Pipe Freeze Protection
Description

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.

Warranty of ten years for heating cables/ connection components, two years for controllers. Extended to 12 years and 6 years respectively when installed by the manufacturer or by a trained installer recognized by them.

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.

Specification data

Product Reference

Pipe Freeze Protection

Low smoke, zero halogen, self-regulating pipe freeze protection trace heating cable

10XL2-ZH

On cold water services or sprinklers.

15/26XL2-ZH

On larger pipes.

31XL2-ZH

On low-pressure hot water services.

Cold applied, insulation displacement interconnection components and end seals

RayClic-CE-02

Power connection with 1.5 m power cable, gel-filled end seal and support bracket. IP68.

RayClic-E-02

Gel-filled end seal.

RayClic-PS-02

Powered splice, connection for two cables with 1.5 m power cable. Supplied with two gel-filled end seals and support bracket. IP68.

RayClic-PT-02

Power T-connection with 1.5 m power cable for three cable connection. Supplied with three gel-filled end seals and support bracket. IP68.

RayClic-S-02

Splice for joining two lengths of heating cable, with one support bracket. IP68.

RayClic-T-02

T-connection for three cables. Includes gel-filled end seals and support bracket. IP68.

RayClic-X-02

Four-way cable connection. Supplied with two gel-filled end seals and support bracket. IP68.

Energy efficient controls

-

Single circuit, single application, programmable energy efficient control thermostat

RAYSTAT V5

Use line sensing mode for LPHW services, or proportional ambient sensing control (PASC) mode for cold water services. Multi circuit, single application control with integrated energy efficient controller and circuit.

Multi circuit, single application control with integrated energy efficient controller and circuit protection

SBS-02-SNR multi-circuit, panel-mounted single application sprinkler controller

One sprinkler line.

SBS-04-SNR multi-circuit, panel-mounted single application sprinkler controller

Two sprinkler lines.

SBS-06-SNR multi-circuit, panel-mounted single application sprinkler controller

Three sprinkler lines.

SBS-08-SNR multi-circuit, panel-mounted single application sprinkler controller

Four sprinkler lines.

SBS-10- SNR multi-circuit, panel-mounted single application sprinkler controller

Five sprinkler lines.

SBS-12-SNR multi-circuit, panel-mounted single application sprinkler controller

Six sprinkler lines.

SBS-FP-3X16A multi-circuit, panel-mounted single application controller

Three circuits.

SBS-FP-6X16A multi-circuit, panel-mounted single application controller

Six circuits.

SBS-FP-9X16A multi-circuit, panel-mounted single application controller

Nine circuits.

SBS-FP-12X16A multi-circuit, panel-mounted single application controller

Twelve circuits.

Multi circuit, multi-application, distributed control and monitoring system with circuit protection

ACS30

Multi circuit, multi-application distributed control and monitoring system.

ACS-30-EU-Moni-RMM2-E

Remote monitoring module for the ACS-30 control and monitoring system, to measure additional temperatures for control and monitoring of heating cable circuits. Up to 16 RMMs may be controlled by a single UIT, with up to 8 RTDs per RMM.

ACS-30-EU-PCM2

Power control module for ACS-30, to provide distributed power connection, control and monitoring of heating cable circuits. At least one PCM must be included.

ACS-30-EU-UIT2

User interface module for the ACS-30 control and monitoring system, for control and monitoring up to 260 heating cable circuits. Up to 52 PCMs may be connected in series to each UIT.

Standard product features

Electrical connection:

  • Supply voltage: 230 VAC/ 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.

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 Vdc megger. Installation of thermal insulation shall be closely coordinated with the responsible sub-contractors. ATE-180 shall be used on plastic pipes:

Product Options

Energy efficient controls:

- Single circuit, single application, programmable energy efficient control thermostat:

Complete with LED touch interface; programmable set temperatures, high and low temperature alarms, hysteresis, offsite programming without external power supply, USB connectivity, for pre-set up in power off mode or firmware upgrades, password protection; non-volatile memory, volt-free alarm relay, 25 A output relay, selectable fail safe mode, wall or din rail mounting, IP65 rated enclosure.

- Multi circuit, single application control panel with integrated energy efficient controller and circuit protection:

Complete with automatic redundant circuit switching (compliant with BS EN 12845); individual sprinkler pipe circuit monitoring (ambient and pipe sensing); automatic switching to redundant circuit in the event of heating circuit failure with audible alarm; digital display of ambient temperature and sprinkler line temperature per circuit; audible alarms (to indicate loss of power or low voltage to the panel or loss of an electrical phase or redundant circuit activation or RCD/ circuit breaker failure); manual over-ride switch to allow testing (main heating circuit on, redundant circuit on/ main heating circuit off, automatic mode controlled via sensor inputs); system reset button and audible alarm reset button; lights to indicate when circuits are on (green) and when redundant circuit has been powered (yellow).

Controls:

- RAYCHEM ACS-30 multi-circuit, single or multi-application, distributed digital control system with integrated energy efficient controller:

A centralized control system with distributed power and control modules, complete with: colour LCD touch-screen, password-protected user interface terminal (UIT) for central programming; power connection modules (PCM) to provide distributed power, circuit protection, control and monitoring; remote monitoring modules (RMM) for additional temperature measurement; and integrated energy-saving proportional ambient-sensing programmable controller (PASC).

BMS interface using ProtoNode high-performance multi-protocol gateway, to allow translation from native ModBus to BacNet protocols; pre-programmed parameters, to deliver concurrent control for heating cables used for pipe freeze protection, hot water temperature maintenance, flow maintenance, surface snow melting, roof/ gutter de-icing and floor heating applications. One UIT shall be included in the system, along with at least 1 PCM (to maximum 52); each PCM shall control up to five circuits. The UIT shall accept up to 16 RMM, each having up to eight temperature inputs. Available with integrated control unit: Elexant 450c .

- RAYCHEM RAYSTAT V5 single circuit, single application controller:

A programmable, energy-efficient electronic controller that provides ambient and/ or line sensing control, with a proportional ambient-sensing control (PASC) algorithm for enhanced energy savings. Complete with low temperature alarm function, digital display, ‘offsite programming’ without external power supply, USB connectivity, 25 A switching capacity, sensor and voltage failure alarms, selectable fail-safe mode (either 'ON' or 'OFF'), alarm relay for remote BMS monitoring and system error codes for quick diagnostic of system failure, wall or din rail mounting, IP65 enclosure.

- RAYCHEM SBS-XX-SNR (for sprinklers): multi-circuit, single application control panel:

All sprinkler pipe freeze protection circuits shall be controlled and monitored by an integrated, multi-circuit, multi-sensor, electrically protected control panel that is EN60204-1/ EN61439-1-compliant with RAL7035 (light grey) coated metal housing (IP54 rated), complete with automatic redundant circuit switching (compliant with BS EN12845), individual sprinkler pipe circuit monitoring (ambient and pipe sensing), automatic switching to redundant circuit (in the event of heating circuit failure) with audible alarm, digital display of ambient temperature and sprinkler line temperature per circuit, audible alarms (to indicate loss of power or low voltage to the panel or loss of an electrical phase or redundant circuit activation or RCD/ circuit breaker failure), manual override switch (to allow system override or testing [main heating circuit on, redundant circuit on/ main heating circuit off, automatic mode controlled via sensor inputs]), system reset button and audible alarm reset button, lights to indicate when circuits are on (green) and when redundant circuit has been powered (yellow).

- RAYCHEM SBS-FP-XX multi-circuit, single application control panel with integrated energy efficient controller:

An integrated, multi-circuit, electrically protected control panel that is EN60204-1/ EN61439-1-compliant with RAL 7035 (light grey) coated metal housing (IP54 rated), complete with type C circuit protection and RCD (30 mA rated) per circuit, proportional ambient-sensing (PASC) and line temperature-sensing control with simultaneous operation capability.

Integrated potential-free alarm contact (to signal circuit breaker failure or RCD failure or loss of power or controller failure), selection switch to enable system testing and override (automatic mode/ off mode/ on mode [override of control and sensor]), lights to indicate when circuits are on (green) and warning lights to indicate alarm or failure (red). Available with integrated control unit: Elexant 450c.

Third party certifications
  • EN 60204-1/ EN 61439-1 compliantDetails: Control Panels
  • IEC : IEC 62395: 2013, IEC60754-1, IEC61034-2, IEC60068-2-5, IEC60068-2-9Details: XL-TRACE LSZH
  • CE marked : XL-TRACE LSZH, Rayclic
  • VDE : XL-TRACE LSZH, Rayclic
  • GOST-R : XL-TRACE LSZH
  • CSTB : Applies to self-regulating pipe freeze protection cables, controls and system components
  • OVE : Rayclic
  • SEV : Rayclic
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