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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
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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 General Information
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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 General Information
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1.5 WarrantyThermalManagement'standardlimitedwarrantyappliestoallproducts.Anextensionofthelimitedwarrantyperiodtoten(10)yearsfromthedateofinstallationisavailableifaproperlycompletedonlinewarrantyformissubmittedwithinthirty(30)daysfromthedateofinstallation.Youcanaccessthecompletewarrantyonourwebsiteatwww.pentairthermal.com.
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2 Pre-Installation Checks
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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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2 Pre-Installation Checks
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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.
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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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3 Heating Cable Installation
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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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TABlE 2: ElECTROMElT SElF-REGUlATING HEATING CABlE
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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TABlE 2: ElECTROMElT SElF-REGUlATING HEATING CABlE
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 Power Supply and Electrical Protection
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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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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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TABlE 5: CONTROl SYSTEMS
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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5 Control, Monitoring and Power Distribution
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
TABlE 5: CONTROl SYSTEMS
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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5 Control, Monitoring and Power Distribution
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
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6 Commissioning and Preventive Maintenance
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
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6 Commissioning and Preventive Maintenance
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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.
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6 Commissioning and Preventive Maintenance
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6.2 TestsAbriefdescriptionofeachtestisfoundbelow.DetailedtestproceduresarefoundinSection7.
Visual InspectionVisuallyinspecttheheatingcable,powerconnec-tionsandsplicesforphysicaldamage.Checkthatnomoistureispresent,electricalconnectionsaretightandgrounded,andcontrolandmonitoringsystemsareoperationalandproperlyset.Damagedheatingcablemustbereplaced.
Insulation ResistanceInsulationResistance(IR)testingisusedtoverifytheintegrityoftheheatingcableinnerandouterjackets.
Power CheckThepowercheckisusedincommissioningtocon-firmthatthecircuitisfunctioningcorrectly.
Ground-Fault TestTestallground-faultbreakerspermanufacturer’sinstructions.
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
• 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.
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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.
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
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7 Test Procedures
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
Theapproximatelocationofthefault,expressedasapercentageoftheheatingcablelengthfromthefrontend,is:
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
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
Theapproximatelocationofthefault,expressedasapercentageoftheheatingcablelengthfromthefrontend,is:
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
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 17/09
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.
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8 Troubleshooting Guide
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 17/09
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.
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8 Troubleshooting Guide
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 17/09
Symptom Probable Cause Corrective Action
Snowandicenotmelting. Nopowertoheatingcable. Checkbranchcircuitbreaker.Repairifnecessary.
Checkmaindistributionpowerandcontactorifused.
Checksystemcontroller-thermostatorautomaticsnowcontroller.
Damagedheatingcable. Locateandremovedamagedsectionofheatingcable.Performinsulationresistancetestperinstallationinstructions.
Weatherconditionstooseverefordesign.
Checkperformancespecificationsfororiginaldesign.
Snowandiceslowtomelt. Weatherconditionstooseverefordesign.
Checkperformancespecificationsfororiginaldesign.
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
8 Troubleshooting Guide
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 17/09
Symptom Probable Cause Corrective Action
Snowandicenotmelting. Nopowertoheatingcable. Checkbranchcircuitbreaker.Repairifnecessary.
Checkmaindistributionpowerandcontactorifused.
Checksystemcontroller-thermostatorautomaticsnowcontroller.
Damagedheatingcable. Locateandremovedamagedsectionofheatingcable.Performinsulationresistancetestperinstallationinstructions.
Weatherconditionstooseverefordesign.
Checkperformancespecificationsfororiginaldesign.
Snowandiceslowtomelt. Weatherconditionstooseverefordesign.
Checkperformancespecificationsfororiginaldesign.
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
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
9 Installation and Inspection Records
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
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
9 Installation and Inspection Records
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
ElectroMelt Circuit Schedule
ProjectName:
ElectricalContractor:
CompletionDate:
Circuit Number location Quantity of Splices Panel locationCircuit
Breaker Size Circuit length
43
9 Installation and Inspection Records
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
ElectroMelt Circuit Schedule
ProjectName:
ElectricalContractor:
CompletionDate:
Circuit Number location Quantity of Splices Panel locationCircuit
Breaker Size Circuit length
44
9 Installation and Inspection Records
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
Periodic Inspection Record
(Photocopythisscheduleforfutureuse.)
ProjectName:
ElectricalContractor:
CompletionDate:
Circuit Number locationMegohmmeter
ReadingCircuit Voltage
Circuit Amperage GFPD Test
Concrete Visual
Inspection
45
9 Installation and Inspection Records
Raychem-IM-H58086-ElectroMeltSnowMeltingCOM-EN 18/01
Periodic Inspection Record
(Photocopythisscheduleforfutureuse.)
ProjectName:
ElectricalContractor:
CompletionDate:
Circuit Number locationMegohmmeter
ReadingCircuit Voltage
Circuit Amperage GFPD Test
Concrete Visual
Inspection
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