Installation systems EKL/EMK for Vessels and Surfaces
Contents
1. Sketch 7 Heating cable coverage with aluminium foil Sketch 8 Installation and Operation BARTEC Fixing material selection chart Self adhesive tape for heating cable type Max temperature Width Roll length Order no Aluminium self adhesive tape EKL 150 C 50 mm 55m 02 5500 0014 Aluminium foil 400 C 1m 100 m 02 2430 0002 Aluminium foil 400 C im 10 m 02 2430 0003 Polyester clamping ring for heating cable fixation EKL 105 C 16 mm 1m 03 6500 0100 Turnbuckle for polyester clamping ring EKL 1 item 03 6515 0203 Accessories Material Width Length P S S clamping ring EMK Stainless steel 3 8 30 m 03 6510 0203 3 4 30 m 03 6510 0204 S S clips clamping ring Stainless steel 3 8 100 items 03 6515 0201 3 4 100 items 03 6515 0202 EKL spacing strip Stainless stee 10 mm 1m 03 6510 0200 EMK spacing strip Stainless stee 12 8 x 0 75 mm 30 m 03 6510 0201 Welding pins Stainless stee 1000 items 03 5470 0002 Galvanized CU 1000 items 03 5470 0001 Spring washers Stainless stee 1000 items 03 5479 0001 Galvanized CU 1000 items 03 5479 0002 Wire mats Stainless steel 1m 25 m 02 2210 0003 Galvanized steel 1m 25 m 03 5479 0002 When selecting the self adhesive tapes and spacing strips observe the maximum surface temperature of the heating cable Mineral insulated heating cables are generally fixed2. C EX version EX EX Temperature class T T Comments Above entries verified City Date Installer Customer BARTEC GmbH Max Eyth StraBe 16 D 97980 Bad Mergentheim Phone 49 0 7931 597 0 Fax 49 0 7931 597 119 Installation and Operation BARTEC 6 Temperature Control Selection of a temperature controller m For operations with single core heating cable systems a temperature controller is always required m When selecting a suitable temperature controller particularly the following technical data must comply with the requirements of the respective application Rated voltage Rated current Temperature control range Max permissible temperature max permissible sensor temperature IP protection Explosion protection if required Type examination certificate m For reasons of an economical power utilisation the use of a controller with surface sensor is in all cases recommendable m Prior to installation verify whether the applied temperature controller complies with the technical requirements and the configuration Room temperature controller m Install a room temperature controller always at the coolest spot of the environment e g north side m Observe the installation instructions of the respective room temperature controller Temperature controller with sensing l
3. Sketch 1 Sketch 2 5 2 2 Installation of the spacing strips m The spacing strips EKL EMK sketch 3a must be attached to the vessel surface by means of the spring washers in accordance with the spacings specified in the configuration sketch 3b Alternatively the spacing strips can be welded to the vessel surface When installing the spacing strips attention must be paid to sharp edges risk of injury O i Ck O O e A U EKL spacing strip O Za A EMK spacing strip 8 Sketch 3a Sketch 3b 5 BARTEC G L cs G L N 5 2 3 Installation of the wire mats m The wire mats must be cut to correspond with the respective shape of the surfaces to be heated These mats are then fixed with a sufficient number of spring washers sketch 4a 4c When installing the wire mats attention must be paid to sharp edges risk of injury If required sharp edges of cutouts must be bent to the inside Sketch 4a Sketch 4b H es Sketch 4c Installation and Operation correct BARTEC 5 2 2 Installation of the heating cable To unroll the heating cable use a stable fixture for the heating cable reel Evenly wind the
4. Ti T2 T3 T4 T5 T6 The temperature limiter s task is to avoid an exceedance of the limit temperature in the tracer heating system e g in case of controller failures or overvoltage by switching off the heating Within this context the selection and installation of the temperature sensor plays a particularly important role As regards the measuring accuracy the selected sensor mass should be as low as possible As a matter of fact the hottest spot in the system is supposedly at the heating cable itself usually at locations where a sound thermal connection of the heating cable to the surface to be heated is hardly possible e g at valves or flanges Artificial hot spot An artificial hot spot is created by fitting a heat insulation between the heating cable and the surface to be heated at which the sensor for the temperature limiter is installed with direct contact to the heating cable sketch 9 m When installing the temperature limiter observe that the sensor is positioned at the hottest system spot Use aluminium to fix the sensor and the heating cable to each other To ensure that the temperature at the artificial hot spot is defin itely higher than the heating cable temperature at spots with minor thermal connection this hot spot must be dimensioned with approx double sensor length m Asa result of the unavoidable heat dissipa mass depends on the heating cable mass pr capacity W m and must b
5. 5 Heating cable or connection line damage Localize the impaired spot and install a new heating cable or connection line 21 22 Installation and Operation 12 3 No or insufficient heating capacity BARTEG Possible cause Measures 1 No or insufficient line voltage 2 Heating circuit length is longer than specified in the configuration a Connections have not been established b The heating cable has been interrupted Control the line voltage at the heating circuit infeed and rectify existing faults Check heating circuit allocation routing and length re calculate required heating capacity a Establish connections and re check the heating capacity b Localize and remove the interruption then re check the heating capacity 3 High transmission resistance due to an improperly installed terminal connection Re install the respective terminal connection etc and ensure for a correct clamping and crimping 4 Temperature controller has been incorrectly connected or set or wrong sensor position Correct the wiring or position the sensor properly 5 Exceedance of the max permissible vessel surface temperature Check the vessel surface temperature 6 Heating cable has been subjected to excessive humidity e g faulty connection or heating cable damage Replace faulty parts 7 Heating cable has been subjected to excessive temperatures Replace the heating cab
6. EKL heating cables also cable ties can be used for heating cable fixation It must however be observed that the cable binder binding wire must not be excessively tightened The heating cable must still be able to move in the loop of the cable binder binding wire sketch 7 When routing the heating cable always observe the minimally permissible bending radius 5 x external diameter for EKL and EMK Example ED heating cable 3 mm Cable spacing Factor bending radius x external diameter heating cable Cable spacing 5x6mm 30mm When routing the heating cable observe that the heating cable can be re routed without any junctions m When routing consider all fixtures and extensions of vessels and surfaces m Both with the EKL as well as with the EMK the heating cable terminations consist of transition sleeves and a connected cold cable For electrical connection the ends of the cold cables are inserted in the terminal box and connected in accordance with the terminal plan If required by the project the entire heated surface is covered with aluminium foil after completion of the installation works sketch 8 BARTEC Installation and Operation Heating cable installation with spacing strip J iat rt l a GJI C J EKL spacing strip Sketch 5 EMK spacing strip Sketch 6 Heating cable installation with wire mats
7. accepted In accordance with the enclosed sample report this acceptance inspection must be documented acceptance inspection m All further inspections must also be documented in the form of an inspection report m After the heat insulation has been completely installed a final inspection of the individual heating circuits is recommendable m Usually such inspection lies in the area of responsibility of the client or the final customer final inspection Commissioning m Each trace heating must only be commissioned if the acceptance certificates are available for each heating circuit and the fault free condition of the trace heating has been confirmed the heat insulation has been completely installed and is in a dry state it is ensured that the heating circuit is operated in compliance with the data specified by BARTEC Note Additional heating energy which is required for heating empty or already filled vessels has usually not been accounted for by the configuration With system cold starts you should therefore grant a sufficient period of time for the vessel to achieve the desired temperature 17 18 Installation and Operation BARTEC Note Electrical equipment must only be operated in hazardous areas if m it is subject to an EC type examination certificate issued by a testing laboratory listed in Section 14 of the 76 117 EEC directive and m thas been marked with the symbol x by the ma
8. by means of stainless steel clamping rings 10 Installation and Operation BARTEC 5 3 Installation of accessories m Only use BARTEC original accessories to comply with existing technical regulations and approvals m Please observe that the use of BARTEC original accessories constitutes a condition for possible warranty claims m Carefully observe the installation instructions and technical notes on the package inserts of the respective accessories This is imperative for a fault free installation 5 3 1 BARTEC system accessories Beside the heating cable the following system accessories are usually required for the complete installation of a heating circuit Heating cable connection system m Cold leads m Fixing accessories for the heating cable m Heat insulation ducts m Warning labels electrically heated Further system accessories may be additionally required m Heating cable connection m Terminal box connection box m Mounting bracket and mounting plate for terminal or connection box m BARTEC control units 5 3 2 Further installation instructions m Prior to installing the power supply lines install the heating cable connections m Install terminal boxes in a freely accessible way m When positioning the terminal boxes make sure that the box entries with cable and heating cable screw connections do not point upwards m When installing connections ensure the existing cable paths can be fu
9. construction site the ends must be effectively protected against humidity e g by installing an end termination Installation and Operation 5 BARTEC Installation 5 1 Installation preparations 5 1 1 Scheduling The installation of the electrical trace heating must be temporally coordinated with other installation works This particularly refers to works carried out at the vessels and surfaces to be heated the electrical installation and heat insulation All installation works at the vessels and surfaces must have been completed m Pressure tests as well as material tests of the piping system should have been terminated prior to installing the electrical trace heating 5 1 2 Inspections prior to installation Measure the installation resistance at the heating cable shortly before starting the installation works Check on the basis of the insulation resistance measuring whether the supplied heating cable length corresponds to the configuration specifications Check whether all material required for the installation of the electrical trace heating is available at the construction site and free of damage gt bove all check whether the identification of the heating cable and the components complies with the configuration documents material list and type examination certificates Check on the basis of the product accompanying installation instructions whether all required tools are completely a
10. faults As the installation costs for the trace heating and the heat insulation exceed the costs for the heating cable by far the following inspection procedures should be consistently followed The insulation resistance is to be measured at the following points of time a Pre inspection Shortly before commencing installation of the heating cable at the construction site b Acceptance inspection After the heating circuit has been completely installed or prior to applying the heat insulation c Final inspection Immediately after the works at the heat insulation have been completed d Commissioning inspection Prior to switching on the system Measuring of the insulation resistance m This inspection procedure serves the detection of heating cable damage and possible installation faults of terminals and connections m An insulation test device with a minimum test voltage of 500 V DC and a maximum test voltage of 2000 V DC is to be used The insulation resistance should be at least 50 MQ per heating circuit irrespective of the length m Measuring The measuring is to be carried out between the heating conductor and the protective braiding A further measuring is to be carried out between the protective braiding and the earthed piping Acceptance and documentation m Upon completion of the installation works prior to applying the heat insulation each heating circuit if possible in the presence of the client must be
11. BARTEC Installation systems EKL EMK for Vessels and Surfaces Installation and Operation Introduction This BARTEC instruction manual for installation and operation is intended to give you important information on electric trace heating systems for pipes Reference is made here only to the use of BARTEC EKL EMK single core heating cables The contents of this manual are intended mainly for persons who are familiar with the planning installation operation and maintenance of electric trace heating systems Reservation Technical data are subject to change without notice Changes errors and printer s errors do not justify claims for damages For safety components and systems the relevant standards and regulations are to be observed as well as the corresponding operating and installation instructions BARTEG Content 1 Introduction 2 2 Important Instructions 2 3 Selection of Heating Cable and configuration 3 4 Storage 3 5 Installation 4 9 5 1 Installation preparations 4 5 2 Installation of the heating cable 5 8 5 3 Installation of accessories 10 5 4 Acceptance and inspection 11 Acceptance certificate 12 6 Temperature Control 13 7 Temperature Limiter 14 8 Heat Insulation 15 9 Power Supply and Electrical Protection Devices 16 10 Inspection and Commissioning 17 11 Operation and Maintenance 18 20 12 Proceeding in Fault Cases 20 22 12 1 Circuit breaker trips 21 12 2 Residual current operated circuit break
12. e considered wh ion of the sensor itself the deviation from the sensor oportion of diameters as well as on the specific heating en setting the limiter temperature m Each EKL EMK heating circuit in hazardous areas must be equipped with a limiter m When using an adjustable temperature lim iter the switch off point must be set at up to T3 min 5K and T2 and T1 min 10K refer to EN 50019 28 below the maximum surface temperature of the temperature class Example For T3 limiter setting 195 C Installation and Operation BARTEC Temperature sensor Artificial hot spot Limiter sensor Sketch 9 8 Heat Insulation Important instruction Prior to fitting the heat insulation verify whether an acceptance inspection of the insulation has been carried out and documented Installation of the heat insulation The reliable functioning and efficiency of an electrical trace heating essentially depends on a proper and professional heat insulation installation The following factors must be particularly observed m Check for the compliance of the heat insulation type insulation thickness with the configuration A heat insulation deviating from the configuration must in no case be installed as otherwise a correct functioning of the trace heating can no longer be guaranteed This must be particularly observed for heating systems of stabilised design m Install the heat insulation immedia
13. ent protection device m For overcurrent protection please only use circuit breakers which comply with the configuration and the technical BARTEC documents Deviations therefrom may result in false tripping of the circuit breaker and impairment of the efficiency of the overcurrent protection m f protection units other than those specified in the configuration or the technical BARTEC documents are to be used please contact the technical department of BARTEC Chapter 12 Residual current operated circuit breaker m Principally the use of a residual current operated circuit breaker with 30 mA is recommended m To ensure for the efficiency of this protection measure a heating cable with protective braiding is to be used This protective braiding must be incorporated into the protection measures this particularly applies to all trace heatings connected to non conducting pipes plastic pipes coated pipes and surfaces Caution m When implementing the electrical protection measures the respectively applicable national technical regulations must be adhered to In the Federal Republic of Germany VDE regulations particularly DIN VDE 0100 DIN VDE 0254 and EN 60519 Installation and Operation BARTEC 10 Inspection and Commissioning Inspections Continuing inspections of the trace heating during installation and operation serve the prevention of additional costs accruing from a belated detection of installation and mounting
14. er trips 22 12 3 No or insufficient heating capacity 22 12 4 Heating capacity seems to be correct the pipe temperature however 22 does not reach the desired temperature The BARTEC warranty only applies if all provisions and recommendations of the manual and the product accompanying installation and mounting instructions are strictly adhered to This particularly applies to the above mentioned instructions Installation and Operation BARTEC 1 Introduction The present BARTEC manual for installation maintenance is to provide you with important information on electrical trace heatings for vessels and surfaces It exclusively applies to the use of m BARTEC EKL flexible single core heating cables as well as m BARTEC EMK single core mineral insulated heating cables The content of this manual is particularly directed towards persons who are entrusted with the planning erection operation and maintenance of electrical trace heatings This manual applies to the following BARTEC products BARTEC EKL heating cables type 27 582 5512 BARTEC EKL light heating cables type 27 582 5514 BARTEC EKL EX heating cables type 27 582 5518 BARTEC EKL standard connection kits type 27 5673 1 BARTEC EKL EX termination kits type 27 5671 2 BARTEC EMK heating cables type 27 383 20 Pre assembled EMK heating circuits EX Standard Pre assembled EMK heating loops EX Standard type 27 361 m Ins
15. heating cable off the reel sketch 5 Avoid extensive pulling as well as bending and crimping of the heating cable When rolling the heating cable off the reel observe that the cable does not run over corners or sharp edges Do not step on the heating cable Do not use the heating conductor as a stepping loop Do not drive over the heating cable with a vehicle and keep other people from driving over the cable wrong Sketch 5 EMK heating cable Starting at the terminal box the heating cable is routed over the surface to be heated in loops and 8 fixed by means of the EMK or EKL spacing strip attached beforehand sketch 5 With the EMK spacing strip the heating cable is routed beneath pre punched lugs which are then bent or tilted over the heating cable With the EKL the heating cable is installed in the provided terminals sketch 6 Prior to routing the heating cable the spacing strips are fixed to the surface to be heated by means of fixing pins and locking washers attached beforehand or by means of welding For this purpose the surface is punctually cleaned in accordance with the partitioning to prepare the fixing pins welding by means of the weld clamp refer to 5 2 1 5 2 2 Or fixed to the vessel surface by means of wire mats installed beforehand The EKL EMK heating cables are fixed to the wire mats by means of binding wire which is twisted together with the help of combination pliers or a different tool When using
16. ine m With surface heatings the temperature sensor should not be positioned directly at the heating cable sketch 9 m When fixing the temperature sensor a sound heat transmission between the sensor and the surface must be ensured e g by using an aluminium self adhesive tape or heat transfer compound m Observe the installation instructions of the respective temperature controller m f the position of the temperature controller should not be defined by configuration please contact the technical department of BARTEC Chapter 12 where you will get expert advise Further installation instructions m During installation keep the casing of temperature controllers closed as long as possible to prevent dirt and humidity from intruding m Ensure for a proper fixing of the casing cover and a close sealing m Use suitable screw connections and filler plugs in accordance with the technical requirements and type examination certificates and check for their impermeability 13 Installation and Operation 7 Temperature Limiter BARTEC For all single core heating cable systems of monitored design EKL or EMK a temperature limiter must be used in hazardous areas A limiter permanently switches off the heating circuit upon exceedance of the limit temperature The temperature limiter must be installed at the hottest spot Maximum surface temperature Temperature class 450 C 300 C 200 C 135 C 100 C 85 C
17. le 8 Temperature limiter has tripped Check and if required replace heating circuit 10 4 Heating capacity seems to be correct the pipe temperature however does not reach the desired temperature Possible cause Measures 1 Damp heat insulation Replace the damp heat insulation by a dry one and ensure for a correct sealing 2 Insufficient fit of the heating cable routing with flanges valves and controls and instruments Use an additional heating cable by means of connections while not exceeding the max permissible heating circuit length 3 Incorrect setting of the temperature controller Correct the controller setting 4 Insufficient thermal dimensioning Check the dimensioning in co operation with the technical department of BARTEC and observe the recommendations of the BARTEC planning department 5 The connection line cross section underruns the permissible value excessive voltage drop Use a connection line with a permissible cross section 6 Wrong sensor position Position the sensor correctly BARTEC protects people and the environment by the safety of components systems and plants BARTEC GmbH Max Eyth StraBe 16 D 97980 Bad Mergentheim Phone 49 7931 597 0 Fax 49 7931 597 494 BARTEC info bartec de www bartec de UK D BEH240604 08 04 BARTEC WerbeAgentur 232188
18. maintenance of process temperatures inspections should be carried out in regular intervals however at least twice a year Personnel training m The regular maintenance works should be carried out by trained and experienced maintenance personnel m You are recommended to support maintenance personnel with the implementation of new developments in the fields of application technology and maintenance by training measures BARTEC service m Apart from establishing complete heating circuits BARTEC also offers its experienced service personnel for accruing maintenance works Servicing works at the heat insulation and pipings m Observe that the system is to be activated prior to each servicing procedure m Ensure not to damage the trace heating system during servicing works at the vessel or the heat insulation m Make sure that upon completion of servicing works the heating circuits including heat insulation are properly and professionally installed in accordance with the configuration m Upon completion of servicing works carry out a visual functional and electrical check at the trace heating and document such checks Note The operation and consequently the maintenance of explosion protected operating equipment and systems are subject to the respectively applicable EC standards and directives the national regulations as well as the respectively valid safety regulations For example EN 50110 German occupational safety regulati
19. n of the heating cable as well as that of terminals and connections into the piping documentation m Measure the insulation resistance in all heating circuits before installing the heat insulations Chapter 9 m The correct installation and functioning of the electrical trace heating must be confirmed by means of an acceptance certificate refer to the following sample form m With stabilised design verify the conditions stipulated in the project documentation for compliance 11 Acceptance Certificate BARTEC Electrical trace heatings Vessel heatings Sheet Heating circuit Customer Date Order Comm No Project system BARTEC order No Serial No Heating circuit No Pipe vessel No Product Heating cable Type Installation number Heating cable length Voltage Current Switch on Operation gt gt lt 53 gt gt lt 3 gt gt lt 3 Capacity W m W m W m Resistance Cold LO gt Q Q Hot _ O _ Q S 9 Insulation resistance Setpoint gt 5 MQ with 1000 V measured voltage gt Mo gt MQ gt MQ Temperature setting Function check Function check Function check yes no yes no yes no Controller C C Limiter C C Low temperature
20. nufacturer m it complies with the respectively applicable EC standards and directives the national regulations as well as with the respectively applicable safety regulations Example German occupational safety regulations BetrSichV EN 50014 EN 50019 11 Operation and Maintenance Operation m During the operation of the electrical trace heating it must be ensured that all system components are operated in compliance with the operating data specified by BARTEC This particularly applies to the observance of maximum temperatures Operation within the range of these operating data forms a condition for possible future warranty claims System documentation m For each system a complete documentation ranging from configuration to installation and commissioning to periodical maintenance works of a trace heating should be kept m Such documents should include Configuration documents Heat loss calculation Selection of the heating cable System plans with heating circuit allocation Circuit diagrams Acceptance certificates Reports on servicing works and interventions with vessels and surfaces the trace heating and the heat insulation Inspection reports Operating manual Maintenance To allow for the best possible safety and reliability of a trace heating system BARTEC recommends the implementation of a maintenance program which provides for visual functional and electrical checks within specified time intervals Im
21. o the trace heating or the adjacent installation meet the electrical mechanical thermal chemical requirements m Has electrical equipment been selected for installation in hazardous areas for which an EC type examination certificate or a conformity certificate is available If a respective configuration documentation is not provided for we recommend a verification of the above mentioned points on the basis of the BARTEC product documentation Should any questions arise during the examination of configuration documents we recommend you to contact the BARTEC technical department Thanks to their comprehensive system know how and a DP supported configuration our expert team will provide you with assistance For the address of our technical department please refer to Chapter 12 4 Storage Incoming goods m Compare the delivery note with the supplied goods m Examine the supplied heating cables and accessory components for possible transport damage Storage m Store heating cables and connection components at a clean and dry location m During storage particularly contact with chemicals and petrochemical products must be effectively avoided m t must be ensured that the heating cables are protected against mechanical damage during storage m The storage temperature is specified in the respective data sheets and must be observed m Even if heating cables and connection components are only shortly stored in damp rooms or at a
22. ons BetrSichV German law on device safety GSGV In Germany the operator must assure that the electrical systems are commissioned inspected and maintained in accordance with the German occupational safety regulations BetrSichV 19 20 BARTEC Installation and Operation 12 Proceeding in Fault Cases Damage in the heating circuit m Never try to repair any damaged heating cables Immediately replace the damaged part of the heating cable by a new one risk of fire m For servicing the heating circuit only use original BARTEC components e g connections terminals sealings etc Instructions for the rectification of faults m f faults occur in the trace heating system we recommend troubleshooting in accordance with the following instructions and if applicable rectification of the fault m f the rectification measure in accordance with the following instructions is not successful please immediately contact the technical department of BARTEC Note For hazardous areas the following provisions are applicable Servicing and modification works at electrical systems during which an explosive atmosphere can be ignited may only be carried out with the approval of the plant manager or a respectively authorised person The most important safety measure is to create and ensure for a voltage free condition prior to commencing works refer to the respectively applicable standards and regulations An a
23. portant maintenance instructions are listed in the following sections Installation and Operation BARTEC Visual and functional check m Carefully check the heat insulation for possible damage lacking sealings cracks outer sheath damage lacking heat insulation ducts for heating cables and other cables intruded water or chemicals lf the heat insulation is subject to damage the heating cable must be checked for possible impairments Damaged heating cables must be replaced by new ones m Wear parts e g sealings locking plates etc must be replaced m Check the terminal boxes connection boxes and casings of temperature controllers for corrosion damage and possible mechanical impairments Make sure that all casing covers are correctly locked m Check the temperature controller s safety temperature limiter s connecting cables and capillary tube systems for damage and mechanically protected routing m Temperature controllers must be checked for their correct functioning m f no safety temperature limiters with permanently adjusted switch off value are applied they must also be checked for their correct functioning Electrical inspection m The measuring of the insulation resistance should be considered as an inherent part of the regular maintenance works Inspection intervals m With anti freeze systems inspections should be carried out annually before the heating period m With systems serving the
24. rther used m During installation keep the terminal boxes closed as long as possible to provide protection against dirt and humidity m Check for a proper establishment of the termination system and the correct functioning of the heating circuit by measuring the insulation and the loop resistance Chapter 9 After the installation of boxes check whether suitable and approved screw connections and filler plugs have been used and whether they have been properly installed for a tight fit of screw connections and filler plugs for a tight fit of the box at the mounting bracket Ensure whether the requirements stipulated in the type examination certificates have been met Installation and Operation 5 4 Acceptance and inspection a Caution Prior to fitting the heat insulation the installed heating circuits must inspected Inspection process m Prior to the correct routing of the heating cable particularly observe that the heating cable fits tightly with the vessel surface a the heating cable does not show any contact points or junctions 8 the heating cable does not show any damage BARTEC be m Check for a proper installation of terminals connections and terminal boxes as well as temperature controllers and sensors visual check m Check for a proper installation of the limiter sensor mandatory for heating circuits areas aS well as for the limiter setting in hazardous m Enter the positio
25. tallation accessories 2 Important Installation and Maintenance Instructions Observance of the following instructions is imperative when installing and maintaining BARTEC EKL and BARTEC EMK heating cables and their respective installation systems Non observance of these instructions may imply serious hazards for both personnel and system components For the installation and maintenance of electrical trace heatings the respective applicable EC standards and directives the national regulations as well as the respectively valid safety regulations must be complied with Examples of applicable standards and directives DIN VDE 100 EN 50110 1 2 VBG A2 EN 60519 Please particularly observe the respective applicable EC standards and directives the national regulations as well as the respectively valid safety regulations for the application of electrical trace heatings in hazardous areas Examples of the valid standards and directives for the application of electrical trace heatings in hazardous areas EN 60079 14 94 9 EC Directive 1999 92 EC Directive BetrSichV German occupational safety regulations m Improper installation of the trace heating and the adjacent system componen damage may bear the risk of short circuits and fire during operation s or heating cable m When using an EKL or EMK heating cable in hazardous areas a temperature monitor as well as a temperature limiter must always be applied given no de
26. tely after the installation of the trace heating to minimise the risk of heating cable damage m Only use dry insulation material Humidity reduces the efficiency of insulation material and thus impairs the function of the trace heating m When installing the heat insulation always take care not to damage the heating cable m Only use BARTEC heat insulation ducts for the ducting of heating and connection cables m Seal the heat insulation at all welds of the steel jacket and entries valve entries Suspenders The entire insulation must be reliably water proof m After installation of the heat insulation measure the insulation resistance at all heating circuits once more to ensure that the heating cable has not been damaged during the installation Marking m Mark the outer sheath of the heat insulation with electrically heated warning labels in clearances of maximally 3 meters in order to draw the attention of maintenance personnel to the electrical trace heating 15 Installation and Operation BARTEC 9 Power Supply and Electrical Protection Devices Rated voltage m BARTEC heating cables are available for various rated voltages Respective information is available in the BARTEC catalogue and from the technical department of BARTEC m Operate the respective heating cable only with the rated voltage provided for The rated voltage is stated on the computer print out of the heating cable layout Overcurr
27. uthorization for the execution of hot works is required and when working with hot surfaces flames respective protection measures must be taken Installation and Operation 12 1 Circuit breaker trips BARTEC Possible cause Measures 1 Underdimensioned circuit breaker 2 Excessive heating circuit length 3 Switch on at too low temperatures observe configuration data Check the current load the overcurrent protection fuse and the max current carrying capacity of the electrical supply line 4 Faulty RCCB Replace the RCCB 5 Short circuit ground fault at terminal connection s connection lines heating cable due to damage Localize and repair faulty terminal or connection or localize and replace the faulty heating cable 12 2 Residual current operated circuit breaker RCCB trips Possible cause Measures 1 Underdimensioned circuit breaker 2 Faulty RCCB 3 Short circuit ground fault at terminal connection s connection lines heating cable due to damage Check the current load the overcurrent protection fuse and the max current carrying capacity of the electrical supply line 4 Excessive humidity in terminal or connection s due to improper and unprofessional installation Localize damp spot s replace the terminal block and dismount affected parts first check and repair casings outside and then casings underneath the heat insulation
28. vailable m Plan the routing of the heating cable by inspecting the vessel surface to be heated m Within this context pay attention to sharp edges and uneven sur aces which may damage the heating cable and remove them Varnished and painted vessels and surfaces must be completely dry before starting installation works Verify whether the actual surface to be heated complies with the calculated surface m Prior to routing the heating cable verify whether the vessel surface dimensions comply with the dimensions used for design dimensioning Only cut the heating cable to length after it has been routed and fixed in accordance with the design dimensioning Installation and Operation BARTEC 5 2 Installation of the heating cable 5 2 1 Routing of the heating cable installation of the fixing accessories spacing strip wire mats m Approx 25 fixing pins per square meter must be attached to the surface to be heated by means of spot welding m The points for the welding spots on the surface to be heated must be cleaned by means of an angle grinder or a similar device sketch 1 m Then the fixing pins are welded to the surface by means of spot welding sketch 2 m Following this the welding points and the blank surfaces must be varnished with a corrosion protection paint After the coating has dried the fixing strip can be installed Cleaned surface Fixing pins
29. viating provisions were specified during the dimensioning and selection of the system m Protect both ends of the single core heating cable against environmental impact m Junctions or contact points of the single core heating cables are impermissible as the limit temperature of the temperature class or the max permissible operating temperature of the heating cable would be exceeded m To ensure a proper installation of BARTEC single core heating cables we recommend the use of BARTEC connection systems Such systems have been specifically developed for BARTEC heating cables and have been tested and approved by test institutes Installation and Operation BARTEG 3 Selection of the Heating Cable and Configuration Prior to any installation of electrical trace heatings the installer must check whether the trace heating has been properly configured Particularly the following aspects must be verified m s an accurate configuration documentation and operation manual available m Does the selected heating cable meet the respective requirements This particularly refers to calculated heat loss temperature class specified in the type examination certificates max permissible operating temperature max permissible ambient temperature m Does the used pipe length exceed or underrun the calculated length m Has a connection system been selected which complies with the requirements m Does further material which belongs t
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