This document is a design guide for BARTEC self-regulating trace heating systems, specifically for hazardous and industrial applications. It covers the design, installation, operation, and maintenance of these systems, utilizing BARTEC HSB+ and HTSB self-regulating trace heating cables.
Function Description
BARTEC self-regulating trace heating systems are designed to maintain the temperature of pipes and tanks in hazardous and industrial locations, or to provide frost protection. The core component, the self-regulating trace heater, features a temperature-dependent resistive element between two parallel copper conductors. This element automatically regulates and limits the heat output based on the workpiece temperature. As the workpiece temperature rises, the trace heater's power output decreases, preventing overheating and potential damage. This self-regulating property also allows for safe crossing or overlapping of trace heaters.
A complete trace heating system comprises one or more trace heater units, each consisting of a power termination, a trace heater, and an end termination. These units can be grouped by a common power termination and are associated with specific design and installation documentation. Optional components for temperature control, limitation, and annunciation can be integrated into the system.
Important Technical Specifications
Trace Heaters (HSB+ and HTSB):
- Power Output (at 10 °C):
- HSB+: 15, 30, 45, 60 W/m
- HTSB: 15, 30, 45, 60, 75, 90 W/m
- Nominal Voltage: 110 V to 120 Vac / 208 V to 277 Vac
- Max. Braid Resistance: < 18.2 Ω/km
- Braid Material: Nickel-plated copper
- Min. Bending Radius: 35 mm (do not bend on the narrow axis)
- Cable Weight:
- HSB+: 13.4 kg/100 m
- HTSB: 14.6 kg/100 m
- Heater Dimensions:
- HSB+: 11.4 x 5.2 mm (fluoropolymer outer jacket)
- HTSB: 12.1 x 5.4 mm (fluoropolymer outer jacket)
- Temperature Classes:
- HSB+: T3
- HTSB: T3 (for 5, 10, 15, 20 W/m), T2 (for 25, 30 W/m)
- Max. Continuous Operating Temperature (energized):
- HSB+: 150 °C
- HTSB: 250 °C
- Max. Continuous Exposure Temperature (de-energized):
- HSB+: 225 °C
- HTSB: 250 °C
- Min. Start-up Temperature: -40 °C
- Min. Installation Temperature: -40 °C
- Protection Classification (Ex):
- HSB+: II 2G Ex 60079-30-1 IIC T3 Gb; II 2D Ex 60079-30-1 IIIC T200°C Db
- HTSB: II 2G Ex 60079-30-1 IIC T2, T3 Gb; II 2D 60079-30-1 IIIC T200°C, T300°C, IP 6x Db
Trace Heater Installation Enclosures (Power Box kits):
- Max. Workpiece Temperature (mounting stand): +240 °C
- Ambient Temperature Range: -55 °C to +55 °C
- Min. Installation Temperature: -55 °C (for PBS/PBM/PBTW), -40 °C (for PBTC)
- Ingress Protection: IP 66 (for PBS/PBM/PBTW), IP 64; IP 66 (EN 60529) (for PBTC)
- Maximum Circuit Breaker Size: 32 A (for PBS/PBM/PBTC), 16 A (for PBTW)
- Terminals: Spring clamp Ex e (various configurations depending on model)
- Power Supply: max. 277 Vac
Trace Heater Installation Enclosures (End of Line Light kit and End of Line Seal kit):
- Max. Workpiece Temperature (mounting stand): +240 °C
- Ambient Temperature Range: -55 °C to +40 °C (for ELL-200-E), -55 °C to +55 °C (for ELL-300-E, ELS-200-E)
- Min. Installation Temperature: -55 °C
- Ingress Protection: IP 64; IP 66 (EN 60529) (for ELL-200-E), IP 66 (EN 60529) (for ELL-300-E, ELS-200-E)
- Maximum Circuit Breaker Size: 32 A
- Power Supply: max. 277 Vac
Outer Jacket Materials:
- Polyolefin: Exposure to aqueous, inorganic chemicals (Type key: -CR)
- Fluoropolymer: Exposure to organic chemicals (Type key: -CT)
Usage Features
- Self-Regulating Property: Prevents overheating and allows for safe crossing or overlapping of trace heaters.
- Cut-to-Length: Trace heaters can be cut and installed to any required length up to the maximum heating circuit length.
- Versatile Applications: Suitable for frost protection, temperature maintenance, and temperature raising of pipes and tanks in hazardous locations.
- Hazardous Area Certification: Approved for use in Zone 1/21 and Zone 2/22 areas, with specific Ex classifications for components.
- Flexible Installation: Multiple options for connection, splicing, and end termination with a wide variety of accessories for customization.
- Temperature Control Options: Mechanical thermostats (PBTW-200-E) and electronic controllers (PBTC-200-E) are available for ambient-sensing, line-sensing, and point-sensing temperature control.
- Monitoring Capabilities: Systems can include ground-fault monitoring, high-profile end seals (ELS-200) for troubleshooting, and end-of-line lights (ELL-200) for visual continuity monitoring.
- Design Guide Support: Provides step-by-step instructions for trace heater selection, length determination, circuit number, and component selection.
- Installation Guidelines: Detailed instructions for unrolling, fastening, and routing trace heaters on pipes, valves, flanges, pumps, and tanks, including minimum bending radius and warning label placement.
- Heat Loss Calculation: Tools and tables are provided to determine the effective heat loss of a pipe setup based on diameter, insulation, maintain temperature, and ambient temperature.
Maintenance Features
- Visual and Functional Inspection: Regular checks for physical damage, missing seals, cracks, and proper functioning of components.
- Electrical Inspection: Measurement of insulation resistance to detect damage or installation faults, performed at various stages (preliminary, acceptance, final, commissioning).
- Inspection Intervals: Defined intervals for visual, functional, and electrical inspections to ensure continuous safe operation.
- Personnel Training: Recommendations for personnel training courses to ensure qualified individuals perform maintenance.
- Repair Work: Guidelines for repair work on piping or thermal insulation, emphasizing safety precautions and adherence to design documentation.
- Disposal and Recycling: Instructions for proper disposal of the appliance and its components in accordance with local laws and regulations.
- Troubleshooting Guide: A comprehensive table to diagnose and remedy common issues such as trace heater remaining cold, circuit breaker tripping, and inconsistent insulation resistance.
- High Profile End Seal (ELS-200): Designed for easy access to the end of the heating circuit for troubleshooting and voltage testing.
- End of Line Light (ELL-200): Provides direct visual feedback on circuit continuity, aiding maintenance.
- Spare Parts: Availability of cable gland kits and splice adaptor kits for replacement of damaged or lost parts.
- Documentation: Requirement for system documentation, including planning, installation, commissioning, and maintenance records, to ensure compliance and facilitate future service.
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