Raychem XL-Trace - User Manual

2. Fire Sprinkler
System Freeze Protection
1. Pipe Freeze
Protection and Flow Maintenance
3. Roof and Gutter
De-Icing
4. Surface Snow
Melting – MI
5. Surface Snow
Melting and Anti- Icing – ElectroMelt
6. Freezer Frost
Heave Prevention
7. Floor Heating 8. Technical Data
Sheets
H55838 2/12 www.tycothermal.com 1 of 44
Pipe Freeze Protection
and Flow Maintenance
This step-by-step design guide provides the tools necessary to design a Raychem XL-Trace
pipe freeze protection or flow maintenance system. For other applications or for design
assistance, contact your Tyco Thermal Controls representative or phone Tyco Thermal
Controls at (800)545-6258. Also, visit our web site at www.tycothermal.com.
Contents
Introduction ..............................................................1
How to Use this Guide ....................................................2
Safety Guidelines ........................................................2
Warranty ...............................................................3
System Overview ..........................................................3
XL-Trace Applications .....................................................3
Self-Regulating Heating Cable Construction ....................................4
Pipe Freeze Protection Applications ...........................................5
Typical Pipe Freeze Protection System ........................................5
General Water Piping .....................................................6
Fire Sprinkler Systems ....................................................8
Flow Maintenance Applications ...............................................9
Typical Flow Maintenance System ...........................................9
Greasy Waste Lines .....................................................10
Fuel Lines .............................................................12
Pipe Freeze Protection and Flow Maintenance Design .............................13
Design Step by Step .....................................................13
Step 1 Determine design conditions and pipe heat loss .....................13
Step
2 Select the heating cable .......................................18
Step
3 Determine the heating cable length ..............................20
Step
4 Determine the electrical parameters .............................. 22
Step
5 Select the connection kits and accessories ........................26
Step
6 Select the control system ...................................... 31
Step
7 Select the power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step
8 Complete the Bill of Materials ...................................36
XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet ......37
Introduction
Raychem XL-Trace is designed for pipe freeze protection and flow maintenance in the
following applications:
• Freeze protection of general water piping (aboveground and buried)
• Freeze protection of fire sprinkler systems (aboveground and buried supply pipes)
• Flow waste lines (aboveground and buried)
• Flow maintenance of fuel lines (aboveground)
XL-Trace System

Summary

Introduction and Overview

How to Use This Guide

Guidance on how to effectively use the XL-Trace design guide for system design.

Safety Guidelines

Essential safety information and warnings for installing and maintaining the heating cable system.

Warranty Information

Details on the Tyco Thermal Controls standard limited warranty and its extension.

System Overview

Provides a general understanding of the XL-Trace system and its components.

XL-Trace Applications

General Water Piping

Details on freeze protection for general water piping, aboveground and buried.

Fire Sprinkler Systems

Information on XL-Trace for freeze protection of fire sprinkler system standpipes and piping.

Greasy Waste Lines

Covers flow maintenance for greasy waste lines, aboveground and buried.

Fuel Lines

Details on flow maintenance for aboveground #2 fuel oil lines.

Pipe Freeze Protection and Flow Maintenance Design Process

Step 1: Determine Design Conditions and Pipe Heat Loss

Collecting data to establish design conditions and calculate pipe heat loss.

Step 2: Select the Heating Cable

Selecting the appropriate XL-Trace heating cable based on power output and temperature ratings.

Step 3: Determine Heating Cable Length

Calculating the total required heating cable length, including allowances for components.

Step 4: Determine Electrical Parameters

Calculating circuit requirements, maximum circuit length, and transformer load.

Step 5: Select Connection Kits and Accessories

Choosing the necessary connection kits, splices, tees, and accessories for the system.

Step 6: Select the Control System

Identifying suitable thermostats, controllers, and sensors for system operation.

Step 7: Select Power Distribution

Choosing the method for providing power to the heating cable circuits.

Step 8: Complete the Bill of Materials

Finalizing the list of all required components for the XL-Trace system.

Raychem XL-Trace Specifications

General

Description	Self-regulating heating cable for freeze protection and temperature maintenance
Application	Freeze protection or temperature maintenance of process pipes, tanks, and equipment
Voltage	120V, 240V, 277V, 480V
Operating Temperature	Up to 150°F (65°C)
Maximum Continuous Exposure Temperature	150°F (65°C)
Minimum Installation Temperature	-40°C (-40°F)
Approvals	ATEX, IECEx
Sheath Material	Fluoropolymer