboxesorsplices.

Dryoutandresealconnectionsandsplices.Performinsulationresistancetestperinstallationinstructions.

Nickorcutinheatingcableorpowerfeedwirewithmoisturepresent.

Locateandreplacedamagedpowerfeedwire.

38




Snowandicenotmelting. Nopowertoheatingcable. Checkbranchcircuitbreaker.Repairifnecessary.

Checkmaindistributionpowerandcontactorifused.

Checksystemcontroller-thermostatorautomaticsnowcontroller.

Damagedheatingcable. Locateandremovedamagedsectionofheatingcable.Performinsulationresistancetestperinstallationinstructions.

Weatherconditionstooseverefordesign.

Checkperformancespecificationsfororiginaldesign.

Snowandiceslowtomelt. Weatherconditionstooseverefordesign.


Thermaltimedelay. Heatingcablenotenergizedsoonenough.Checksystemcon-trols.Adjustormodifyoperation.

Loworinconsistentinsula-tionresistance

Nicksorcutsintheheatingcable.

Shortbetweenthebraidandheatingcablecore

Checkpower,splice,andendconnectionsforcuts,improperstrippingdistance,andsignsofmoisture.Ifheatingcableisstillaccessible,visuallyinspecttheentirelengthfordam-age,especiallyatelbowsandflangesandaroundvalves.Ifthesystemisinsulated,disconnectheatingcablesectionbetweenpowerkits,splices,etc.,andtestagaintoisolatedamagedsection.

Arcingduetodamagedheat-ing-cableinsulation.

Replacedamagedheating-cablesections.

Moisturepresentinthecon-nectionkits.

Ifmoistureispresent,dryouttheconnectionsandretest.Besureallconduitentriesaresealed,andthatcondensateinconduitcannotenterpowerconnectionboxes.Ifheating-cablecoreorbuswiresareexposedtolargequantitiesofwater,replacetheheatingcable.(Dryingtheheatingcableisnotsufficient,asthepoweroutputoftheheatingcablecanbesignificantlyreduced.)

Testleadstouchingthejunc-tionbox.

Clearthetestleadsfromjunctionboxandrestart.

39




Snowandicenotmelting. Nopowertoheatingcable. Checkbranchcircuitbreaker.Repairifnecessary.

Checkmaindistributionpowerandcontactorifused.

Checksystemcontroller-thermostatorautomaticsnowcontroller.

Damagedheatingcable. Locateandremovedamagedsectionofheatingcable.Performinsulationresistancetestperinstallationinstructions.

Weatherconditionstooseverefordesign.


Snowandiceslowtomelt. Weatherconditionstooseverefordesign.


Thermaltimedelay. Heatingcablenotenergizedsoonenough.Checksystemcon-trols.Adjustormodifyoperation.

Loworinconsistentinsula-tionresistance

Nicksorcutsintheheatingcable.

Shortbetweenthebraidandheatingcablecore

Checkpower,splice,andendconnectionsforcuts,improperstrippingdistance,andsignsofmoisture.Ifheatingcableisstillaccessible,visuallyinspecttheentirelengthfordam-age,especiallyatelbowsandflangesandaroundvalves.Ifthesystemisinsulated,disconnectheatingcablesectionbetweenpowerkits,splices,etc.,andtestagaintoisolatedamagedsection.

Arcingduetodamagedheat-ing-cableinsulation.

Replacedamagedheating-cablesections.

Moisturepresentinthecon-nectionkits.

Ifmoistureispresent,dryouttheconnectionsandretest.Besureallconduitentriesaresealed,andthatcondensateinconduitcannotenterpowerconnectionboxes.Ifheating-cablecoreorbuswiresareexposedtolargequantitiesofwater,replacetheheatingcable.(Dryingtheheatingcableisnotsufficient,asthepoweroutputoftheheatingcablecanbesignificantlyreduced.)

Testleadstouchingthejunc-tionbox.

Clearthetestleadsfromjunctionboxandrestart.

40

9 Installation and Inspection Records


Installation and Inspection RecordFacility

TestDate:

Circuitnumber:

Heatingcabletype:

Controllers:

Temperaturesetting:

Circuitlength:

Commission

Inspection date:

Visual inspection

Confirm30-mAground-faultdevice(properrating/function)

Visualinspectioninsideconnectionboxesforoverheating,corrosion,moisture,looseconnections,andotherproblems.

Properelectricalconnection,ground,andbuswiresinsulatedoverfulllength

Checkcontrollersformoisture,corrosion,setpoint,switchoperation.

Insulation resistance test M-Ohms

Bustobraid(TestA) 500Vdc

1000Vdc

2500Vdc

Circuit length verificationCapacitancetest:Circuitlength(ft)=Capacitance(nF)xCapacitancefactor(x3.28=m)

Power check

Circuitvoltage

Panel (Vac)

Circuitampsafter30minutes (Amps)

41



Installation and Inspection RecordFacility

TestDate:

Circuitnumber:

Heatingcabletype:

Controllers:

Temperaturesetting:

Circuitlength:

Commission

Inspection date:

Visual inspection

Confirm30-mAground-faultdevice(properrating/function)

Visualinspectioninsideconnectionboxesforoverheating,corrosion,moisture,looseconnections,andotherproblems.

Properelectricalconnection,ground,andbuswiresinsulatedoverfulllength

Checkcontrollersformoisture,corrosion,setpoint,switchoperation.

Insulation resistance test M-Ohms

Bustobraid(TestA) 500Vdc

1000Vdc

2500Vdc

Circuit length verificationCapacitancetest:Circuitlength(ft)=Capacitance(nF)xCapacitancefactor(x3.28=m)

Power check

Circuitvoltage

Panel (Vac)

Circuitampsafter30minutes (Amps)

42



ElectroMelt Circuit Schedule

ProjectName:

ElectricalContractor:

CompletionDate:

Circuit Number location Quantity of Splices Panel locationCircuit

Breaker Size Circuit length

43



ElectroMelt Circuit Schedule

ProjectName:


CompletionDate:

Circuit Number location Quantity of Splices Panel locationCircuit

Breaker Size Circuit length

44



Periodic Inspection Record

(Photocopythisscheduleforfutureuse.)

ProjectName:


CompletionDate:

Circuit Number locationMegohmmeter

ReadingCircuit Voltage

Circuit Amperage GFPD Test

Concrete Visual

Inspection

45



Periodic Inspection Record

(Photocopythisscheduleforfutureuse.)

ProjectName:


CompletionDate:

Circuit Number locationMegohmmeter

ReadingCircuit Voltage

Circuit Amperage GFPD Test

Concrete Visual

Inspection

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