Pipe Freeze Protection

An energy-efficient, self-regulating trace heating system for use on all insulated pipes exposed to the risk of freezing. The system is complete with low smoke zero-halogen self-regulating heating cables, advanced energy-efficient controller and cold-applied components, CE marked and certified according to IEC (EN) codes.

System components:

• Low smoke, zero halogen, self-regulating trace heating cable.
• Cold applied, insulation displacement components, for interconnection.
• Cold applied, gel-filled end seal.
• Single circuit, single application energy efficient controller.
• Multi circuit, single application control panel with integrated energy efficient controller.
• Multi circuit, multi-application distributed control and monitoring system with integrated energy efficient controller.

Self-regulating heating cables (XL-Trace):

The self-regulating heating cables are tested to and compliant with IEC 61034-2, IEC 60754-1, IEC 62395: 2013, IEC 60068-2-5 and 2-9 (for low smoke emission, zero halogen, self-extinguishing properties, UV resistance and colour fastness under UV exposure), qualified for a useful lifetime in excess of 25 years, highly flexible with a 10 mm bend radius and suitable for use with 20 A circuit breakers.

The self-regulating heating cables include a conductive polymer core, modified low smoke zero-halogen electrical insulation (radiation cross-linked to ensure long life expectancy), tinned copper braid and modified low smoke zero-halogen over jacket printed with cable model, batch number and metre marks for ease of installation within maximum circuit lengths.

All insulated pipework exposed to risk of freezing is fitted with self-regulating heating cables, with 10XL2-ZH on cold water services or sprinklers (or 15/26XL2-ZH on larger pipes) and 31XL2-ZH on low-pressure hot water services, all installed to a maximum circuit length of 215 m at 5°C switch on for 10XL2-ZH (or 160, 135 or 118 m for 15/26/31XL2-ZH respectively).

Cold applied interconnection and termination components (Rayclic):

Interconnection and termination are made with cold-applied insulation displacement connectors and gel-type end seals which are UV-resistant, IP68 and 65°C rated, suitable for 2500 VDC insulation resistance test, with Torx head fittings and both audible and visual installation confirmation.

Cold water services - single circuit, single application energy efficient controller:

All cold water pipe freeze protection are controlled with a programmable, energy-efficient proportional ambient sensing control (PASC) thermostat (RAYSTAT- V5).

LPHW services - single circuit, single application energy efficient controller:

All LPHW pipe freeze protection circuits are controlled with a programmable, energy-efficient line sensing thermostat (RAYSTAT V5).

Cold water or LPHW services - multi circuit, single application control panel with integrated energy efficient controller:

All cold water or LPHW pipe freeze protection circuits are controlled and monitored by an integrated, multi-circuit, electrically protected control panel (SBS-FP-xx), complete with integrated energy efficient controller (Elexant 450c ).

Sprinklers - multi circuit, single application control panel with integrated energy efficient controller:

All sprinkler pipe freeze protection circuits are controlled and monitored by an energy saving, integrated, multi-circuit, multi-sensor, electrically protected control panel (SBS-xx-SNR), complete with integrated energy efficient control.

Cold Water or LPHW services - multi circuit, multi-application distributed control and monitoring system with integrated energy efficient controller:

All pipe freeze protection circuits shall be controlled and monitored using a centralized control system with distributed power and control modules (RAYCHEM ACS-30), complete with integrated energy efficient controller (Elexant 450c ). The centralized control system provides pre-programmed parameters to provide concurrent control for hot water temperature maintenance, pipe freeze protection, flow maintenance, surface snow melting, roof and gutter de-icing and floor heating applications.

Thermal insulation:

Insulation selection and thickness is strictly in accordance with the XL-Trace design guide.

Design:

The manufacturer shall be able to provide all design calculations, including heat loss and corresponding selection of heating cables; electrical schedules providing cable lengths, circuit breakers, circuit start up currents, operating currents and loads, line list summary and single line details; system layout and schematic drawings indicating power connections, tees and end seals; controller configuration listing and wiring diagrams.

Installation:

All pipe freeze protection cables shall be installed in accordance with the design plans, within the defined maximum circuit lengths, tested and commissioned strictly in accordance with the manufacturer’s instructions (IM-CDE1547) using a 2500 V DC megger. Installation of thermal insulation shall be closely coordinated with the responsible sub-contractors. ATE-180 shall be used on plastic pipes:

Electrical connection:

• Supply voltage: 230 V a.c./ 50 Hz.
• Connections between the electrical supply, control panel and trace heating circuits shall be installed by an approved electrical contractor.
• Circuit breaker protection required by MCB (BS EN 60898 type C or D). Residual current device required, RCD (30 mA sensitivity, tripping within 100ms). Maximum approximately 500 m of self-regulating heating cable can be monitored per RCD.