Tracing Design Guide

Chromalox
PRECISION HEAT AND CONTROL
Electrical Heat Tracing Systems Design Guide
INTRODUCTION
TABLE OF CONTENTS
TABLE OF CONTENTS
Thermal Design - Pipes: . . 1 Thermal Design - Tanks:. . 6 Heating Cable Selection: . 8
Mineral Insulated Cable Design: . . . . . . . . . . . . . 17 Electrical Design: . . . . . . 18
Component Selection and Accessories: . . . . . . 24 Control Selection:. . . . . . 32
This design guide provides a step-by-step approach for the design, specification, and selection of a bill of materials for an electric heat tracing system. Electric heat tracing systems are designed to make up for the heat lost from process system equipment through the thermal insulation. In some cases, the heat tracing system can be used for system heat-up at initial startup or after a power shutdown. The information in this design guide will allow the user to design, specify, and select a complete bill of materials for freeze protection or process maintenance applications for a piping system or tank. By following the steps in this guide the user can easily select a complete bill of materials for the system, including heating cable, connection accessories, and temperature controls.
IntelliTRACE Controls . . . 36
THERMAL DESIGN PIPES

The first step in designing a heat trace system is to determine the heat loss from each pipe or tank to be traced. Collect the following data for each pipe (for tank applications go to page 6). Then follow the steps below to determine the heat loss. Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Nominal Pipe/ Tubing Size, DP: Additional Safety Factor, if required: Thermal Insulation Type and Thickness:
Example: Step 3. Adjust for Insulation
Table 1 (page 2) is based on ASTM C547 Fiberglas insulation. QP, as found in the step above, must be adjusted for the insulation type. Multiply your heat loss by Ia, the Insulation Adjustment Factor, from the values in Table 2 (page 5). QF = QP x Ia For Cellular Glass, Ia = 1.48 English QF = 3.3 W/ft x 1.48 = 4.88 W/ft Metric QF = 10.8 W/m x 1.48 = 15.98 W/m
English Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Nominal Pipe/ Tubing Size, DP: Additional Safety Factor, if required: Thermal Insulation Type and Thickness:
Example:
40F -20F Outdoor 10 mph 3" Steel None 2" Cellular Glass
Step 4. Correct for Indoor Location/ Windspeed
If location is indoors multiply QF by 0.9.

Step 5. Correct for Additional Safety Factor
Table 1 is based on 10% safety factor and 20 mph (32 kph) windspeed, add 5% margin for each 5 mph (8 kph) over 20 mph (32 kph).
Metric Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Nominal Pipe/ Tubing Size, DP: Additional Safety Factor, if required: Thermal Insulation Type and Thickness:
Step 1. Calculate T
4.4C -28.9C Outdoor 16 kph 76 mm Steel None 51mm Cellular Glass
T = Tm - Ta English = 40F - (-20F) = 60F Metric = 4.4C - (-28.9C) = 33.3C

Step 2. Determine Pipe Heat Loss
Find QP in Table 1 (page 2) for the nominal pipe size and insulation thickness based on T. For example, for a 3" (76 mm) pipe with 2" (51 mm) insulation and T = 60F (33.3C), the value for QP is 5.5 W/ft (10.8 W/m).
THERMAL DESIGNPIPES
THERMAL DESIGN-PIPES
1
THERMAL DESIGNPIPES
Table 1 Pipe Heat Loss (QP) in W/ft and W/m Based on Temperature Differential and Insulation Thickness
Nominal Pipe Size, 50F 60F in. (ID) DegF 40F mm (OD) DegC 23.0C 28.0C 33.4C Si Temperature Difference Between Pipe and Ambient
70F 39.0C 80F 44.5C 90F 50.0C 100F 55.6C 120F 66.7C 140F 77.8C 160F 180F 200F 220F 240F 260F
88.9C 100.0C 111.1C 122.2C 133.4C 144.5C
1" (25.4 mm) Insulation Thickness

1
/2"
W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m W/ft W/m
1.4 4.6 1.6 5.2 1.8 5.9 2.4 7.9 2.8 9.2 3.2 10.5 3.7 12.1 4.6 15.1 6.4 21.0 8.1 26.6 9.9 32.5 11.6 38.1 12.6 41.3 14.3 46.9 16.0 52.5 17.7 58.1 19.4 63.7 21.1 69.2
1.8 5.9 2.0 6.6 2.3 7.5 3.1 10.2 3.5 11.5 4.0 13.1 4.7 15.4 5.8 19.0 8.0 26.2 10.1 33.1 12.4 40.7 14.5 47.6 15.8 51.8 17.9 58.7 20.1 65.9 22.2 72.8 24.3 79.7 26.4 86.6
2.1 6.9 2.4 7.9 2.8 9.2 3.7 12.1 4.1 13.5 4.8 15.7 5.6 18.4 6.9 22.6 9.6 31.5 12.1 39.7 14.8 48.6 17.4 57.1 19.0 62.3 21.5 70.5 24.1 79.1 26.6 87.3 29.1 95.5 31.6 103.7
2.5 8.2 2.8 9.2 3.2 10.5 4.3 14.1 4.8 15.7 5.6 18.4 6.5 21.3 8.1 26.6 11.2 36.7 14.1 46.3 17.3 56.8 20.3 66.6 22.1 72.5 25.1 82.4 28.1 92.2 31.0 101.7 34.0 111.6 36.9 121.1
2.8 9.2 3.2 10.5 3.7 12.1 4.9 16.1 5.5 18.0 6.4 21.0 7.4 24.3 9.2 30.2 12.8 42.0 16.2 53.2 19.8 65.0 23.2 76.1 25.3 83.0 28.7 94.2 32.1 105.3 35.4 116.1 38.8 127.3 42.2 138.5
3.2 10.5 3.6 11.8 4.1 13.5 5.5 18.0 6.2 20.3 7.2 23.6 8.4 27.6 10.4 34.1 14.4 47.2 18.2 59.7 22.2 72.8 26.1 85.6 28.4 93.2 32.3 106.0 36.1 118.4 39.9 130.9 43.7 143.4 47.4 155.5
3.5 11.5 4.0 13.1 4.6 15.1 6.1 20.0 6.9 22.6 8.0 26.2 9.3 30.5 11.5 37.7 16.0 52.5 20.2 66.3 24.7 81.0 29.0 95.1 31.6 103.7 35.9 117.8 40.1 131.6 44.3 145.3 48.5 159.1 52.7 172.9
4.2 13.8 4.8 15.7 5.5 18.0 7.3 24.0 8.3 27.2 9.6 31.5 11.2 36.7 13.8 45.3 19.2 63.0 24.2 79.4 29.6 97.1 34.8 114.2 37.9 124.3 43.0 141.1 48.1 157.8 53.2 174.5 58.2 191.0 63.2 207.4
5.1 16.7 5.9 19.4 6.8 22.3 9.0 29.5 10.1 33.1 11.8 38.7 13.7 44.9 16.9 55.4 23.5 77.1 29.7 97.4 36.3 119.1 42.6 139.8 46.5 152.6 52.7 172.9 58.9 193.3 65.1 213.6 71.3 233.9 77.5 254.3
5.9 19.4 6.7 22.0 7.7 25.3 10.2 33.5 11.6 38.1 13.4 44.0 15.6 51.2 19.3 63.3 26.9 88.3 33.9 111.2 41.5 136.2 48.7 159.8 53.1 174.2 60.2 197.5 67.4 221.1 74.4 244.1 81.5 267.4 88.5 290.4
6.6 21.7 7.6 24.9 8.7 28.5 11.5 37.7 13.0 42.7 15.1 49.5 17.6 57.7 21.7 71.2 30.2 99.1 38.2 125.3 46.7 153.2 54.8 179.8 59.7 195.9 67.8 222.5 75.8 248.7 83.7 274.6 91.7 300.9 99.6 326.8
7.7 25.3 8.8 28.9 10.1 33.1 13.4 44.0 15.2 49.9 17.6 57.7 20.5 67.3 25.3 83.0 35.2 115.5 44.4 145.7 54.3 178.2 63.8 209.3 69.5 228.0 78.9 258.9 88.2 289.4 97.5 319.9 106.7 350.1 115.9 380.3
8.5 27.9 9.7 31.8 11.1 36.4 14.8 48.6 16.7 54.8 19.4 63.7 22.5 73.8 27.8 91.2 38.7 127.0 48.9 160.4 59.8 196.2 70.2 230.3 76.5 251.0 86.8 284.8 97.0 318.3 107.2 351.7 117.4 385.2 127.5 418.3
9.2 30.2 10.6 34.8 12.1 39.7 16.1 52.8 18.2 59.7 21.1 69.2 24.6 80.7 30.4 99.7 42.2 138.5 53.3 174.9 65.2 213.9 76.6 251.3 83.4 273.6 94.6 310.4 105.9 347.5 117.0 383.9 128.0 420.0 139.1 456.4
10.0 32.8 11.4 37.4 13.2 43.3 17.4 57.1 19.7 64.6 22.9 75.1 26.6 87.3 32.9 107.9 45.8 150.3 57.8 189.6 70.6 231.6 82.9 272.0 90.4 296.6 102.5 336.3 114.7 376.3 126.7 415.7 138.7 455.1 150.7 494.4
21.3 mm
3
/4"
26.7 mm 1" 33.4 mm 11/2" 48.3 mm 2" 60.3 mm 21/2" 73.0 mm 3" 88.9 mm 4" 114.3 mm 6" 168.3 mm 8" 219.1 mm 10" 273.1 mm 12" 323.9 mm 14" 355.6 mm 16" 406.4 mm 18" 457.2 mm 20" 508.0 mm 22" 558.8 mm 24" 609.6 mm
Table 1 cont'd.
Nominal Pipe Size, 50F in. (ID) DegF 40F mm (OD) DegC 23.0C 28.0C Si Temperature Difference Between Pipe and Ambient
60F 33.4C 70F 39.0C 80F 44.5C 90F 50.0C 100F 55.6C 120F 66.7C 140F 77.8C 160F 180F 200F 220F 240F 260F
88.9C 100.0C 111.1C 122.2C 133.4C 144.5C
1.5" (38 mm) Insulation Thickness

1
/2"
1.1 3.6 1.2 3.9 1.4 4.6 1.8 5.9 2.1 6.9 2.4 7.9 2.7 8.9 3.3 10.8 4.5 14.8 5.6 18.4 6.8 22.3 8.0 26.2 8.7 28.5 9.8 32.2 11.0 36.1 12.1 39.7 13.2 43.3 14.3 46.9
1.4 4.6 1.6 5.2 1.8 5.9 2.3 7.5 2.6 8.5 3.0 9.8 3.4 11.2 4.2 13.8 5.7 18.7 7.1 23.3 8.0 26.2 10.0 32.8 10.9 35.8 12.3 40.4 13.7 44.9 15.1 49.5 16.5 54.1 17.9 58.7
1.7 5.6 1.9 6.2 2.2 7.2 2.8 9.2 3.1 10.2 3.5 11.5 4.1 13.5 5.0 16.4 6.8 22.3 8.5 27.9 10.3 33.8 12.0 39.4 13.0 42.7 14.8 48.6 16.4 53.8 18.1 59.4 19.8 65.0 21.5 70.5
2.0 6.6 2.2 7.2 2.5 8.2 3.2 10.5 3.6 11.8 4.1 13.5 4.8 15.7 5.8 19.0 7.9 25.9 9.9 32.5 12.0 39.4 14.0 45.9 15.2 49.9 17.2 56.4 19.2 63.0 21.1 69.2 23.1 75.8 25.1 82.4
2.2 7.2 2.5 8.2 2.9 9.5 3.7 12.1 4.2 13.8 4.7 15.4 5.4 17.7 6.6 21.7 9.0 29.5 11.3 37.1 13.7 44.9 16.0 52.5 17.4 57.1 19.7 64.6 21.9 71.9 24.2 79.4 26.4 86.6 28.6 93.8
2.5 8.2 2.8 9.2 3.2 10.5 4.1 13.5 4.7 15.4 5.3 17.4 6.1 20.0 7.5 24.6 10.2 33.5 12.7 41.7 15.4 50.5 18.0 59.1 19.5 64.0 22.1 72.5 24.7 81.0 27.2 89.2 29.7 97.4 32.2 105.6
2.8 9.2 3.1 10.2 3.6 11.8 4.6 15.1 5.2 17.1 5.9 19.4 6.8 22.3 8.3 27.2 11.3 37.1 14.1 46.3 17.1 56.1 20.0 65.6 21.7 71.2 24.6 80.7 27.4 89.9 30.2 99.1 33.0 108.3 35.8 117.5
3.5 11.5 3.9 12.8 4.5 14.8 5.8 19.0 6.6 21.7 7.4 24.3 8.6 28.2 10.5 34.5 14.2 46.6 17.8 58.4 21.5 70.5 25.2 82.7 27.3 89.6 31.0 101.7 34.5 113.2 38.1 125.0 41.6 136.5 45.1 148.0
4.1 13.5 4.6 15.1 5.3 17.4 6.8 22.3 7.6 24.9 8.7 28.5 10.0 32.8 12.2 40.0 16.6 54.5 20.7 67.9 25.1 82.4 29.4 96.5 31.9 104.7 36.2 118.8 40.3 132.2 44.4 145.7 48.5 159.1 52.6 172.6
4.7 15.4 5.2 17.1 6.0 19.7 7.7 25.3 8.7 28.5 9.9 32.5 11.4 37.4 13.9 45.6 19.0 62.3 23.7 77.8 28.7 94.2 33.6 110.2 36.5 119.8 41.3 135.5 46.0 150.9 50.7 166.3 55.4 181.8 60.1 197.2
5.5 18.0 6.1 20.0 7.1 23.3 9.1 29.9 10.3 33.8 11.7 38.4 13.5 44.3 16.4 53.8 22.4 73.5 27.9 91.5 33.9 111.2 39.6 129.9 43.0 141.1 48.7 159.8 54.3 178.2 59.8 196.2 65.3 214.2 70.9 232.6
6.2 20.3 6.8 22.3 7.9 25.9 10.1 33.1 11.4 37.4 13.0 42.7 15.0 49.2 18.3 60.0 24.9 81.7 31.0 101.7 37.6 123.4 44.0 144.4 47.7 156.5 54.1 177.5 60.3 197.8 66.4 217.9 72.6 238.2 78.8 258.5
6.8 22.3 7.5 24.6 8.7 28.5 11.1 36.4 12.6 41.3 14.3 46.9 16.5 54.1 20.1 65.9 27.3 89.6 34.1 111.9 41.4 135.8 48.4 158.8 52.5 172.3 59.5 195.2 66.3 217.5 73.1 239.8 79.9 262.2 86.6 284.1
7.4 24.3 8.2 26.9 9.5 31.2 12.1 39.7 13.7 44.9 15.6 51.2 18.0 59.1 21.9 71.9 29.8 97.8 37.2 122.1 45.1 148.0 52.8 173.2 57.3 188.0 64.9 212.9 72.3 237.2 79.7 261.5 87.1 285.8 94.5 310.1
8.0 26.2 8.9 29.2 10.3 33.8 13.2 43.3 14.9 48.9 16.9 55.4 19.4 63.7 23.7 77.8 32.3 106.0 40.3 132.2 48.9 160.4 57.2 187.7 62.1 203.8 70.4 231 78.4 257.2 86.4 283.5 94.4 309.7 102.4 336.0
21.3 mm
3
/4"
THERMAL DESIGNPIPES
3
THERMAL DESIGNPIPES
Table 1 cont'd.
88.9C 100.0C 111.1C 122.2C 133.4C 144.5C
2" (50.8mm) Insulation Thickness

1
/2"
1.0 3.3 1.1 3.6 1.2 3.9 1.5 4.9 1.7 5.6 1.9 6.2 2.2 7.2 2.6 8.5 3.6 11.8 4.4 14.4 5.3 17.4 6.2 20.3 6.7 22.0 7.6 24.9 8.4 27.6 9.2 30.2 10.1 33.1 11.0 36.1
1.2 3.9 1.4 4.6 1.5 4.9 1.9 6.2 2.2 7.2 2.4 7.9 2.8 9.2 3.3 10.8 4.5 14.8 5.6 18.4 6.7 22.0 7.8 25.6 8.4 27.6 9.5 31.2 10.5 34.5 11.6 38.1 12.6 41.3 13.7 44.9
1.4 4.6 1.6 5.2 1.8 5.9 2.3 7.5 2.6 8.5 2.9 9.5 3.3 10.8 4.0 13.1 5.3 17.4 6.7 22.0 8.0 26.2 9.3 30.5 10.1 33.1 11.3 37.1 12.6 41.3 13.9 45.6 15.2 49.9 16.4 53.8
1.7 5.6 1.9 6.2 2.1 6.9 2.7 8.9 3.0 9.8 3.4 11.2 3.9 12.8 4.6 15.1 6.2 20.3 7.8 25.6 9.3 30.5 10.9 35.8 11.8 38.7 13.2 43.3 14.7 48.2 16.2 53.2 17.7 58.1 19.2 63.0
1.9 6.2 2.2 7.2 2.4 7.9 3.0 9.8 3.4 11.2 3.8 12.5 4.4 14.4 5.3 17.4 7.1 23.3 8.9 29.2 10.6 34.8 12.4 40.7 13.4 44.0 15.1 49.5 16.8 55.1 18.5 60.7 20.2 66.3 21.9 71.9
2.2 7.2 2.4 7.9 2.7 8.9 3.4 11.2 3.9 12.8 4.3 14.1 5.0 16.4 5.9 19.4 8.0 26.2 10.0 32.8 12.0 39.4 14.0 45.9 15.1 49.5 17.0 55.8 18.9 62.0 20.8 68.2 22.7 74.5 24.7 81.0
2.4 7.9 2.7 8.9 3.0 9.8 3.8 12.5 4.3 14.1 4.8 15.7 5.5 18.0 6.6 21.7 8.9 29.2 11.1 36.4 13.3 43.6 15.5 50.9 16.8 55.1 18.9 62.0 21.0 68.9 23.1 75.8 25.3 83.0 27.4 89.9
3.0 9.8 3.4 11.2 3.8 12.5 4.8 15.7 5.4 17.7 6.0 19.7 6.9 22.6 8.3 27.2 11.2 36.7 14.0 45.9 16.8 55.1 19.5 64.0 21.2 69.6 23.8 78.1 26.5 86.9 29.1 95.5 31.8 104.3 34.5 113.2
3.5 11.5 4.0 13.1 4.4 14.4 5.6 18.4 6.3 20.7 7.1 23.3 8.1 26.6 9.7 31.8 13.1 43.0 16.3 53.5 19.6 64.3 22.8 74.8 24.7 81.0 27.8 91.2 30.9 101.4 34.0 111.6 37.1 121.7 40.3 132.2
4.0 13.1 4.5 14.8 5.0 16.4 6.4 21.0 7.2 23.6 8.1 26.6 9.2 30.2 11.1 36.4 15.0 49.2 18.6 61.0 22.3 73.2 26.0 85.3 28.2 92.5 31.8 104.3 35.3 115.8 38.8 127.3 42.4 139.1 46.0 150.9
4.8 15.7 5.3 17.4 5.9 19.4 7.5 24.6 8.5 27.9 9.5 31.2 10.9 35.8 13.1 43.0 17.6 57.7 22.0 72.2 26.3 86.3 30.7 100.7 33.3 109.3 37.4 122.7 41.6 136.5 45.7 149.9 50.0 164.1 54.3 178.2
5.3 17.4 5.9 19.4 6.6 21.7 8.4 27.6 9.5 31.2 10.6 34.8 12.1 39.7 14.5 47.6 19.6 64.3 24.4 80.1 29.3 96.1 34.1 111.9 37.0 121.4 41.6 136.5 46.2 151.6 50.8 166.7 55.6 182.4 60.3 197.8
5.8 19.0 6.5 21.3 7.3 24.0 9.2 30.2 10.4 34.1 11.6 38.1 13.3 43.6 16.0 52.5 21.5 70.5 26.9 88.3 32.2 105.6 37.5 123.0 40.7 133.5 45.7 149.9 50.8 166.7 55.9 183.4 61.1 200.5 66.3 217.5
6.3 20.7 7.1 23.3 7.9 25.9 10.0 32.8 11.4 37.4 12.7 41.7 14.5 47.6 17.4 57.1 23.5 77.1 29.3 96.1 35.1 115.2 40.9 134.2 44.4 145.7 49.9 163.7 55.4 181.8 61.0 200.1 66.7 218.8 72.3 237.2
7.2 23.6 8.1 26.6 9.0 29.5 11.4 37.4 12.9 42.3 14.4 47.2 16.4 53.8 19.7 64.6 26.6 87.3 33.2 108.9 39.8 130.6 46.3 151.9 50.2 164.7 56.5 185.4 62.8 206.0 69.1 226.7 75.5 247.7 81.9 268.7
21.3 mm
3
/4"
Table 1 cont'd.
88.9C 100.0C 111.1C 122.2C 133.4C 144.5C
3" (76.2 mm) Insulation Thickness

1
/2"
0.8 2.6 0.9 3.0 1.0 3.3 1.2 3.9 1.3 4.3 1.5 4.9 1.7 5.6 2.0 6.6 2.6 8.5 3.2 10.5 3.8 12.5 4.4 14.4 4.7 15.4 5.3 17.4 5.9 19.4 6.4 21.0 7.0 23.0 7.6 24.9
1.0 3.3 1.1 3.6 1.3 4.3 1.5 4.9 1.7 5.6 1.9 6.2 2.1 6.9 2.5 8.2 3.3 10.8 4.0 13.1 4.8 15.7 5.5 18.0 5.9 19.4 6.7 22.0 7.4 24.3 8.1 26.6 8.8 28.9 9.5 31.2
1.2 3.9 1.3 4.3 1.5 4.9 1.8 5.9 2.0 6.6 2.2 7.2 2.5 8.2 3.0 9.8 3.9 12.8 4.8 15.7 5.7 18.7 6.5 21.3 7.1 23.3 8.0 26.2 8.8 28.9 9.7 31.8 10.5 34.5 11.3 37.1
1.4 4.6 1.5 4.9 1.8 5.9 2.1 6.9 2.3 7.5 2.6 8.5 2.9 9.5 3.5 11.5 4.6 15.1 5.6 18.4 6.7 22.0 7.6 24.9 8.3 27.2 9.3 30.5 10.3 33.8 11.3 37.1 12.3 40.4 13.2 43.3
1.6 5.2 1.8 5.9 2.0 6.6 2.4 7.9 2.6 8.5 3.0 9.8 3.4 11.2 4.0 13.1 5.2 17.1 6.4 21.0 7.6 24.9 8.7 28.5 9.4 30.8 10.6 34.8 11.8 38.7 12.9 42.3 14.0 45.9 15.1 49.5
1.8 5.9 2.0 6.6 2.3 7.5 2.7 8.9 3.0 9.8 3.3 10.8 3.8 12.5 4.5 14.8 5.9 19.4 7.2 23.6 8.6 28.2 9.8 32.2 10.6 34.8 12.0 39.4 13.2 43.3 14.5 47.6 15.8 51.8 17.0 55.8
2.0 6.6 2.2 7.2 2.5 8.2 3.0 9.8 3.3 10.8 3.7 12.1 4.2 13.8 5.0 16.4 6.5 21.3 8.0 26.2 9.5 31.2 10.9 35.8 11.8 38.7 13.3 43.6 14.7 48.2 16.1 52.8 17.5 57.4 18.9 62.0
2.5 8.2 2.8 9.2 3.2 10.5 3.8 12.5 4.2 13.8 4.7 15.4 5.3 17.4 6.3 20.7 8.2 26.9 10.1 33.1 12.0 39.4 13.7 44.9 14.9 48.9 16.8 55.1 18.5 60.7 20.3 66.6 22.1 72.5 23.8 78.1
2.9 9.5 3.2 10.5 3.7 12.1 4.4 14.4 4.9 16.1 5.4 17.7 6.2 20.3 7.4 24.3 9.6 31.5 11.8 38.7 14.0 45.9 16.0 52.5 17.3 56.8 19.6 64.3 21.6 70.9 23.7 77.8 25.7 84.3 27.8 91.2
3.4 11.2 3.7 12.1 4.2 13.8 5.0 16.4 5.5 18.0 6.2 20.3 7.1 23.3 8.4 27.6 10.9 35.8 13.4 44.0 16.0 52.5 18.3 60.0 19.8 65.0 22.3 73.2 24.7 81.0 27.0 88.6 29.4 96.5 31.8 104.3
4.0 13.1 4.4 14.4 5.0 16.4 5.9 19.4 6.5 21.3 7.3 24.0 8.3 27.2 9.9 32.5 12.9 42.3 15.8 51.8 18.8 61.7 21.6 70.9 23.4 76.8 26.3 86.3 29.1 95.5 31.9 104.7 34.7 113.9 37.4 122.7
4.4 14.4 4.8 15.7 5.5 18.0 6.6 21.7 7.3 24.0 8.1 26.6 9.2 30.2 11.0 36.1 14.3 46.9 17.6 57.7 20.9 68.6 24.0 78.7 26.0 85.3 29.3 96.1 32.3 106.0 35.4 116.1 38.5 126.3 41.6 136.5
4.8 15.7 5.3 17.4 6.1 20.0 7.3 24.0 8.0 26.2 9.0 29.5 10.2 33.5 12.1 39.7 15.7 51.5 19.4 63.7 23.0 75.5 26.4 86.6 28.6 93.8 32.2 105.6 35.6 116.8 39.0 128.0 42.4 139.1 45.7 149.9
5.5 18.0 6.1 20.0 6.9 22.6 8.3 27.2 9.1 29.9 10.2 33.5 11.6 38.1 13.8 45.3 17.9 58.7 22.1 72.5 26.2 86.0 30.1 98.8 32.6 107.0 36.7 120.4 40.6 133.2 44.4 145.7 48.3 158.5 52.2 171.3
6.0 19.7 6.6 21.7 7.5 24.6 9.0 29.5 9.9 32.5 11.1 36.4 12.6 41.3 15.0 49.2 19.4 63.7 23.9 78.4 28.4 93.2 32.6 107.0 35.3 115.8 39.8 130.6 44.0 144.4 48.1 157.8 52.3 171.6 56.5 185.4
21.3 mm
3
/4"
26.7 mm 1" 33.4 mm 11/2" 48.3 mm 2" 60.3 mm 21/2" 73.0 mm 3" 88.9 mm 4" 114.3 mm 6" 168.3 mm 8" 219.1 mm 10" 273.1 mm 12" 323.9 mm 14" 355.6 mm 16" 406.4 mm 18 457.2 mm 20" 508.0 mm 22" 558.8 mm 24" 609.6 mm
Table 2 Insulation Adjustment Factors

Pipe Insulation Type
Glass fiber (ASTM C547) Calcium silicate (ASTM C533) Cellular glass (ASTM C552) Rigid cellular urethane (ASTM C591) Foamed elastomer (ASTM C534) Mineral fiber blanket (ASTM C553) Expanded perlite (ASTM C610)
Insulation Adjustment Factor

1.00 1.48 1.48 0.64 1.16 1.16 1.90
THERMAL DESIGNPIPES
5
THERMAL DESIGNTANKS
THERMAL DESIGN TANKS

Collect the following information for each tank. Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Tank Shape and Surface Area: Additional Safety Factor, if required: Thermal Insulation Type and Thickness:
Example:
D
D H H CYLINDRICAL TANK, FLAT AREA = AREA (ENDS) + AREA (SIDE) 2 = D /2 + DH
D CYLINDRICAL TANK, DISHED AREA = AREA (TOP) + AREA (SIDE) + AREA (BOTTOM) = (/4)(D2+4h2) + DH +D2/4
THERMAL DESIGN-TANKS
S d CYLINDRICAL TANK, CONICAL AREA = AREA (TOP) + AREA (SIDE) + AREA (CONE) 2 = D /4 + DH + (/2)(D+d) (Dd)2 2 +h 4 RECTANGULAR TANK AREA = AREA (TOP) + AREA (SIDE) + AREA (BOTTOM) = 2(WH+HL+WL)
L
W
English Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Tank Shape and Surface Area:
40F -20F Outdoor 20 mph Steel Horizontal Cylinder 3 ft dia. 6 ft long None 2" Cellular Glass
Additional Safety Factor, if required: Thermal Insulation Type and Thickness:

Example:
Table 3 Heat Loss (QT) for Various Insulation Thicknesses

Insulation Thickness in.
1/ 2
Heat Loss (QT) W/ft2/F W/m2/C
mm
12.7 0.161 3.120 1 25.4 0.081 1.569 11/2 38.1 0.054 1.046 2 50.8 0.040 0.775 3 76.2 0.027 0.523 4 101.6 0.020 0.388 5 127.0 0.016 0.130 6 152.4 0.013 0.252 NOTE: Heat loss values based on 20 mph (32 kph) wind, 10% safety factor, and Fiberglas insulation at 50F (10C).
Metric Maintenance Temperature, Tm: Minimum Ambient Temperature, Ta: Location, Indoor/ Outdoor: Wind Speed, if applicable: Tank Shape and Surface Area:
4.4C -28.9C Outdoor 32 kph Steel Horizontal Cylinder 0.92 m dia. 1.83 m long None 51mm Cellular Glass
Additional Safety Factor, if required: Thermal Insulation Type and Thickness:

Step 1. Calculate T
T = Tm - Ta English = 40F - (-20F) = 60F Metric = 4.4C - (-28.9C) = 33.3C
Step 2. Determine Total Surface Area of Tank
Most tanks are a combination of shapes. Determine the surface area of each section and then add the areas for each section to determine the overall surface area, A. A = D2 /2 + DH English = (3.14)(3 ft)2/2 + (3.14)(3 ft)(6 ft) = 70.7 ft2 Metric = (3.14)(0.92 m)2/2 + (3.14)(0.92 m)(1.83 m) = 6.6 m2
Step 3. Determine QT
Find QT in Table 3 for the corresponding insulation thickness.

Step 4. Calculate Heat Loss, Q
Q = (QT)(T)(A) English = (0.040 W/ft2/F)(60F)(70.7 ft2) = 170 W Metric = (0.775 W/m2/C)(33.3C)(6.6m2) = 170 W
Step 5. Adjust for Insulation
For example, additional heat loss for 4 support legs: QA = (QS) (T) x number of legs English = (0.5 W/F)(60F) x 4 = 120 W Metric = (0.9 W/C)(33.3/C) x 4 = 120 W
Step 9. Calculate the Cable Length Required
Q, as found in the step above, must be adjusted for the insulation type. Multiply your heat loss by Ia, the Insulation Adjustment Factor, from the values in Table 2. Using the Insulation Adjustment Factor (Ia) for cellular glass (1.48): QF = Q x Ia = 170 W x 1.48 = 252 W
Step 6. Correct for Indoor Location/Windspeed
To determine the length required, take the total heat loss as calculated in the previous steps and divide by the chosen cable output at the maintenance temperature. (See Figures 1-4.) Q = QF + QA = 252 W + 120 W = 372 W SRL5-CT Output @ 40F = 4.8 W/ft L = 372 W 4.8 W/ft L = 78 ft
Table 4 Tank Equipment Heat Loss Calculation (QS)
Support Legs 0.5 W/F (0.9 W/C) x number of legs Ladder Manways 2.5 W/F (4.5 W/C) x number of ladders 10.0 W/F (18.0 W/C) x number of manways
If the application is indoors, multiply QF by 0.9. Since Table 3 is based on 20 mph (32 kph) windspeed, add 5% margin for each additional 5 mph (8 kph) over 20 mph (32 kph).
Step 7. Correct for Additional Safety Factors Step 8. Additional Equipment Heat Losses
Equipment such as ladders, manways, and support legs act as heat sinks and increase the overall heat loss of the tanks. For each piece of equipment, use Table 4 to calculate equipment heat loss and add to the heat loss calculated above.
THERMAL DESIGNTANKS
7
HEATING CABLE SELECTION

To determine the correct cable for your application, determine the following information: Maintenance Temperature = Max. Exposure Temperature = Pipe Material = Service Voltage = Chemical Environment = Area Classification = Heat Requirement (from Thermal Design Section) =
Example: English
Example: Metric
Maintenance Temperature = Max. Exposure Temperature = Pipe Material = Service Voltage = Chemical Environment = Area Classification = Heat Requirement (from Thermal Design Section) =
4.4C 37.8C Stainless Steel 120V Organic CID2 Group B 15.98 W/m
Step 1. Select Heating Cable Family
Maintenance Temperature = Max. Exposure Temperature = Pipe Material = Service Voltage = Chemical Environment = Area Classification = Heat Requirement (from Thermal Design Section) =
40F 100F Stainless Steel 120V Organic CID2 Group B 4.88 W/ft
Based on the maximum maintainance temperature, maximum exposure temperature, and area classification, select the heating cable family from Table 5.
Note: Maximum maintenance temperatures for constant wattage cables (CWM) are dependent upon cable wattage rating and the use of alumium foil tape. See Table 6 (page 10).
Example:
Based on information, select the SRL (SelfRegulating Low Temperature) Cable Family. Selection: SRL * - * *
Heating Cable Family
Area Classification
Pipe Material
Maximum Maintenance Temperature F C 65C
Maximum Exposure Temperature (Power Off) F 185F C 85C
Approvals U.S. Other
SRL Ordinary (Self-Regulating Low Temperature ) Class I, Div. 2,
Plastic/Metal
150F
UL, CSA, FM
GOST, Cenelec, CE, ATEX
Gr. B, C, D Class II, Div. 2, Gr. E, F, G Class III, Div. 2, Ordinary Class I Div. 2, Gr. A, B, C, D, Class II, Div. 2, Gr. F, G
HSRL (H-SelfRegulating Low Temperature )
CSA, FM GOST, Cenelec, (Gr. A, CSA Only) CE, ATEX CSA, FM GOST, Cenelec (Gr. E, CSA Only) CE FM Only Metal Only 302F 150C 420F 215C UL, CSA, FM GOST, Cenelec, CE, ATEX GOST, Cenelec, CE, ATEX
SRM/E (Self-Regulating Medium Temperature )
CSA, FM GOST, Cenelec, (Gr. A, CSA Only) CE, ATEX CSA Only GOST, Cenelec, CE, ATEX
Class I, Div. 1, Gr. B, C, D Class II, Div. 1, Gr. E, F, G Class III, Div. 1
Plastic/Metal
150F
66C
185F
85C
FM Only FM Only FM Only
HSRM (H-SelfRegulating Medium Temperature )
Class I, Div. 1, Gr. B, C, D Class II, Div. 1, Gr. E, F, G Class III, Div. 1
Metal Only
302F
150C
420F 215C
FM Only FM Only FM Only
CWM (Constant Wattage)
Ordinary Hazardous Area Consult Factory Ordinary Hazardous Area Consult Factory
Metal Only
See Table 4
392F
200C
UL, CSA
MI (Mineral Insulated)
Metal Only
See Section
1,100F 593C
Consult Factory
Consult Factory
NOTE: It is the responsibility of the facility manager or engineer to determine the classification of an area where heat trace will be installed. The factory can help determine a suitable cable based on the information provided.

9
Table 5 Heating Cable Families
Step 2. Select Heating Cable Construction Options
Step 3. Select Thermal Output Rating 1. For Self-Regulating Cable See Figures 1 and 2
Select from Table 7 the appropriate construction option for the desired level of mechanical and corrosive chemical protection. -C option cable is constructed with a tinned copper grounding braid only. -CR option cable is constructed with a tinned copper braid and polyolefin overjacket. -CT option cable is constructed with a tinned copper braid and fluoropolymer overjacket.
Note: If your area classification is Class I Division 1, Class II Division 1, or Class III Division 1, the HSRL and HSRM cable families are constructed with -CT option only.
Example:
(page 12) if piping is metallic and Figures 3 and 4 (page 13) if piping is plastic. Find your actual heat loss, Q, (as previously calculated on pages 1 or 7) on the Y-axis of the graph and the maintenance temperature required on the X-axis. Select the cable for which the thermal output is Q at Tm.
Example:
In the step above, we have chosen the SRL cable family and our piping is metallic. Therefore, refer to Figure 1. Calculated heat loss, W, is 4.88 W/ft (0 W/m). Find this point on the Y-axis. Maintenance temperature is 40F (4.4C). Find this point on the X-axis. Choose the cable that lies above this point on the graph. Selection: SRL5-*CT
2. For Constant Wattage Cable Select the cable output that most closely exceeds the calculated heat loss, Q. Cable wattage outputs offered are 4, 8, and 12 W/ft (13, 26, and 40 W/m).
Since the environment in our example contained organic chemical solutions, choose the -CT option for the fluoropolymer overjacket to provide mechanical and corrosion protection. Selection: SRL*-* CT
3. For Mineral Insulated Cable See pages 17 and 18 for information on cable assemblies.
Table 6 Maximum Maintenance Temperatures for Constant Wattage Cables (CWM)

Cable Rating, W/ft (W/m) 4W 8W Maximum Temperature F Without Aluminum Tape With Aluminum Tape 325 344 C 163 174 F 262 320 C 128 160 F 200 296 C 93 147 12 W
Table 7 Heating Cable Construction Options

SRL, SRM/E, CWM Exposure Conditions Moisture Aqueous Solutions of Inorganic Compounds Liquid Organic Chemicals Acids or Bases -C -CR -CT Mineral Insulated
10
Recalculate with thicker insulation. Select insulation with a lower K factor and recalculate heat loss. Use two or more heating cable runs in parallel. Spiral the heating cable. DO NOT SPIRAL WRAP CONSTANT WATTAGE CABLE. If you choose to spiral the cable: spiral factor, length of cable/ ft (m) of pipe = Q/Heater output at Tm.
Example, Using SRL 3-1CT:
Step 4. Check T-Ratings
4.88 heat loss/3.8 SRL 3-1CT output at 40F (4.4C) = 1.28 spiral factor
For self-regulating cable, use Table 8 to determine if the T-rating for the cable selected is acceptable for use per area classification guidelines. The Tratings shown in Table 8 are determined based on the product classification approach method per IEEE Standard 515-1997. Please consult the factory if your application requires a T-rating different from those shown in the table. Please consult the factory to determine sheath temperature for applications using constant wattage or mineral insulated cables in hazardous areas.
Table 8 T-Ratings for Self-Regulating Cable

Cable Family SRL Watts / Volts 3-1,3-2 5-1,5-2 8-1,8-2 10-1,10-2 HSRL 3-1,3-2 5-1,5-2 8-1,8-2 10-1,10-2 SRM/E 3-1,3-2 5-1,5-2 8-1,8-2 10-1,10-2 15-1,15-2 20-1,20-2 HSRM 5-1,5-2 8-1,8-2 10-1,10-2 15-1,15-2 20-1,20-2 T-Rating F T6 T5 T5 T4A T6 T5 T5 T4A T3 T3 T3 T2D T2D T2D T3C T3C T3A T2C T2C 185F 212F 212F 248F 185F 212F 212F 248F 392F 392F 392F 419F 419F 419F 320F 320F 356F 446F 446F Max. Temp C 85C 100C 100C 120C 85C 100C 100C 120C 200C 200C 200C (215C) (215C) (215C) (160C) (160C) (180C) (230C) (230C)
NOTE: In Division 2 applications the sheath temperature of the cable should not exceed 99% of the AIT (auto-ignition temperature) in C of the material with the lowest AIT in the atmosphere. In Division 1, the sheath temperature shall not exceed 80% of the lowest AIT in C.

11
In some instances, the calculated heat loss, Q, is greater than the thermal output of the highest rated cable. Should this happen, you can:
Bending the heating cable can cause damage. Therefore, it is recommended that multiple straight runs of heat trace be used instead of spiral wrapping, especially if your pipe is smaller than 3" (88.9 mm) IPS . Straight runs facilitate installation significantly.
Figure 1
SRL & HSRL Thermal Output Ratings on Insulated Metal Pipe
English
14 13 12 11 4.5
Metric
SRL10 & HSRL10 SRL8 & HSRL8
4.0
SRL10 & HSRL10

3.5
Thermal Output (W/ft)
10 9 8 7 6 5 4 3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Thermal Output (W/m)
SRL8 & HSRL8
3.0
2.5
SRL5 & HSRL5
SRL5 & HSRL5

2.0
SRL3 & HSRL3

4.88
4.88
1.5
SRL3 & HSRL3 Cable Output versus Temperature

1.0
0.5
Cable Output versus Temperature
0 -18 -11 -4 3 10 17 24 31 38 45 52 59 66
Pipe Temperature (F)

Maintenance Temperature
Pipe Temperature (C)

Maintenance Temperature
Figure 2
SRM/E & HSRM Thermal Output Ratings on Insulated Metal Pipe
English
24 8.0
Metric
Cable Output versus Temperature Cable Output versus Temperature SRM/E20 & HSRM20
6.0
20
SRM/E20 & HSRM20 SRM/E15 & HSRM15
7.0
Power Output (W/ft)
Power Output (W/m)
16
5.0
SRM/E15 & HSRM15
12
SRM/E10 & HSRM10
4.0
SRM/E10 & HSRM10

3.0
SRM/E8 & HSRM8

8
SRM/E8 & HSRM8 SRM/E5 & HSRM5 SRM/E3 & HSRM3
SRM/E5 & HSRM5

4
2.0
SRM/E3 & HSRM3

1.0
0 0 50 100 150 200 250 300
0 -18 10 38 66 93 121 149
12
SRL & HSRL Thermal Output Ratings on Plastic Pipes with Aluminum Tape Over Cable
English
9 3.0
Metric
SRL10 & HSRL10

7
2.5
SRL8 & HSRL8
SRL10 & HSRL10
2.0
SRL8 & HSRL8
SRL5 & HSRL5

4
1.5
SRL5 & HSRL5
1.0
SRL3 & HSRL3

2 0.5 1
SRL3 & HSRL3

0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 -18

-11 -4 3 10 17 24 31 38 45 52 59 66
Figure 4
SRL & HSRL Thermal Output Ratings on Plastic Pipes with Aluminum Tape Under and Over Cable
English
11 10 9 8 3.5
Metric
SRL10 & HSRL10
3.0
SRL10 & HSRL10
SRL8 & HSRL8
2.5
7 6
SRL8 & HSRL8

2.0
SRL5 & HSRL5

5 4
SRL5 & HSRL5

1.5
SRL3 & HSRL3

3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
1.0
SRL3 & HSRL3
0.5

0 -18 -11 -4 3 10 17 24 31 38 45 52 59 66

13
Figure 3
Step 5. Select Voltage Rating and Adjust for Alternate Voltages
Example:
Nominal Voltage Options: 1 = 120V or 2 = 240V If the service voltage is 208V, 220V, 230V, or 277V, multiply the thermal output rating on the 240V cable by the appropriate power output factor for self-regulating cable or constant wattage cable found in Table 9. This will give the adjusted power output at the service voltage.
Service Voltage is 120V. No need to apply any adjustment factors. Therefore, choose Option 1. Selection: SRL 5-1CT
Note: If your service voltage is 208V, 220V, or 230V, make sure that after your output has been adjusted that it does not drop below the calculated heat loss. If heat loss is greater than adjusted power output choose the next highest wattage cable.
Step 6. Determine Chromalox Part Number
To order Chromalox self-regulating or constant wattage heating cable, consult Table 10 (page 15), for the Chromalox model number for the chosen cable.
Table 9 Output Adjustment Factors for Alternate Voltages for Self-Regulating and Constant Wattage Cables
Cable Type SRL or HSRL Watts/Volts 3-2 5-2 8-2 10-2 SRM/E or HSRM 3-2 5-2 8-2 10-2 15-2 20-2 CWM 4-2 8-2 12-2 208V 80% 82% 86% 87% 78% 79% 81% 81% 85% 88% 75% 75% 75% 220V 87% 90% 91% 92% 86% 87% 88% 88% 90% 92% 84% 84% 84% 230V 92% 92% 94% 95% 92% 92% 93% 94% 95% 95% 92% 92% 92% 240V 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 277V 115% 113% 112% 110% 124% 123% 123% 122% 123% 122% 133% 133% 133%
NOTE: If your service voltage is 208V or 220V, make sure that after your output has been adjusted that it does not drop below the calculated heat loss. If heat loss is greater than adjusted power output choose the next highest wattage cable.
14
Heating Cable Family SRL Self-Regulating Low Temperature With Tinned Copper Braid
Model Number SRL3-1C SRL3-2C SRL5-1C SRL5-2C SRL8-1C SRL8-2C SRL10-1C SRL10-2C SRL3-1CR SRL3-2CR SRL5-1CR SRL5-2CR SRL8-1CR SRL8-2CR SRL10-1CR SRL10-2CR SRL3-1CT SRL3-2CT SRL5-1CT SRL5-2CT SRL8-1CT SRL8-2CT SRL10-1CT SRL10-2CT SRM/E3-1C SRM/E3-2C SRM/E5-1C SRM/E5-2C SRM/E8-1C SRM/E8-2C SRM/E10-1C SRM/E10-2C SRM/E15-1C SRM/E15-2C SRM/E20-1C SRM/E20-2C SRM/E3-1CT SRM/E3-2CT SRM/E5-1CT SRM/E5-2CT SRM/E8-1CT SRM/E8-2CT SRM/E10-1CT SRM/E10-2CT SRM/E15-1CT SRM/E15-2CT SRM/E20-1CT SRM/E20-2CT
Specifications 3 W/ft @50F, 120V 3 W/ft @50F, 240V 5 W/ft @50F, 120V 5 W/ft @50F, 240V 8 W/ft @50F, 120V 8 W/ft @50F, 240V 10 W/ft @50F, 120V 10 W/ft @50F, 240V 3 W/ft @50F, 120V 3 W/ft @50F, 240V 5 W/ft @50F, 120V 5 W/ft @50F, 240V 8 W/ft @50F, 120V 8 W/ft @50F, 240V 10 W/ft @50F, 120V 10 W/ft @50F, 240V 3 W/ft @50F, 120V 3 W/ft @50F, 240V 5 W/ft @50F, 120V 5 W/ft @50F, 240V 8 W/ft @50F, 120V 8 W/ft @50F, 240V 10 W/ft @50F, 120V 10 W/ft @50F, 240V 3 W/ft @50F, 120V 3 W/ft @50F, 240V 5 W/ft @50F, 120V 5 W/ft @50F, 240V 8 W/ft @50F, 120V 8 W/ft @50F, 240V 10 W/ft @50F, 120V 10 W/ft @50F, 240V 15 W/ft @50F, 120V 15 W/ft @50F, 240V 20 W/ft @50F, 120V 20 W/ft @50F, 240V 3 W/ft @50F, 120V 3 W/ft @50F, 240V 5 W/ft @50F, 120V 5 W/ft @50F, 240V 8 W/ft @50F, 120V 8 W/ft @50F, 240V 10 W/ft @50F, 120V 10 W/ft @50F, 240V 15 W/ft @50F, 120V 15 W/ft @50F, 240V 20 W/ft @50F, 120V 20 W/ft @50F, 240V
With Braid and Polyolefin Overjacket
With Braid and Fluoropolymer Overjacket
SRM/E Self-Regulating Medium Temperature With Tinned Copper Braid
With Braid and Fluoropolymer Overjacket

15
Table 10 Ordering Information for Chromalox Self-Regulating and Constant Wattage Heating Cable
Table 10, contd.

Heating Cable Family SRL Self-Regulating Low Temperature Division 1 Hazardous Location Cable Model Number HSRL3-1CT HSRL3-2CT HSRL5-1CT HSRL5-2CT HSRL8-1CT HSRL8-2CT HSRL10-1CT HSRL10-2CT HSRM Self-Regulating Medium Temperature Division 1 Hazardous Location Cable HSRM5-1CT HSRM5-2CT HSRM8-1CT HSRM8-2CT HSRM10-1CT HSRM10-2CT HSRM15-1CT HSRM15-2CT HSRM20-1CT HSRM20-2CT CWM Constant Wattage Heating Cable With Tinned Copper Braid CWM4-1C CWM4-2C CWM8-1C CWM8-2C CWM12-1C CWM12-2C With Braid and Fluoropolymer Overjacket CWM4-1CT CWM4-2CT CWM8-1CT CWM8-1CT CWM12-1CT CWM12-2CT Specifications 3 W/ft @ 50F, 120V 3 W/ft @ 50F, 240V 5 W/ft @ 50F, 120V 5 W/ft @ 50F, 240V 8 W/ft @ 50F, 120V 8 W/ft @ 50F, 240V 10 W/ft @ 50F, 120V 10 W/ft @ 50F, 240V 5 W/ft @ 50F, 120V 5 W/ft @ 50F, 240V 8 W/ft @ 50F, 120V 8 W/ft @ 50F, 240V 10 W/ft @ 50F, 120V 10 W/ft @ 50F, 240V 15 W/ft @ 50F, 120V 15 W/ft @ 50F, 240V 20 W/ft @ 50F, 120V 20 W/ft @ 50F, 240V 4 W/ft, 120V 4 W/ft, 240V 8 W/ft, 120V 8 W/ft, 240V 12 W/ft, 120V 12 W/ft, 240V 4 W/ft, 120V 4 W/ft, 240V 8 W/ft, 120V 8 W/ft, 120V 12 W/ft, 120V 12 W/ft, 240V
16
MINERAL INSULATED CABLE DESIGN
Form A
Total Heated Length Cold Lead Length
For Pipe Length: Diameter: Material: For Tank Length: Width: Height: Radius: Diameter: Surface Area: Material: Type of Insulation: Insulation Thickness: Voltage: Maintenance Temperature: Minimum Ambient Temperature: Minimum Startup Temperature: Maximum Exposure Temperature: Area Classification: Indoor or Outdoor: Maximum Wind Speed: Corrosive(s) Present: Safety Factor: Equipment and Quantity: Flange Pair: Pipe Support: Butterfly Valve: Ball Valve: Glove Valve: Gate Valve: Desired Cable Form: Form A: Form E: One-Conductor: Two-Conductor: Desired Cold Lead Length:
Form E
Total Heated Length One Conductor Cold Lead Length
Total Heated Length Cold Lead Length Two Conductor

17
Mineral Insulated Cable can be manufactured into the heater designs shown below as Form A and Form E. The following information is required to properly design mineral insulated cable units. Determine the following information and contact the Chromalox Application Group for assistance (see back cover).
ELECTRICAL DESIGN
ELECTRICAL DESIGN
ELECTRICAL DESIGN
Circuit Breaker Selection
To select the circuit breaker size, determine the following information: Maintenance Temperature: Heat Loss per Foot of Pipe, QT: Pipe or Tubing Size: Pipe Length: Type and Number of Valves & Supports: Heating Cable Catalog Number: Minimum Start-Up Temperature:
Example: English
Maintenance Temperature: Heat Loss per Foot of Pipe, QT: Pipe or Tubing Size: Pipe Length: Type and Number of Valves & Supports:
40F 4.88 W/ft 3" steel 124 ft 2 Butterfly Valves, 12 Pipe Hanger Supports Heating Cable Catalog Number: SRL 5-1CT Minimum Start-Up Temperature: -20F
Example: Metric
Maintenance Temperature: Heat Loss per Foot of Pipe, QT: Pipe or Tubing Size: Pipe Length: Type and Number of Valves & Supports:
4.4C 15.98 W/m 76 mm steel 38 m 2 Butterfly Valves, 12 Pipe Hanger Supports Heating Cable Catalog Number: SRL 5-1CT Minimum Start-Up Temperature: -28.9C
Step 1. Determine the Total Cable Length
See Table 11 (page 19) for additional cable lengths required for each type of in-line equipment based on piping size. Calculate the total length of heating cable required by combining lengths from each component of the piping system.
In addition to piping, in-line equipment such as valves, flanges, and pipe supports require additional heat tracing to maintain the system operating temperatures.
Example:
Pipe length of 124 ft (38 m) single pass application 2 Butterfly Valves, additional cable 2.5 ft (0.76 m) each valve 12 Pipe Hanger Supports, additional cable per support is 2.0 ft (0.61 m) Total length required
= = = =
124 ft (38 m) SRL 5-1CT 5.0 ft (1.52 m) SRL 5-1CT 24.0 ft (7.3 m) SRL 5-1CT
= = 153 ft (46.82 m) SRL 5-1CT
18
1. For Self-Regulating Cable - From Table 12 (page 20) select the circuit breaker trip rating by finding the heating cable type and the minimum expected start-up temperature. Compare the maximum circuit length for each breaker rating to the total cable length required for each pipe. Select the breaker rating whose maximum circuit length just exceeds the total cable required for the pipe.
If the required cable length exceeds the maximum circuit length, determine the number of circuits required:
Number of Circuits = Total Cable Length / Maximum Circuit Length
Table 11 Additional Cable Lengths Required for In-line Equipment

Piping Size Gate Valve Globe Valve Ball Valve Butterfly Valve ft/m
12
Shoe Support
Hanger Support
Sleeper Support 1.00 0.30 1.00 0.30 1.00 0.30 2.00 0.61 2.00 0.61 2.00 0.61 2.00 0.61 2.50 0.76 2.50 0.76 2.50 0.76 3.00 0.91 3.00 0.91 3.00 0.91 3.50 1.07 3.50 1.07 3.50 1.07 3.50 1.07 4.00 1.22
Flange Pair
/ in. / in.
1.00 0.30 1.50 0.46 2.00 0.61 2.50 0.76 2.50 0.76 2.50 0.76 3.00 0.91 4.00 1.22 5.00 1.52 7.00 2.13 8.00 2.44 9.00 2.74 10.00 3.05 11.00 3.35 12.00 3.66 13.00 3.96 13.00 3.96 15.00 4.57
1.00 0.30 1.00 0.30 1.00 0.30 1.50 0.46 2.00 0.61 2.00 0.61 2.50 0.76 3.00 0.91 3.50 1.07 4.00 1.22 4.50 1.37 5.00 1.52 5.50 1.68 6.00 1.83 7.00 2.13 7.50 2.29 7.50 2.29 8.00 2.44
1.00 0.30 1.00 0.30 1.00 0.30 1.50 0.46 2.00 0.61 2.00 0.61 2.50 0.76 3.00 0.91 3.50 1.07 4.00 1.22 4.50 1.37 5.00 1.52 5.50 1.68 6.00 1.83 7.00 2.13 7.50 2.29 7.50 2.29 8.00 2.44
1.00 0.30 1.00 0.30 1.00 0.30 1.50 0.46 2.00 0.61 2.00 0.61 2.50 0.76 3.00 0.91 3.50 1.07 4.00 1.22 4.50 1.37 5.00 1.52 5.50 1.68 6.00 1.83 7.00 2.13 7.50 2.29 7.50 2.29 8.00 2.44
1.00 0.30 1.50 0.46 1.50 0.46 2.00 0.61 2.00 0.61 2.00 0.61 2.00 0.61 2.50 0.76 2.50 0.76 2.50 0.76 3.00 0.91 3.00 0.91 3.00 0.91 3.50 1.07 3.50 1.07 3.50 1.07 3.50 1.07 4.00 1.22
1.00 0.30 1.00 0.30 1.00 0.30 2.00 0.61 2.00 0.61 2.00 0.61 2.00 0.61 2.50 0.76 2.50 0.76 2.50 0.76 3.00 0.91 3.00 0.91 3.00 0.91 3.50 1.07 3.50 1.07 3.50 1.07 3.50 1.07 4.00 1.22
0.30 0.09 0.30 0.09 0.30 0.09 0.30 0.09 0.30 0.09 0.30 0.09 0.50 0.15 0.50 0.15 0.80 0.24 0.80 0.24 0.80 0.24 0.80 0.24 1.00 0.30 1.00 0.30 1.00 0.30 1.00 0.30 1.00 0.30 1.00 0.30
21.3 mm
34
26.7 mm 1 in. 33.4 mm 11/2 in. 48.3 mm 2 in. 60.3 mm 21/2 in. 73.0 mm 3 in. 88.9 mm 4 in. 114.3 mm 6 in. 168.3 mm 8 in. 219.1 mm 10 in. 273.1 mm 12 in. 323.9 mm 14 in. 355.6 mm 16 in. 406.4 mm 18 in. 457.2 mm 20 in. 508.0 mm 22 in. 558.8 mm 24 in. 609.6 mm
ELECTRICAL DESIGN
19
Step 2. Determine the Circuit Breaker Rating
If the circuit breaker rating is predetermined, use the maximum circuit length shown in Table 12 for the cable type at the minimum startup temperature.
ELECTRICAL DESIGN
Table 12 Maximum Circuit Length by Start-Up Temperature and Breaker Size for Self-Regulating Cable
Cable Rating
10A 15A Maximum Circuit Length Circuit Breaker 20A 25A 30A
50F (10C) Start-Up
40A
50A
SRL / HSRL 3-1 (ft) SRL / HSRL 3-1 (m) SRL / HSRL 3-2 (ft) SRL / HSRL 3-2 (m) SRL / HSRL 5-1 (ft) SRL / HSRL 5-1 (m) SRL / HSRL 5-2 (ft) SRL / HSRL 5-2 (m) SRL / HSRL 8-1 (ft) SRL / HSRL 8-1 (m) SRL / HSRL 8-2 (ft) SRL / HSRL 8-2 (m) SRL / HSRL 10-1 (ft) SRL / HSRL 10-1 (m) SRL / HSRL 10-2 (ft) SRL / HSRL 10-2 (m) SRM/E / HSRM 3-1 (ft) SRM/E / HSRM 3-1 (m) SRM/E / HSRM 3-2 (ft) SRM/E / HSRM 3-2 (m) SRM/E / HSRM 5-1 (ft) SRM/E / HSRM 5-1 (m) SRM/E / HSRM 5-2 (ft) SRM/E / HSRM 5-2 (m) SRM/E / HSRM 8-1 (ft) SRM/E / HSRM 8-1 (m) SRM/E / HSRM 8-2 (ft) SRM/E / HSRM 8-2 (m) SRM/E / HSRM 10-1 (ft) SRM/E / HSRM 10-1 (m) SRM/E / HSRM 10-2 (ft) SRM/E / HSRM 10-2 (m) SRM/E / HSRM 15-1 (ft) SRM/E / HSRM 15-1 (m) SRM/E / HSRM 15-2 (ft) SRM/E / HSRM 15-2 (m) SRM/E / HSRM 20-1 (ft) SRM/E / HSRM 20-1 (m) SRM/E / HSRM 20-2 (ft) SRM/E / HSRM 20-2 (m)
205 62 400 122 125 38 250 76 100 30 185 56 60 18 100 30 190 58 380 116 115 35 235 72 90 27 185 56 60 18 125 38 45 14 90 27 35 11 75 23
305 93 600 183 185 56 375 114 150 46 285 87 95 29 160 49 285 87 575 175 180 55 360 110 145 44 285 87 95 29 190 58 70 21 145 44 60 18 115 35
360 110 660 201 250 76 505 154 200 61 375 114 130 40 210 64 385 117 770 235 240 73 480 146 190 58 380 116 125 38 255 78 95 29 190 58 75 23 155 47
NR NR NR NR 270 82 540 165 215 66 420 128 160 49 260 79 NR NR 775 236 295 90 590 180 235 72 470 143 155 47 310 94 115 35 235 72 90 27 185 56
NR NR NR NR NR NR NR NR NR NR NR NR 180 55 315 96 NR NR 780 238 360 110 720 219 285 87 575 175 190 58 385 117 145 44 290 88 115 35 230 70
NR NR NR NR NR NR NR NR NR NR NR NR NR NR 360 110 NR NR NR NR 375 114 750 229 325 99 650 198 250 76 490 149 190 58 385 117 155 47 305 93
NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 210 64 420 128 160 49 350 107
NOTE: This table takes into account start-up current characteristics of self-regulating cable and the 20% safety factor as required by the NEC Article 384-16(c). NR = Not Recommended.
20
Table 12, cont'd.

Cable Rating
10A 15A Maximum Circuit Length Circuit Breaker 20A 25A 30A
0F (-18C) Start-Up
40A
50A
135 41 275 84 90 27 180 55 70 21 135 41 50 15 80 24 160 49 320 98 100 30 200 61 80 24 165 50 55 17 105 32 40 12 80 24 35 11 70 21
200 61 415 126 135 41 270 82 110 34 200 61 80 24 125 38 275 84 540 165 165 50 325 99 135 41 255 78 90 27 165 50 65 20 120 37 50 15 100 30
270 82 555 169 180 55 360 110 145 44 265 81 105 32 170 52 375 114 750 229 220 67 430 131 175 53 345 105 110 34 225 69 85 26 175 53 65 20 135 41
330 101 660 201 225 69 450 137 180 55 335 102 130 40 210 64 380 116 770 235 255 78 510 155 205 62 345 105 135 41 270 82 105 32 205 62 85 26 170 52
360 110 NR NR 270 82 540 165 215 66 395 120 155 47 255 78 385 117 780 238 330 101 645 197 265 81 520 158 175 53 345 105 125 38 270 82 105 32 200 61
NR NR NR NR NR NR NR NR NR NR 420 128 180 55 340 104 NR NR NR NR 375 114 750 229 325 99 650 198 250 76 490 149 165 50 360 110 140 43 270 82
NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 210 64 420 128 160 49 350 107
ELECTRICAL DESIGN
21
Table 12, cont'd.
ELECTRICAL DESIGN
Cable Rating
10A 15A
Maximum Circuit Length Circuit Breaker 20A 25A 30A

-20F (-29C) Start-Up
40A
50A
120 37 245 75 80 24 160 49 65 20 120 37 45 14 75 23 155 47 300 91 95 29 195 59 75 23 155 47 50 15 100 30 40 12 80 24 30 9 65 20
185 56 370 113 120 37 245 75 100 30 175 53 70 21 120 37 265 81 525 160 155 47 310 94 130 40 245 75 85 26 155 47 60 18 155 47 45 14 90 27
245 75 495 151 160 49 325 99 130 40 235 72 95 29 160 49 365 111 740 226 210 64 415 126 165 50 335 102 100 30 215 66 80 24 165 50 65 20 130 40
300 91 600 183 205 62 405 123 165 50 300 91 120 37 195 59 370 113 760 232 245 75 480 146 195 59 390 119 125 38 255 78 100 30 200 61 80 24 160 49
360 110 660 201 245 75 490 149 200 61 350 107 140 43 240 73 385 117 780 238 310 94 620 189 250 76 490 149 170 52 330 101 120 37 260 79 100 30 195 59
NR NR NR NR 270 82 540 165 210 64 420 128 180 55 320 98 NR NR NR NR 375 114 750 229 325 99 650 198 245 75 470 143 150 46 340 104 135 41 255 78
NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR 250 76 490 149 210 64 420 128 160 49 335 102
22
Adjusted Current Draw = Total Circuit Current Draw x 1.20
2. For Constant Wattage Cable - Determine the total current draw by determining the circuit load in A/ft (A/m) from Table 13 and multiply this number by the total length required for the piping.
Total Circuit Current Draw = Circuit Load A/ft (A/m) x Total Cable Length for the Pipe
Choose the circuit breaker rating that exceeds the adjusted current draw.
Step 3. Select the Circuit Breaker The National Electric Code (NEC 1996) and European Union (EU) code require the use of ground-fault style breakers for heating cable circuit protection. If heating cable is improperly installed or physically damaged to the point that water contacts the bus wires, sustained arcing or fire could result. If arcing does occur, the fault current may be too low to trip conventional circuit breakers. Chromalox recommends the use of thermal magnetic style circuit breakers with a trip rating set at 30mA (equipment protection device) to eliminate nuisance tripping that can occur at low temperatures with magnetic type or lower rated ground fault trip breakers.
Then adjust this total current draw by the 20% safety factor required by the National Electric Code (NEC):
Adjusted Current Draw = Total Circuit Current Draw x 1.20
Choose the circuit breaker rating that exceeds the adjusted current draw. To determine the number of circuits required for each pipe, divide the total cable length required by the maximum circuit length shown in Table 13 for the cable selected.
Number of Circuits = Total Cable Length / Maximum Circuit Length
The following are some ground-fault breakers that meet these requirements: Square D: Type QOB-EPD Westinghouse: Types GFEP, GFEPD Cutler-Hammer: Type QBGFEP
3. For Mineral Insulated Cable Find the total current draw by dividing the total cable wattage by the operating voltage:
Total Circuit Current Draw = Total Cable Wattage/Operating Voltage
Table 13 Circuit Load and Maximum Circuit Lengths for Constant Wattage Cable
Model Number Circuit Load A/ft A/m Maximum Circuit Length ft m
CWM 4-1 CWM 4-2 CWM 8-1 CWM 8-2 CWM 12-1 CWM 12-2
0.033 0.017 0.067 0.033 0.100 0.050
0.108 0.056 0.220 0.108 0.328 0.164
350 700 240 480 200 400
107 213 73 146 61 122
ELECTRICAL DESIGN
23
Total heating cable length required for piping is 153 ft (46.82 m) SRL 5-1CT. The minimum startup temperature for the system is -20F (-29C). Therefore, based on Table 12, the circuit breaker required is 20A.
Then adjust the total current draw for the 20% safety factor required by the NEC:
COMPONENT SELECTION AND ACCESSORIES

Heat tracing circuits require a power connection and an end seal. Splice and tee kits are used as required. See diagrams and tables below and on the following pages for typical system details. Choose a series of components based on area classification and preference.
Figure 5
EL Series Components
In addition, choose attachment accessories from Table 18 (page 29) based on requirements listed in Table 19 (page 29).
EL Series Components - For use in Ordinary and Division 2 Hazardous Areas as shown in Table 14.
RT-RES RT-TES
RT-RST RT-TST
JBLT with SLK RT-RST RT-TST
RT-RCL JBLT JBLT
RT-JBC-1 RT-JBC-2
COLD LEAD
Table 14 EL Series Connection Components for Installation, U.S. Only

Approvals Cable Type Component Model Ordinary Area
Junction Box Connection Kit Junction Box End Seal Tee Connection Splice Connection Junction Box Connection Kit Junction Box End Seal Tee Connection Splice Connection RT-JBC-1 JBLT RT-RES RT-RST RT-RST RT-JBC-2 JBLT RT-TES RT-TST RT-TST UL,CSA, FM UL,CSA, FM UL,CSA, FM UL,CSA, FM UL,CSA, FM UL, CSA UL,CSA, FM UL, CSA UL, CSA UL, CSA FM FM FM
Class I Div. 2 Gr. B, C, D

FM FM FM FM FM
Class II Div. 2 Gr. G

FM FM FM FM FM
Class III Div. 2

FM FM FM FM FM
NOTE: EL Series not to be used with SRME cable. SLK-1 and SLK-2 are no longer offered.
24
CWM-C & CWM-CT
SRL-C, SRL-CR, SRL-CT
Figure 6
DL Series Components
DL Series Components - DL Series Accessories include enclosures molded of durable Ryton PPS plastic material and are rated NEMA 4X. For use in Ordinary and Division 2 Hazardous Areas as shown in the table below.
Additional accessories are required (see Table 18 and Table 19, page 29) for descriptions and part numbers): RTPC models require 1 conduit hub. RTPC and RTST models require 1 pipe strap each to fasten the kit to the pipe. Grommets are required for DL Series Components. (See Table 16): Each cable entry requires 1.
RTST-XSL
Each RTPC (Power Connection) requires at least 1. Each RTST (Splice & Tee) requires at least 3.
RTPC-XSL
RTST-X
RTES-X
RTST-X
TO SUPPLY POWER
RTPC-X

25
Table 15 DL Series Connection Components for Installation, U.S. Only

Approvals
Cable Type
Component
Model Ordinary Areas

CSA, FM
Class II Div. 2 Gr. F, G

CSA, FM
Class III Div. 2

FM
Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit
RTPC-1 RTPC-1SL1 RTPC-1SL2 RTPC-1SL3 RTES-1 RTST-1SL1 RTST-1SL2 RTST-1SL3 RTST-1 RTPC-2 RTPC-2SL1 RTPC-2SL2 RTPC-2SL3 RTES-1 RTST-2SL1 RTST-2SL2 RTST-2SL3 RTST-2 RTPC-7 RTPC-7SL1 RTPC-7SL2 RTPC-7SL3 RTES-7 RTST-7SL1 RTST-7SL2 RTST-7SL3 RTST-7 RTPC-8 RTPC-8SL1 RTPC-8SL2 RTPC-8SL3 RTES-8 RTST-8SL1 RTST-8SL2 RTST-8SL3 RTST-8
UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM
SRL-C
CSA, FM
CSA, FM
FM
CSA, FM CSA, FM
CSA, FM CSA, FM
FM FM
SRL-CR & SRL-CT
CSA, FM
CSA, FM
FM
CSA, FM CSA, FM
CSA, FM CSA, FM
FM FM
SRM/E-C
CSA, FM
CSA, FM
FM
CSA, FM CSA, FM
CSA, FM CSA, FM
FM FM
SRM/E-CT
CSA, FM
CSA, FM
FM
CSA, FM
CSA, FM
FM
26
Table 15 , con't.
Approvals
Cable Type
Component
Model Ordinary Areas

CSA, FM
Class II Div. 2 Gr. F, G

CSA, FM
Class III Div. 2

FM
Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit Power Connection Kit Power Connection Kit w/ Signal Light, 120V Power Connection Kit w/ Signal Light, 208-240V Power Connection Kit w/ Signal Light, 277V End Seal Kit End Seal Kit w/ Signal Light, 120V End Seal Kit w/ Signal Light, 208-240V End Seal Kit w/ Signal Light, 277V Splice and Tee Kit
RTPC-3 RTPC-3SL1 RTPC-3SL2 RTPC-3SL3 RTES-3 RTST-3SL1 RTST-3SL2 RTST-3SL3 RTST-3 RTPC-4 RTPC-4SL1 RTPC-4SL2 RTPC-4SL3 RTES-4 RTST-4SL1 RTST-4SL2 RTST-4SL3 RTST-4
UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM UL, CSA, FM
CSA, FM
CSA, FM
FM
CSA, FM CSA, FM
CSA, FM CSA, FM
FM FM
CSA, FM
CSA, FM
FM
CSA, FM
CSA, FM
FM
Table 16 Grommets for DL Series Components

Cable Type
RTO/Capillary Type Blank SRL-C SRL-CR, SRL-CT CWM-C CWM-CT SRL-MC SRL-MCR, SRL-MCT SRM/E-C SRM/E-CT
Grommet Model No.

GRS GRO GR1 GR2 GR3 GR4 GR5 GR6 GR7 GR8

27
CWM-CT
CWM-C
Figure 7
HL Series Components
HL Series Components For use in Division 1 Hazardous Areas with HSRL and HSRM Heating Cables.
Additional accessories are required (see Table 18 and Table 19, page 29 for descriptions and part numbers): All models require 2 pipe straps to fasten kit to pipe.
HL-ES HL-S
HL-T
TO SUPPLY POWER
HL-PC
Table 17 HL Series Components

Approvals
Cable Type
Component
Model
HSRL- CT
Power Connection End Seal Tee Connection Splice Connection Power Connection End Seal Tee Connection Splice Connection
HL-PC HL-ES HL-T HL-S HL-PC HL-ES HL-T HL-S
Class I Div. 1 Gr. B, C, D FM

FM FM FM FM FM FM FM
Class II Div. 1 Gr. E, F, G FM

Class III Div. 1 FM

28
HSRM- CT
Table 18 Attachment Accessories, U.S. Only

Designation Model
Pipe Strap for 1/2" to 3/4" (21.3 mm to 26.7 mm) pipes Pipe Strap for 1" to 31/2" (33.4 mm to 101.6 mm) pipes Pipe Strap for 21/2" to 9" (73.0 mm to 262.8 mm) pipes Fiberglass Tape 21/2" (73.0 m) wide, 180 ft (55 m) roll Fiberglass Tape 21/2" (73.0 mm) wide, 66 ft (20 m) roll Nylon Cable Ties, Interlocking, 100 per pack Aluminum Tape 21/2" (73.0 mm) wide, 180 ft (55 m) roll Conduit Hub Attachment 3/4" (18.80 mm) NPT Conduit Hub Attachment 3/4" (18.80 mm) NPT w/Ground connector Mounting Plate for Installing RTPC & RTST on Flat Surface Caution Labels, 5 per pack applied at 10 ft (3 m) intervals
PS-1 PS-3 PS-10 FT-1 FT-2 CT-100 AT-1 CCH-1 CCH-2 MP-1 CL-1
Table 19 Attachment Requirements - Minimum Number of Kits Required per 100 ft (30 m) of Pipe Length
Pipe Size
12 34
Minimum No. of Kits Required Per 100 ft (30 m) of Pipe CT-100 FT-1 FT-2 1 1 1 1 1 1 1 1 2 2 2 2 3 3 4 4 4 5 5 6 0.31 0.39 0.48 0.61 0.70 0.87 1.10 1.30 1.50 1.70 2.00 2.40 3.20 3.90 4.70 5.10 5.90 6.60 7.30 8.80 0.51 0.64 0.79 1.00 1.15 1.42 1.80 2.13 2.45 2.78 3.27 3.93 5.24 6.38 7.69 8.35 9.65 10.80 11.95 14.40
/ " (21.3 mm) / " (26.7 mm)
1" (33.4 mm) 11/4" (42.2 mm) 11/2" (48.3 mm) 2" (60.3 mm) 2 / " (73.0 mm) 3" (88.9 mm) 3 /2" (101.6 mm) 4" (114.3 mm) 5" (141.3 mm) 6" (168.3 mm) 8" (219.1 mm) 10" (273.1 mm) 12" (323.9 mm) 14" (355.6 mm) 16" (406.4 mm) 18" (457.2 mm) 20" (508.0 mm) 24" (609.6 mm)
1 12
NOTE: Strap fiberglass tape or cable ties at 1-ft (0.31-m) intervals to hold cable to metal pipe. Use aluminum tape for non-metal pipe concentrically under and over heating cable to aid in heat transfer.

29
Table 20 Connection Accessories for Heat Trace Installation Outside of the United States
Cable Type Component
Power Connection - Polyester Power Connection - Aluminum Termination Kit for Use with Power Connection Kit
Model
BJP002N BJA001 KCA001 KIE002A KECPE001 KECME001 RT-RST Domo Click BJP002N BJA001 BJEP004N BJEA004 BJDA004N KCA001 KIE002A KECPE001 KECME001 RT-RST Domo Click KEJ-Ex BJP002N BJA001 BJEP004N BJEA004 BJDA004N KCA001 KIE002C KECPE003 KECME003 RT-RST Domo Click KEJ-Ex BJP002N BJA001 KCA001 KIE002A KECPE004 KECME004
RT-RST
Approvals
ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX
SRL SRL-C SRL-CR & SRL-CT SRME
End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut Splice and Tee Kit - Shrink-On Sleeve Splice and Tee Kit - Fast Connection Power Connection - Polyester Power Connection - Aluminum Power Connection - EEx'e' Polyester Power Connection - EEx'e' Aluminum Power Connection - EEx'd' Aluminum Termination Kit for Use with Power Connection Kit End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut Splice and Tee Kit - Shrink-On Sleeve Splice and Tee Kit - Fast Connection In-Line Splice Kit - Hazardous Areas Power Connection - Polyester Power Connection - Aluminum Power Connection - EEx'e' Polyester Power Connection - EEx'e' Aluminum Power Connection - EEx'd' Aluminum Termination Kit for Use with Power Connection Kit End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut Splice and Tee Kit - Shrink-On Sleeve Splice and Tee Kit - Fast Connection In-Line Splice Kit - Hazardous Areas Power Connection - Polyester Power Connection - Aluminum Termination Kit for Use with Power Connection Kit End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut
Splice & Tee Kit - Shrink-On Sleeve
Domo Click KECPE001 KECME001 KECPE003 KECME003 KECPE004 KECME004 KECPE005 KECME005
RT-RST
BJP002N BJA001 BJEP00
BJEA004 BJEA004N
KCA001
KEJ-Ex
KIE002A KEI002C
30
Table 20, con't.

Cable Type Component
Power Connection - Polyester Power Connection - Aluminum Power Connection - EEx'e' Polyester Power Connection - EEx'e' Aluminum Power Connection - EEx'd' Aluminum Termination Kit for Use with Power Connection Kit End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut Splice and Tee Kit - Shrink-On Sleeve In-Line Splice Kit - Hazardous Areas Power Connection - Polyester Power Connection - Aluminum Power Connection - EEx'e' Polyester Power Connection - EEx'e' Aluminum Power Connection - EEx'd' Aluminum Termination Kit for Use with Power Connection Kit End Seal Kit - 150C Maximum Temperature Polyamide Ex'e' Gland with Cable Sealing Washer and Backnut Brass Ex'e' Gland with Cable Sealing Washer and Backnut Splice and Tee Kit - Shrink-On Sleeve In-Line Splice Kit - Hazardous Areas
Model
BJP002N BJA001 BJEP004N BJEA004 BJDA004N KCA001 KIE002A KECPE004 KECME004 RT-RST KEJ-Ex BJP002N BJA001 BJEP004N BJEA004 BJDA004N KCA001 KIE002C KECPE005 KECME005 RT-RST KEJ-Ex
Approvals
ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX ATEX
Table 21 Attachment Accessories for Heat Trace Installation Outside the U.S.
Designation
Fiberglass Adhesive Tape, 90C Maximum Temperature, 50 m Long Fiberglass Adhesive Tape, 110C Maximum Temperature, 50 m Long Fiberglass Adhesive Tape, 180C Maximum Temperature, 33 m Long Aluminum Adhesive Tape, 95C Maximum Temperature, 50 m Long Through Bulkhead Kit, SRL & SRL-C Cable Through Bulkhead Kit, SRL-CR & SRL-CT Cable Through Bulkhead Kit, SRM & SRM-C Cable Through Bulkhead Kit, SRM-CT Cable Insulation Outlet Kit Box Support Bracket for use with Power Connection Kit - Vertical Box Support Bracket for use with Power Connection Kit - Horizontal Self-Adhesive Warning Labels
Model
FT04 FT02 FT03 AT03 RCC1 RCC3 RCC4 RCC5 KSCA003 KSB001 KSB002 CL02
RCC1 RCC3 RCC4
FT02 FT03 FT04
AT03
KSB001 KSB002
KSCA003
RCC1 RCC3 RCC4

31
SRME-CT
SRME-C
CONTROL SELECTION
Typical heat trace temperature control is accomplished by one of two methods: ambient air sensing or pipe wall sensing. When designing a heat trace system with relatively few circuits, temperature controls can be accomplished by using single-point on/off controls. When designing a system with a large number of circuits or a system that protects critical plant functions, it is often advantageous to use central control panels that employ electronic control.
Ambient Air Sensing Control
the heating cable on and off at a preset ambient temperature. For a small number of circuits singlepoint thermostats can be used to switch individual circuits on and off. If a large number of circuits is involved, a single strategically located thermostat can be used in conjunction with a contactor to switch all circuits on or off at a preset temperature. Select your thermostat from among the figures below based on your installation needs for operating voltage, switching current, setpoint range, and area classification. NOTE: If your circuit current exceeds the switch rating of the device selected, use the device in conjunction with a contactor suitable for your circuit current.
In an ambient air sensing control system, a thermostat is used to sense ambient air and switch
Figure 8
RTAS Ambient Air Sensing Control Thermostats
Approvals: Ordinary Areas: UL, CSA, FM Enclosure: NEMA 4X Ryton PPS Setpoint Range: 0 to 225F (-18 to 107C), Factory Preset at 40F (4.4C) Deadband: 10% of Range Operating Temperature Range: -40 to 160F (-40 to 70C) Scale Division: 10F (5.6C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 9/16" (14.29 mm) OD x 3" (76.2 mm) L Stainless Steel Maximum Sensor Exposure Temperature: 450F (230C)
This unit can serve as power connection box. Heating cable can be terminated directly into enclosure. Requires a sealing grommet for the type of cable being used.
32
Figure 9
RTAS-EP Ambient Air Sensing Control Thermostats
Approvals: Ordinary Areas: UL, CSA, FM Class I, Div. 2, Groups B,C,D: CSA, FM Class II, Div. 2, Groups F,G: CSA, FM Class III, Div. 2: FM Enclosure: NEMA 4X Ryton PPS Setpoint Range: 0 - 225F (-18 to 107C), Factory Preset at 40F (4.4C) Deadband: 10% of Range Operating Temperature Range: -40 to 160F (-40 to 70C) Scale Division: 10F (5.6C) Switch Type: SPDT Switch Rating: 11A at 120/250 Vac Sensor: 9/16" (14.29 mm) OD x 3" (76.2 mm) L Stainless Steel Maximum Sensor Exposure Temperature: 450F (230C)
Figure 10
B-100 Ambient Air Sensing Control Thermostats
Approvals: Ordinary Areas: UL, CSA Enclosure: NEMA 4X Setpoint Range: 15 to 140F (-10 to 60C) Deadband: 2% of Range Operating Temperature Range: -40 to 160F (-40 to 71C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 9/16" (14.29 mm) OD x 3" (76.2 mm) L Stainless Steel
CONTROL SELECTION
CONTROL SELECTION
33
CONTROL SELECTION
Figure 11121 Ambient Air Sensing Control Thermostats

B-121 Ambient Air Sensing Control Thermostats
Approvals: Ordinary Areas: UL, CSA, FM Class I, Groups B,C,D: FM Class II, Groups E, F,G: FM Class III: FM Enclosure: NEMA 4X,7,9 Cast Aluminum Setpoint Range: 15 to 140F (-10 to 60C) Deadband: 2% of Range Operating Temperature Range: -40 to 160F (-40 to 71C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 9/16" (14.29 mm) OD x 3" (76.2 mm) L Stainless Steel
Line Sensing Control
Line sensing control is used for process maintenance applications where the process temperature must be controlled within a moderate or narrow band. In a pipe wall sensing control system, a thermostat or RTD is used to sense pipe wall temperature and switch the heating cable on and off at a preset temperature. For a small number of circuits, single-point thermostats can be used to switch individual circuits on and off. If a large
number of circuits is involved, a centralized panel board and electronic circuit monitoring system is often used. See next section on intelliTRACE controls. Select your thermostat from the figures below based on your installation needs for operating voltage, switching current, set point range, and area classification. NOTE: If your circuit current exceeds the switch rating of the device selected, use the device in conjunction with a contactor suitable for your circuit current.
Figure 12
RTBC Line Sensing Control Thermostat
Approvals: Ordinary Areas: UL, CSA, FM Enclosure: NEMA 4X Ryton PPS Setpoint Range: 0 to 400F (-18 to 200C) Deadband: 10% of Range Operating Temperature Range: -40 to 160F (-40 to 71C) Scale Division: 10F (5.6C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 1/8" (3.175 mm) OD x 11 5/8" (295.28 mm) L Bulb, 10 ft (3 m) Stainless Steel Capillary Maximum Sensor Exposure Temperature: 450F (230C)
34
Figure 13
RTBC-EP Line Sensing Control Thermostat
Part No.: 384841 Approvals: Ordinary Areas: UL, CSA, FM Class I, Div. 2, Groups B, C, D:CSA FM Class II, Div. 2, Groups F, G: CSA FM Class III, Div. 2: FM Enclosure: NEMA 4X Ryton PPS Setpoint Range: 0 to 400F (-18 to 200C) Deadband: 10% of Range Operating Temperature Range: -40 to 160F (-40 to 71C) Scale Division: 10F (5.6C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 1/8" (3.175 mm) OD x 11 5/8" (295.28 mm) L Bulb, 10 ft (3 m) Stainless Steel Capillary Maximum Sensor Exposure Temperature: 450F (230C)
Figure 14E-100 Line Sensing Control Thermostat

E-100 Line Sensing Control Thermostat
Approvals: Ordinary Areas: UL, CSA Enclosure: NEMA 4X Setpoint Range: 25 to 325F (-5 to 163C) Deadband: 2% of Range Operating Temperature Range: -40 to 160F (-40 to 71C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 1/8" (3.175 mm) OD x 11 5/8" (295.28 mm) L Bulb, 10 ft (3 m) Stainless Steel Capillary
Figure 15 121 Line Sensing Control Thermostat

E-121 Line Sensing Control Thermostat
Approvals: Ordinary Areas: UL, CSA, FM Class I, Groups B,C,D: CSA, FM Class II, Groups E, F,G: CSA, FM Class III: FM Enclosure: NEMA 4X, 7, 9 Setpoint Range: 25 to 325F (-5 to 163C) Deadband: 10% of Range Operating Temperature Range: -58 to 160F (-50 to 71C) Switch Type: SPDT Switch Rating: 22A at 120/250/480 Vac Sensor: 1/8" (3.175 mm) OD x 11 5/8" (295.28 mm) L Bulb, 10 ft (3 m) Stainless Steel Capillary
35
CONTROL SELECTION
intelliTRACE CONTROLS
The intelliTRACE System is a complete control solution designed for heat trace applications, such as process temperature maintenance, freeze protection, and roof/gutter de-icing. The modular design of the intelliTRACE control panel and components allows users to select only features needed for their specific heat trace installation. This system uses microprocessor-based control and comes completely pre-wired and assembled. A variety of options is available that include three different AC line voltages (120, 240, and 277), RS-485 communications interface, and ground fault indicator.
Single-Loop Line-Sensing Control Panel
10.5" (26.67 cm) 8.0" (20.32 cm) 0.31 x 0.5" (1.27 cm)
Technical Specifications
1.75" (4.45 cm)
Supply Voltage: 120, 240 and 277 Operating Environment: 30 to 120F (0 to 40C)
CONTROLLER
Chromalox
83
GR/RESET
Communications: RS-485 MODBUS*

CAUTION
12.5" (31.75 cm) 12.94" (32.89 cm)
HAZARD OF ELECTRIC SHOCK DISCONNECT ALL POWER BEFORE SERVICING THIS UNIT
Input Voltage: Thermocouple J,K,L,N,R,S,RTD, current, Field Programmable for F or C
Chromalox
Front View
6.25" (15.88 cm)
Output: Solid State Relay Rated @ 30A @ 40C Current Alarm (Low): 0 to 30A in 1A Increments Ground Fault Alarm Trip: 5 to 100mA Temperature Alarms: Process, Deviation, Band, High/Low, Latching/ Non-Latching (Manual/Automatic Reset) Programmable. Control Modes: Field Selectable On/Off, PID, SMART
12.5" (31.75 cm)
Side View
Ordering Information
Model HTLS HTLS Series Heat Trace Panel UL Listed Single-Phase Temperature/Monitor Heat Trace Panel. NEMA 4X fiber glass enclosure 12.5" (31.75 cm) H x 10.5" (26.67 cm) W x 6.25" (15.24 cm) D. Includes complete prewired controller, solid state relay mounted on external heatsink, current transformer to measure operating current, and temperature/current alarms. PID or On/Off control, digital dual displays, terminal blocks for field connections, and optional GFI Indication or Shutdown. Code Amps 1 30 Code 0 1 2 Voltage 120 Vac 240 Vac 277 Vac Code Digital Indicating Temperature Controller 0 1604-61230 1/16 DIN Dual Four Digit Display, Alarm Outputs, and Current Input 1 1604-61430 1/16 DIN Dual Four Digit Display, Alarm Outputs, Current Input and RS-485 Code 0 1 2 3 GFI Options None 120 V (Includes GFI Module, Shutdown Contactor, and Illuminated Reset Switch) 240 V (Includes GFI Module, Shutdown Contactor, and Illuminated Reset Switch) 277 V (Includes GFI Module, Shutdown Contactor, and Illuminated Reset Switch) Code 0 Add to complete model number HTLS 1 1 1 1 0 Typical Model Number
*MODBUS is a registered trademark of Gould Inc.
36
Supply Voltage: Operating Environment: Communications: Input Voltage: Output: Current Alarm (Low): Ground Fault Alarm Trip: Temperature Alarms: Control Modes:
120, 208, 240 and 277 Vac Three Phase 30 to 104F (-1 to 40C) RS-485 MODBUS* Thermocouple J,K,L,N,R,S,RTD, Current, and Voltage Field Programmable, for F or C Solid State Relay Rated @ 30A @ 40C 0 to 30A in 1A Increments 5 to 100mA Process, Deviation, Band, High/Low, Latching/Non-Latching (Manual/Automatic Reset) Programmable. Field Selectable On/Off, PID, SMART
Model HTLS IntelliTRACE 2000 Series Line Sensing Heat Trace Panel For indoor/outdoor applications. cUL and UL Listed NEMA 4X rated enclosure 16 in. H x 14 in. W x 8 in. D (406mm H x 356mm W x 203mm D). Factory pre-wired for quick installation. Includes solid state relays, current transformer, high/low temperature alarms, low current alarm, on/off or PID control, universal sensor inputs, dual digital displays, terminal blocks for field connections, and loop enable/disable. Options include ground fault monitoring or shutdown and RS-485 communications. Code Number of Loops 2 30A Rating Code 0 1 2 3 Voltage 120 Vac 240 Vac 277 Vac 208 Vac Code Controller 0 1604-61230 Controller 1 1604-61430 Controller with Communications Code 0 1 2 3 4 Ground Fault Monitoring None GFI 120 Vac (Includes Shutdown Contactor and Illuminate Reset Switch) GFI 240 Vac (Includes Shutdown Contactor and Illuminate Reset Switch) GFI 277 Vac (Includes Shutdown Contactor and Illuminate Reset Switch) GFI 208 Vac (Includes Shutdown Contactor and Illuminate Reset Switch) Code Enclosure Heater 0 None 1 Thermostat Controlled Enclosure Heater
HTLS
Typical Model Number
37
IntelliTRACE Dual-Loop Line Sensing Control Panel
intelliTRACE Multi-Loop Line-Sensing Control Panel
Supply Voltage: 120, 240 and 277 Vac Three-Phase Operating Environment: 30 to 120F (0 to 40C) Communications: RS-485 MODBUS* Input: RTD 100 Platinum Three-Wire Maximum Current: 24A/Ckt Temperature Alarms: High/Low 2F Deadband Non-Latching Ground Fault Alarm: Adjustable 25 to 500mA, Factory Set @ 30mA Continuity Alarm: < 2A Non-Latching Load Management: 15-Second Non-Overlap to Reduce In-Rush Auto-Cycle: Programmable to 720 Hr (30 days) Failed Sensor Output Setting: 0% to 100% Control Mode: On/Off with Adjustable Deadband
Model HTLS HTLS Series Heat Trace Panel cUL Listed Floor Mount NEMA 4 Steel Enclosure. Includes prewired controller, two-pole contactors, current transformer to measure operating currents, high/low temperature alarms, On/Off control, RTD sensor input, color touchscreen programming, GFI indication or shutdown, common alarm output, Hand/Off/Auto selection loop enable/disable, and auto-cycle feature. Code Number of Loops 8 Independent Loops of Heat Trace Control 12 24 Code 0 1 2 Voltage 120 Vac 240 Vac 277 Vac Code 1 2 3 Circuit Breaker Rating Selection 15A Thermal Magnetic Circuit Breakers 20A Thermal Magnetic Circuit Breakers 30A Thermal Magnetic Circuit Breakers Code Cabinet Heater 0 None 1 Thermostat Controller Enclosure Heater Code Pressurization Control System 0 None 1 Type Z for Class I Division 2 Hazardous Location HTLS 8 1 2 1 0 Typical Model Number
38
Supply Voltage: 120, 240 and 277 Vac Three-Phase Operating Environment: 30 to 120F (0 to 40C) Communications: RS-485 MODBUS* Maximum Current: 24A/Ckt Ground Fault Alarm: Adjustable 25 to 500mA, Factory Set @ 30mA Continuity Alarm: < 2A Non-Latching Load Management: 15-Second Non-Overlap to Reduce In-Rush Auto-Cycle: Programmable to 720 Hr (30 days) Control Mode: Optional Ambient Sensing Controller
Model HTAS HTAS Series Heat Trace Panel cUL Listed Floor Mount NEMA 4 Steel Enclosure. Includes optional ambient sensing controller, two-pole contactors current transformer to measure operating currents, continuity alarms, color touchscreen programming, GFI indication or shutdown, common alarm output, Hand/Off/Auto selection, loop enable/disable, and auto-cycle feature. Code Number of Loops 8 Independent Loops of Heat Trace Control 12 24 Code 0 1 2 Voltage 120 Vac 240 Vac 277 Vac Code 1 2 3 Circuit Breaker Rating Selection 15A Thermal Magnetic Circuit Breakers 20A Thermal Magnetic Circuit Breakers 30A Thermal Magnetic Circuit Breakers Code Cabinet Heater 0 None 1 Thermostat Controller Enclosure Heater Code 0 1 2 Ambient Sensing Controller None (Remote Mounted) 1601-11030, Three-Digit, Dual Display 1/16 Din Controller w/ Temp Alarms 1603-11030, Three-Digit, Dual Display 1/16 Din Controller w/ Temp Alarms Code Pressurization Control System 0 None 1 Type Z for Class I Division II Hazardous Location HTAS 12 1 2 1 0 1 Typical Model Number
39
intelliTRACE Multi-Loop Ambient-Sensing Control Panel
intelliTRACE Controls for Hazardous Location Applications
Description The Chromalox HTLSC1D2 series panels are microprocessor based temperature control and monitoring units for heat tracing used in freeze protection and process temperature control applications. This series of panels can be configured for ambient or line sensing control. The HTLSC1D2 series implement a scaleable design such that they can be configured with or without communications, ground fault monitoring or enclosure heater. This unique format offers a design that can be tailored both by price and features to meet the most challenging demands in heat trace applications. For example: The HTLSC1D2 series can be networked together via RS-485 MODBUS and the Chromalox Windows based Chromasoft SpecView software package. The optional ground fault monitoring addresses the national electric code requirements and reduces the cost of installing costly ground-fault circuit breakers. In the event of sub-zero temperatures the optional enclosure heater is available. The Chromalox HTLSC1D2 series offers single and dual loop designs and are approved for Class 1 Division 2 Areas. The HTLSC1D2 series have programmable inputs (thermocouple, RTD, mA, VDC), On/Off or PID control, Auto-tune function, High/Low temperature alarms, current alarm, and sensor failure indication. The heat tracing circuit is switched by a 30 amp solid state relay rated at 40C ambient. The Chromalox HTLSC1D2 series panel comes ready to install and includes control and power wiring terminal blocks for field connections.
40
Area of Use: Class 1 Division 2 Approvals: UL, cUL, CE Supply Voltage: 120, 208, 240, 277, and 480 Vac. Ambient Operating Temperature: 32 to 104F (0 to 40C), -32 to 104F (-35.5 to 40C) with Optional Enclosure Heater. Protection: NEMA 4X Fiber Glass Communications: RS-485 MODBUS*
Front View
Temperature Sensor Input: J, K, T, E, B, R, S, N, L, PT100, mV, mA, V Output: Solid State Relay Rated 30A @ 40C. Current Alarm (Low): 0 - 50A in .1A Resolution. Temperature Alarms: Field Selectable Deviation High/Low, Deviation Band High/Low, Process Low /High, Latching, Non-Latching. Control Modes: Field Selectable On/Off, PID, Auto-Tune. Ground Fault Alarm: Adjustable Trip Level 30 to 300mA; Adjustable Trip Delay 0 to 1 sec.
Side View
Model HTLSC1D2 HTLSC1D2 Series Heat Trace Panel cUL, UL and CE Listed Single Loop Line Sensing Temperature/Monitor Heat Trace Panel. Factory pre-wired for quick installation. Includes: Solid State Relay, Current Transformer, High-Low Temperature Alarms, Low Current Alarm, On/Off or PID Control, Universal Sensor Inputs, Dual Digital Displays, Terminal Blocks for Field Connections, Loop Enable/Disable, NEMA 4X rated Enclosure (16H x 14W x 8D) for Indoor/Outdoor Applications. Options Include: Ground Fault Monitoring, Digital Communications and Enclosure Heater. Code 1 Amps 30 Code 0 1 2 3 4 Voltage 120 Vac 208 Vac 240 Vac 277 Vac 480 Vac Code Controller 0 ETR-9300-412690 Controller 1 ETR-9300-412691 Controller with Communications Code Ground Fault Monitoring 0 None 1 Ground fault Module (Includes Illuminated Reset Switch) Code 0 1 HTLSC1D2 1 0 0 1 0 Enclosure Heater None Thermostat Controlled Enclosure Heater Typical Model Number
41
HTLS C1D2 Single-Loop Sensing Control Panel
HTLS C1D2 Dual-Loop Sensing Control Panel
Area of Use: Class 1 Division 2 Approvals: UL, cUL, CE Supply Voltage: 120, 208, 240, 277, and 480 Vac. Ambient Operating Temperature: 32 to 104F (0 to 40C), -32 to 104F (-35.5 to 40C) with Optional Enclosure Heater. Protection: NEMA 4X Fiber Glass
Front View
Communications: RS-485 MODBUS* Temperature Sensor Input: J, K, T, E, B, R, S, N, L, PT100, mV, mA, V Output: Solid State Relay Rated 30A @ 40C. Current Alarm (Low): 0 to 50A in .1A Resolution.
Side View
Temperature Alarms: Field Selectable Deviation High/Low, Deviation Band High/Low, Process Low /High, Latching, Non-Latching. Control Modes: Field Selectable On/Off, PID, Auto-Tune. Ground Fault Alarm: Adjustable Trip Level 30 to 300mA; Adjustable Trip Delay 0 to 1 sec.
Model HTLSC1D2 HTLSC1D2 Series Heat Trace Panel cUL, UL and CE Listed Dual Loop Line Sensing Temperature/Monitor Heat Trace Panel. Factory pre-wired for quick installation. Includes: Solid State Relay, Current Transformer, High-Low Temperature Alarms, Low Current Alarm, On/Off or PID Control, Universal Sensor Inputs, Dual Digital Displays, Terminal Blocks for Field Connections, Loop Enable/Disable, NEMA 4X rated Enclosure (18H x 16W x 10D) for Indoor/Outdoor Applications. Options Include: Ground Fault Monitoring, Digital Communications and Enclosure Heater. Code 2 Amps 30 Code 0 1 2 3 4 Voltage 120 Vac 208 Vac 240 Vac 277 Vac 480 Vac Code Controller 0 ETR-9300-412690 Controller 1 ETR-9300-412691 Controller with Communications Code Ground Fault Monitoring 0 None 1 Ground fault Module (Includes Illuminated Reset Switch) Code 0 1 HTLSC1D2 2 0 0 1 0 Enclosure Heater None Thermostat Controlled Enclosure Heater Typical Model Number
42
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Chromalox
103 Gamma Drive Ext. Pittsburgh, PA 15238 USA Phone: (412) 967-3800 Fax: (412) 967-5148 Toll-Free: 1-800-443-2640 www.chromalox.com
PRECISION HEAT AND CONTROL
Eltron Chromalox Eltron House 20-28 Whitehorse Road Croydon, Surrey, CR9 2NA, UK Tel: +44 (0)20 8665 8900 Fax: +44 (0)20 8689 0571 email: uksales@chromalox.com www.chromalox.co.uk
Etirex Chromalox Route de Chteau-Thierry Noyant et Aconin F-02203 SOISSONS Cedex, France Tel: +33 (0)3 23 74 39 39 Fax: +33 (0)3 23 74 39 00 email: be.etirexchromalox@wanadoo.fr www.chromalox.fr
2003 Chromalox, Inc.
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Chromalox

PRECISION HEAT AND CONTROL

Electrical Heat Tracing Systems Design Guide

Mineral Insulated Cable Design: . . . . . . . . . . . . . 17 Electrical Design: . . . . . . 18

Component Selection and Accessories: . . . . . . 24 Control Selection:. . . . . . 32

THERMAL DESIGN PIPES

Step 4. Correct for Indoor Location/ Windspeed

If location is indoors multiply QF by 0.9.

4.4C -28.9C Outdoor 16 kph 76 mm Steel None 51mm Cellular Glass

T = Tm - Ta English = 40F - (-20F) = 60F Metric = 4.4C - (-28.9C) = 33.3C

88.9C 100.0C 111.1C 122.2C 133.4C 144.5C

1" (25.4 mm) Insulation Thickness

88.9C 100.0C 111.1C 122.2C 133.4C 144.5C

1.5" (38 mm) Insulation Thickness

88.9C 100.0C 111.1C 122.2C 133.4C 144.5C

2" (50.8mm) Insulation Thickness

88.9C 100.0C 111.1C 122.2C 133.4C 144.5C

3" (76.2 mm) Insulation Thickness

Table 2 Insulation Adjustment Factors

Insulation Adjustment Factor

THERMAL DESIGN TANKS

D H H CYLINDRICAL TANK, FLAT AREA = AREA (ENDS) + AREA (SIDE) 2 = D /2 + DH

Additional Safety Factor, if required: Thermal Insulation Type and Thickness:

Table 3 Heat Loss (QT) for Various Insulation Thicknesses

Heat Loss (QT) W/ft2/F W/m2/C

Additional Safety Factor, if required: Thermal Insulation Type and Thickness:

T = Tm - Ta English = 40F - (-20F) = 60F Metric = 4.4C - (-28.9C) = 33.3C

Step 2. Determine Total Surface Area of Tank

Find QT in Table 3 for the corresponding insulation thickness.

HEATING CABLE SELECTION

HEATING CABLE SELECTION

Step 1. Select Heating Cable Family

Heating Cable Family

Maximum Maintenance Temperature F C 65C

Maximum Exposure Temperature (Power Off) F 185F C 85C

Approvals U.S. Other

SRL Ordinary (Self-Regulating Low Temperature ) Class I, Div. 2,

GOST, Cenelec, CE, ATEX

SRM/E (Self-Regulating Medium Temperature )

FM Only FM Only FM Only

HSRM (H-SelfRegulating Medium Temperature )

FM Only FM Only FM Only

CWM (Constant Wattage)

HEATING CABLE SELECTION

Table 5 Heating Cable Families

HEATING CABLE SELECTION

Step 2. Select Heating Cable Construction Options

Table 6 Maximum Maintenance Temperatures for Constant Wattage Cables (CWM)

Table 7 Heating Cable Construction Options

Step 4. Check T-Ratings

Table 8 T-Ratings for Self-Regulating Cable

HEATING CABLE SELECTION

HEATING CABLE SELECTION

SRL10 & HSRL10 SRL8 & HSRL8

SRL10 & HSRL10

Thermal Output (W/ft)

10 9 8 7 6 5 4 3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Thermal Output (W/m)

SRL8 & HSRL8

SRL5 & HSRL5

SRL5 & HSRL5

SRL3 & HSRL3

SRL3 & HSRL3 Cable Output versus Temperature

Cable Output versus Temperature