Mineral Insulated Heater Cable

Installation & Operation Manual

CONTENTS
general information.............................................................................1

How Heating Systems Work................................................................1

PrOduct selection..................................................................................1

RECEIPT & STORAGE....................................................................................1

PIPE LENGTH VERFICATION........................................................................1

DRAWINGS.....................................................................................................2

INSTALLATION..............................................................................................2

heater cable construction...............................................................4

high temperature & wattage installations...............................5

Assembly instructions.........................................................................6

HEATer cable attachment....................................................................7

heat sink installation..........................................................................8

pumps...........................................................................................................11

INSTRUMENTATION...................................................................................12

thermal insulation..............................................................................12

electrical connections.....................................................................13

electrical requirements....................................................................13

testing........................................................................................................14

Periodic inspection record..............................................................15

start-up......................................................................................................16

operation & maintenance.................................................................16

tROUBLESHOOTING..................................................................................17

Heat trace installation record....................................................18

LIMITED WARRANTY..................................................................................19

GENERAL INFORMATION
This manual is designed for use with Easy Heat Mineral Insulated Heater Products.
For applications not specifically addressed, please contact your local representative.
 1
How Heating Systems Work
An electric heating cable system uses the electric heater cable to replace the heat that is lost
through the thermal insulation system. Replacing the lost heat allows the pipe and product
inside the pipe to be kept at a constant temperature. This will keep water from freezing and
bursting a pipe, or a liquid from setting up and plugging the pipe. A simple system may be
turned on with a contactor or switch, while others will use a thermostat with each heater
cable to control the temperature for each pipe separately.
PRODUCT SELECTION
Check and verify that the proper heaters are being installed on each pipe and vessel. If
no design/installation documents exist, check Easy Heat’s Design and Selection Guides to
determine the proper equipment for the application.

RECEIPT & STORAGE

Receipt
• Compare the materials against the shipping bill to verify receipt of proper materials.
• Inspect heater cable and components for transit damage. Insulation resistance tests on
each cable set are recommended. Use at least 500VDC although 1000VDC megger test
voltage is recommended. Insulation resistance should be 20 megohms minimum.
• If design documents (line lists or per circuit bills of material) exist, check the materials
received against the lists to verify receipt of all needed materials. If no design documents
exists, keep a receipt of all materials received.
Storage
Cables and system components should be stored in a clean, dry area. The equipment should
be protected from mechanical damage during storage.
Withdrawal from Storage
It is recommended that a check-out record be kept (in conjunction with the receipt records)
on equipment as it is removed from storage. This will serve to identify developing material
shortages before they happen, since project additions often cause the use of material for
other than designated piping.

PIPE LENGTH VERFICATION

Each heater cable is factory fabricated for a specific length of a certain size pipe, and may be
used in conjunction with certain other series wired cables. The cables are not interchangeable
and the system will not operate properly if cable segments are not installed on the correct
pipes. The pipe lengths must be determined before the heater cable circuit can be designed.
There are two standard methods of pipe lengths verification:

• Field measurements, where the actual piping is measured to determine the correct
length.
• The second method is usually less accurate and it involves dimensioning from
construction drawings. To use this method the field installation must closely follow
the construction drawings. A 5% adder, not to exceed 5 feet (1.52m) can be added
to each cable to help absorb variations. Any cable overage can be absorbed at heat
sinks. Any deviations should be reviewed by the system designer.
In both of these methods all heat sinks (pipe supports, valves, hangers, wall penetrations,
etc.) must be noted, since they will require additional heat.
2
DRAWINGS
On engineered systems, drawings for all individual electric trace circuits may be provided for
installation of heat tracing. An electric trace circuit number, a segment number, and a catalog
number is assigned to each cable for identification purposes. Each installation drawing will
have a complete bill of material, including cables, temperature controller, junction boxes,
strapping material and electrical parameters.
The electrical parameters include a note to verify the circuit wiring, normally series
connected.

INSTALLATION

Warnings!
While there are many acceptable ways of installing Easy Heat electric heating equipment,
certain actions can be dangerous to personnel and your installations. Please take care to avoid
the following problems:

• install cable so minimal re-bending is required to service

equipment. Cable will work harden and break if repeatedly re-bent. Pumps,
valves, strainers, etc. should be traced in a manner to allow the cable to be
moved away with minimal bending.
• Heater cable sets cannot be randomly switched. Each cable
is designed for a specific wattage, pipe size, length, and maintenance
temperature. Cables may not work in a different situation. Changes should
be reviewed for design adequacy.
• Do Not overlap heater cables in hazardous areas. Overlapped
contact points will produce hotter spots that could exceed ignition
temperatures. Overlapping is acceptable in non-hazardous areas.
• Do not bend the heater cable within 3” (76.2mm) of fittings.
Fitting joints could be damaged.
• Do not bend the heater cable to an inside radius of less
than five times the cable’s diameter. This will damage the cable.
• Heater cables for hazardous classified areas should be
tagged as being certified for a specific area. Sheath temperatures
are controlled by design. Be sure the cable is designed for the proper
temperature limits.
• Hazardous (classified) area (explosive dust or gas) require
the use of special controls and components. Any area having
explosive gases (such as chemical or petrochemical installations), or explosive
dust (such as coal handling or granaries), require connection components and
controls that are approved for use in these areas. Installation of non-approved
heaters can result in a fire or explosion.
• Leave all tags on the cable. They contain electrical, approval and
further installation information.
 3
Scheduling
Pressure testing of the pipe and installation of the instruments should be completed prior
to the start of the heater cable installation. The installation of the electric heat tracing needs
to be coordinated with the piping, insulation, electrical and instrument groups. It should
begin only after mechanical construction is completed.
Pre-Installation Check
Walk the piping system and plan the routing of the heater cable. Use this check to verify
completion of instrumentation and mechanical work. All coatings (paint, etc.) must be dry
before attempting the heater cable installation.
Heater Handling
• When handling the heater cable, avoid pulling it over or installing against sharp
edges.
• Do not kink or crush the heater cable; including walking on or driving over it with
equipment.
• Unroll heater cable adjacent to the pipe to be traced, starting at the power connection
end of the circuit.
• Keep the cable strung loosely, but close to the pipe being traced. This will avoid
interference with supports and other equipment.
• Attach cable to the pipe at both ends of the circuit and work toward the middle.
• Additional heater cable is required on valves, pipe supports and other equipment. See
Section 10 (Heat Sink Installation) for exact lengths and method of installation.
• Make a loop with the required cable length at each heat sink. Looped lengths can be
slightly adjusted to ensure a proper cable fit along the pipe.
• Shape loops against heat sink in a manner that will allow easy removal.
See Section 10.
Heater Cable Location on Pipe
The heater cable should be installed at either ten o’clock, two o’clock, four o’clock or eight
o’clock positions. This helps prevent physical damage to the heater cable from falling objects
and being walked on. See Figure 1.

Figure 1

Installation of Heater Cable on a

Single Trace and Double Traced Pipe
4
heater cable construction
General
The heater cable type will be MI Trace, single- or two-conductor resistance element,
insulated with magnesium oxide, and covered with a metallic sheath. The metallic sheath is
Alloy 825, which may be used to 1100°F (593°C). The cable type, lengths of hot and cold
sections, and cable form can be determined by Easy Heat.
It is recommended that all heater cables be tagged with a discrete circuit number when
they are built. This will facilitate identification, components needed, and electrical wiring
during installation.
Figure 2

(.51”)

heater cable configuration

Table 1

Heater unit forms

Factory assembled heater cables consist of heating sections, cold section, box connector,
and 305mm (12”) long insulated leads.

Figure 3

Use of dmi & DDmi Form Cables

in Single Trace Application
(2 Conductor Cable)
 5
Figure 4

Use of SMI Form Cable on Multiple

Trace Application (1 Conductor Cable)
Note: Length of heating cable must be double the actual pipe length (double traced) to
provide an electrical path.

High temperature & wattage installations

The cold lead and hot-cold junction have copper wire in them. This copper has to be kept
below 315°C (600°F) to prevent deterioration of the conductors. The junction and cold lead
mounting is changed, based on the application temperatures and cable wattage.

Figure 5

Standard Regular Cable

• Conductor temp below 316°C (600°F)
• Process maintenance under 149°C (300°F)

Figure 6

High Temp/Low wattage

• Wattage below 65 w/m (20 w/ft.)
• Steam piping freeze protection

EM Suffix
6
Figure 7

High Temp/high wattage

• Wattage above 65 w/m (20 w/ft.)
• Process maintain over 149°C (300°F)

(QT Suffix or QHT-3)

Figure 8

qht-3 ATTACHMENT TO HEATER CABLE

assembly instructions
1. Install heater cable, but do not fasten last two feet of the hot section to the pipe.
2. Slip the unthreaded end of the tubing over the cold section of cable. Slide tubing down
past the hot-to-cold fitting.
3. Slip the body, sleeve, and gland nut over the cold section of cable in order given. Align
sleeve as shown.
4. Position sleeve about .25” (6mm) from the cold section end of the hot-to-cold fitting.
5. Tighten body to tubing.
6. Position sleeve and attach to the gland nut. Apply sufficient pressure to snug lead sleeve
onto hot-to-cold fitting.
7. Tie down last 6” (152mm) of tubing on pipe with tie wire.
8. Form tubing to shape desired to exit insulation. The hot-to-cold fitting should be outside
the insulation.
 7

Figure 9

hIGH tEMP cABLE

jUNCTION
iNSTALLATION
sUFFIX qt OR em

HEATer cable attachment

Heater cable shall be fastened to the piping with stainless steel straps or tie wire. Steel
straps or tie wire shall be installed with approx. 12" (305mm) spacing as shown in Figure 10.
Stainless steel straps or tie wire should be used to secure heater cable to pipe and irregular
shaped objects such as valves, etc. Cable should be loosely attached to allow for expansion
and contraction without work hardening during thermal cycling of the heater.
Figure 10

Figure 11 Cold Lead

Mounting of
hot-cold junction

Pipe
Stainless Steel Banding Straps or Tie Wire
8
heat sink installation
Extra heater cable is required at all heat sinks. Heater cables should be applied in a manner
to facilitate the easy removal of valves and small in-line devices, without the removal of
excessive thermal insulation or having to cut the cable. The best way to accomplish this is
to loop the heater cable. The amount of heater cable installed on each valve, hanger, etc.
varies with the pipe size and type of device. Table 3 gives the correct additional cable to
be installed on each device.
The following figures show installation details for various typical situations. Figures 12 &
13 show the area of the pipe that is affected by heat losses from items penetrating the
insulation such as supports, hangers, valve yokes, etc. Heater cable adders can be applied
anywhere in this area to compensate for these heat losses. Refer to Table 3 for proper
footage of cable adder required.
Figure 12

hanger

Figure 13

support

Assembly Notes
1. For cable length at hanger and support, refer to Table 3.
2. Exact configuration may vary.
3. Fully insulate and weather-seal.
 9
Figure 14

Flange Valve

Figure 15

Screw or
Welded Valve

Assembly Notes
1. Exact configuration may vary per valve type.
2. For removable valve bodies, leave a loop of tracing of the proper length when tracing the
pipe. Then trace the valve so that it can be serviced without cutting the heater.
3. For correct amount of tracing per valve type, refer to Table 3.
4. Secure cable with tie wire criss-crossed over valve body.
5. Take care to keep the heater in as good physical contact with the valve body as possible.
6. Fully insulate and weather-seal.

Figure 16

FLANGE

Assembly Notes
1. For cable length at flange, refer to Table 3.
2. Exact configuration may vary.
3. Fully insulate and weather-seal.
10
Table 3—Heat Loss Adder

PIPE FITTING TYPE

Pipe Size Flange Vent & Pipe Globe, Ball & Gate
in (mm) Pair Drain Support Butterfly Valves Valve
.50 .30 1.0 1.0 1.0 1.0
(12.70) (.09) (.30) (.30) (.30) (.30)
.75 .30 1.0 1.5 1.0 1.5
(19.05) (.09) (.30) (.46) (.30) (.46)
1.00 .30 1.0 1.5 1.0 2.0
(25.40) (.09) (.30) (.46) (.30) (.61)
1.50 .30 1.0 2.0 1.5 2.5
(38.10) (.09) (.30) (.61) (.46) (.76)
2.00 .30 1.0 2.0 2.0 2.5
(50.80) (.09) (.30) (.61) (.61) (.76)
3.00 .30 1.0 2.0 2.5 3.0
(76.20) (.09) (.30) (.61) (.76) (.91)
4.00 .50 1.0 2.5 3.0 4.0
(101.60) (.15) (.30) (.76) (.91) (1.22)
6.00 .80 1.0 2.5 3.5 5.0
(152.40) (.24) (.30) (.76) (1.07) (1.52)
8.00 .80 1.0 2.5 4.0 7.0
(203.20) (.24) (.30) (.76) (1.22) (2.13)
10.00 .80 1.0 3.0 4.5 8.0
(254.00) (.24) (.30) (.91) (1.37) (2.44)
12.00 .80 1.0 3.0 5.0 9.0
(304.80) (.24) (.30) (.91) (1.52) (2.74)
14.00 1.0 1.0 3.0 5.5 10.0
(355.60) (.30) (.30) (.91) (1.68) (3.05)
16.00 1.0 1.0 3.5 6.0 11.0
(406.40) (.30) (.30) (1.07) (1.83) (3.35)
18.00 1.0 1.0 3.5 7.0 12.0
(457.20) (.30) (.30) (1.07) (2.13) (3.66)
20.00 1.0 1.0 3.5 7.5 13.0
(508.00) (.30) (.30) (1.07) (2.29) (3.96)
24.00 1.0 1.75 4.0 8.0 15.0
(609.60) (.30) (.53) (1.22) (2.44) (4.57)

Notes
1. Nominal pipe length in feet (meters).
2. Adders are for various in-line fittings to compensate for areas of greater heat loss.
3. Values above are based on area average of various fittings available, with the assumption that fitting
insulation will be equivalent to pipe insulation. The nominal length of tracer to be applied to a particular
fitting would be the value shown in this chart plus the flange-to-flange length of the fitting.
 11
pumps
All pumps should be heat traced when suction and discharge lines are heat traced. Pumps
should be heat traced with a separate cable. Each pump shall be traced in a manner that will
allow the cable to be moved away from the pump for servicing or removal, see Figures 17
& 18. The cables should be pulled away from the pump without kinking the cable. Remove
with care so that cable may be replaced in its original condition. If pumps require frequent
maintenance, removable insulated enclosures with heaters attached to the enclosure are
recommended.

Figure 17

Centrifugal
Pump
Assembly Notes
1. Pre-bend loops to fit over the edges of the pump, a minimum of 4” (100mm), before
installing.
2. Mount on pump, adjusting spacing between loops to cover pump body.
3. Use tie wire or aluminum tape to hold cable in place on pump. See step 3.
4. Pump must be fully insulated and weather-sealed.
5. Heater length required for pump application will vary with pump size. Contact your Easy Heat
representative or the factory for details.

Figure 18

Pump

Assembly Notes
1. Determine the width of the pump to be traced.
2. Pre-bend the heater cable starting with the end of the hot section and bend it approximately
at the distance as shown below.
3. Continue to make these “S” bends until the whole hot section has been bent.
12
INSTRUMENTATION
Instrument lines and their associated instruments shall be traced. Any supports or other
heat sinks shall have additional cable serpentine on the object. If space will not allow, put
the extra cable on the tubing in the area of the heat sink. A separate thermostat should
control long runs of instrument lines if the system is process control tracing. The instrument
itself should be traced if fluid is in the instrument body. See Figures 19 & 20 for typical
instrument tracing details.
Figure 19 Figure 20

or Piping Level gauge

thermal insulation
Pre-Insulation Checks
Inspect the heater cable and components for correct installation and possible damage. In particular,
verify that:
• Heater is not on the top of the pipe and is installed flat against the pipe.
• The proper extra amount of heater cable has been installed at each valve, flange, pipe support,
etc., and that it is free from nicks, tears, or gouging.

Installation
• The proper selection and installation of pipe insulation is essential for good performance of a heat
tracing system.
• Rigid insulation should be oversized—min. 0.5” (13mm), or the next larger pipe size to
accommodate the heater installation.
• Check the thermal insulation type and thickness against the design criteria. Changes in insulation
type or thickness may require a different wattage heater cable.
• Long vertical runs of oversized pipe insulation will experience temperature piling (heated air
circulating upward). This can be reduced by installing air baffles at approximately 10’ (3m) intervals.
See Figure 21.
• Whenever blown on or muddied insulation is used, the cable should be covered with some type of foil
after it is attached to the pipe, valve, pump, etc., to prevent thermal isolation of heating element.
• Leaks at valves, flanges or pumps should be repaired and the insulation dried.
Figure 21

Baffle for
Oversized Insulation
 13

a
Warning: All thermal insulation must be
dry to ensure proper functioning of the heat
trace system.

• Verify that all pipe work, including wall penetrations, fittings, etc., has been completely
insulated.
• Insulation must not be wet from rainfall prior to the application of waterproofing. See
warning below.
• Lap joints on vertical piping must be properly overlapped with the higher piece lapped
over the top of the lower piece.
• Band seals must be used at lap joints to prevent the ingress of water.
• All penetrations of the lagging (valve stems, hanger rods, etc.) must be properly
waterproofed.
• Irregular shaped items (pumps, etc.) must be properly waterproofed.
• Wet pipe insulation has poor thermal insulating capabilities which will result in line
freeze-up. It will also cause electrolysis & corrosion.
• It is recommended that another insulation resistance (megger) test be done after the
insulation has been installed to verify that the heating cable was not damaged during
the insulation installation.

NOTE: To minimize potential damage to the heater cable, install the insulation as soon as possible.

Marking
Install “Electric Trace” signs on alternating sides fo the piping at 10-20 feet (3.05-6.10m) intervals
as a warning to maintenance personnel.

electrical connections
moisture inside the electrical connection enclosure will cause both corrosion and electrical
shorting problems. The potential for this type of problem can be greatly reduced by:
• Low point conduit drains—condensation from conduit can fill small enclosures.
• Proper sealing of all enclosure openings.
• Bottom conduit entry into enclosures.
• Keeping conduit fittings/pull box covers closed at all times.
• Keeping enclosure covers closed and secured as much as possible during installation
sequence.
• Proper closing and sealing of enclosure covers to prevent leaking into the housing.
• Use of a moisture proofing/electrical spray sealant on the thermostat and electrical
connections (including all metal parts) at completion of installation.

electrical requirements
Voltage Rating
Verify that the heater cable voltage rating is suitable for the service used. Voltage and wattage
ratings are printed on the cable tag.

Electrical Loading
Size over-current protective devices according to National Electric Code. If devices are
other than standard thermal magnetic circuit breakers, consult factory.

Voltage Surge Protection

Surge protection should be installed at the breaker panel if the panel is not isolated from
its 600V/480V supply by an isolation transformer.
14
Ground Fault Protection
Ground fault circuit breakers are required on most heater applications per the National
Electric Code—check code for appropriate circuit breaker protection. Typically, 30 ma trip
devices are required due to the capacitive leakage of the heater cable and its associated
power wiring.

Waterproofing
Moisture penetration of the electric system is the single largest source of problems in a heater
cable system installation. Therefore, particular care must be given to the proper sealing of
all electrical connections. All electrical connections (heater to power wiring, thermostat
connections, panel and breaker connections, etc.) should be sealed or moisture proofed
in some fashion. See warning.

a
Warning: Nuisance tripping of ground fault
circuit breakers will occur unless all electrical con-
nections are waterproofed and kept dry.

testing
Recommendations
Electrical tests are recommended at specific points on the receipt and installation of heater
cable. This periodic testing is designed to prevent the expenditure of wasted labor in the
event of damage to the product. Installation costs of the cable and thermal insulation are
much greater that the heater cable. Quick identification of any heater cable damage is the
most economic approach to an installation. An insulation resistance test is recommended
at the following points of the installation process:
• UPON RECEIPT of the heater cable
• BEFORE thermal INSULATION installation
• IMMEDIATELY AFTER thermal INSULATION installation
• As part of a PERIODIC MAINTENANCE program
Procedure
The insulation resistance test is used to check for damage to heater jackets. Connections
for the megger are made as shown in Figure 22 to the pigtail wires & the metal sheath. Test
should use at least a 500VDC megger, however, a 1000VDC megger test is recommended.
Minimum acceptable readings should be 20 megohms per cable.

Figure 22 A record should be kept of the readings

taken from the time the cable is first
installed on the pipe. A history of the
insulation resistance reading can be
helpful in spotting moisture ingress
into the electrical system (by seeing
a gradual decline in the insulation
resistance) or physical damage to the
heating cable (sharp decline in the
insulation resistance). A sample record
form is shown in Figure 23.
 15

Pipe Number
Circuit Number
Heater Type
Circuit Length
Freeze Protection Circuits–
Perform these checks as season requiring
use approaches.

Temperature Maintenance Controls–

Perform these checks at least twice per year.

Maintenance Checks
Visual inspection inside connection Initial
box for corrosion, moisture, etc. Date
Damage or cracks (leaks) in insulation Initial
seals at valves, hangers, pumps, etc. Date
Heater cable properly connected and Initial
grounded.
Date
Thermostat checked for moisture, Set Point
corrosion, set point, switch operation, Initial
and capillary damage. Date
Megger tests performed at power con- Reading
nection with both lead wires discon- Initial
nected from power wiring Date
Circuit voltage at power connection. Reading
Circuit amperage after 5 minutes. Reading
Insure removable blankets are installed
properly and all air gaps sealed. Reading
Watts/Ft/30.48cm.
Volts × Amps = w/ft/30.48cm. Initial
feet Date
All connections, boxes, and thermostats Initial
have been resealed. Date

Remarks & Comments

Figure 23
Periodic Inspection Record
16
The Periodic Inspection Record Form may be used in one of two ways:
• One sheet per circuit. The results of periodic tests of a single circuit are posted in vertical columns,
beginning on the left and working toward the right. This allows easy comparison of test values
for up to seven test sequences on an individual circuit.
• On circuit per column. Test data for a single test sequence on as many as seven circuits can be
recorded on a single sheet.

Start-Up
Heat-Up Time
Heat-up capacity (the ability to heat the pipe and it’s contents rapidly) is not normally designed into the
system. Cold start-ups should allow adequate time for the pipe to come up to temperature.

Operation & Maintenance

System Design Installation & Documentation
The heating cable system must be properly designed, installed and documented. This documentation should at
least include line lists and location identification documentation. As-built installation drawings provide the optimum
maintenance tool. Test records should also be considered as part of the system documentation requirements.

Preventive Maintenance
A preventive maintenance program is needed which will encompass both visual and electrical checks of the
system. These should be done not only before initial operation of the system, but also after any maintenance
has been performed.

Periodic Inspections
• Thermal insulation - check weatherproofing for damage, missing seals, cracks, or gaps in caulking
and mastic coatings, damaged, or missing lagging. When damage does exist, the insulation will need
to be repaired or replaced, and then re-sealed. WET INSULATION HAS POOR INSULATING
PROPERTIES, THEREFORE THE INSULATION MUST BE KEPT DRY. If insulation has been
damaged, check the heater cable for damage—replace any damaged sections.
• Inspect junction boxes, connection boxes, and thermostats for corrosion, moisture or foreign matter.
• Check tightness of electrical connections, proper electrical insulation of heating cable wires, and
adequacy of moisture seal on electrical connections.
• Check all thermostat capillaries to insure they are shielded from physical damage and secured
properly to the pipe.
• Verify that all thermostat power and probe leads are securely connected and on the correct terminal.
• Verify that all enclosure, connection box, etc., covers are properly closed. Also make sure that the
thermostat is switching on & off by rotating knob set point back and forth, and on by measuring current
flow in the circuit when the unit switches on. Reset the knob to the proper temperature after completion
of the test.

Frequency
Inspections should be made prior to the start of the freeze season on freeze protection systems. Process
maintenance systems should be checked on a frequent basis—at least twice a year.

Personnel Training
Qualified maintenance personnel must be used to maintain the system. It is recommended that periodic training
programs be utilized to assist in keeping maintenance personnel up to date on equipment and procedures.

Maintenance
The heater cables will not require any maintenance, unless damaged. Mechanical temperature controls should
have dial stem lubricated and be sprayed with a moisture repellent/corrosion inhibitor once a year on all metal
parts. Disconnect the electrical connection for the heater cable and protect it from mechanical or thermal
damage during any repair of the piping system. Check the heater cable installation after any piping system
repairs per established procedures. Replace and water seal the thermal insulation system.

Damaged Products
Replace the damaged cable immediately. Moisture migration into the good section of the cable may
cause electrical shorting in that cable after repair of the damaged section.
 17
Troubleshooting
SYMPTOMS
PROBABLE CAUSE CORRECTION
A. Circuit Breaker 1. Circuit breaker undersized. 1, 2, 3. Determine total current load and
Trips (Standard) 2. Circuit oversized. resize the breakers. Verify that power wire
3. Start-up at too low temp. size is compatible with larger size breaker.
4. Defective circuit breaker. 4. Replace circuit breaker.
5. Wiring connections 5. Locate and repair faulty connections.
Megger may be shorting out per installation
instructions.
6. Physical damage to the heater 6. Locate and repair damaged sections or
cable may be causing a short. heater.* Megger per installation instructions.
7. Thermostat 7. Disconnect wires and perform a
current check for possible other damage.

B. Circuit Breaker 1. All of section A. 1. All of section A.

Trips (Ground 2. Excessive moisture in 2. Dry out and seal connections. Megger per
Leakage Type) connection boxes. Installation Instructions (20 megohms min.).
3. Nick or cut in heater or 3. Locate and repair or replace damaged
power feed wire with heater cable or power wire.*
moisture present.
* To locate shorting problems, follow these steps:
1) Visually inspect the power connections for proper installation.
2) Check around the valves, pumps, and any area where there may have been maintenance work done, for visual indications of damage.
3) Look for crushed or damaged insulation lagging along the pipe.
4) Inspect heater cable under the thermal insulation.
5) If you have not located the problem after completing these steps, you will have to isolate one section of the heater cable at a time until
you determine the general area of damage. First, isolate by disconnecting any series or parallel wired cable sets, and megger each cable.
Remove cold section from heating section and megger each. For long runs of cable, it may be necessary to cut the cable in half to isolate
the shorted heating section.

SYMPTOMS
PROBABLE CAUSE CORRECTION
C. Power output is 1. Low or no input voltage. 1. Repair electrical supply lines equipment.
zero or lower 2. Circuit is wired incorrectly. 2. Check to see if cables are wired correctly.
than rated.** 3. Tees may not have been 3. Connect and recheck the power.
connected.
4. Heater may have been 4. Locate and repair the damaged
severed. heater. Recheck the power.
5. Improper crimping of power 5. Recrimp using correct procedure.
connections causing a high
resistance connection.
6. Control thermostat is wired 6. Rewire in the normally closed position.
in the opened position.
7. Pipe is at an elevated temper- 7. Check pipe temperature and recalculate
ature (above designed maintain). the output.*

D. Power output 1. Insulation is wet. 1. Remove and replace with dry insulation and
appears correct insure proper weatherproofing.
but pipe temps. 2. Insufficient heater cable was 2a.For a single heat sink—a separate additional
are below used on valves, supports, cable can be installed and wired in parallel to the
design value. power connection point for the circuit.
2b.For several heat sinks replace cable
with longer cable set.
3. Thermostat was set incorrectly. 3. Reset the thermostat.
4. Different thermal insulation 4. Check with the local or factory representatives
was used. for design conditions. Modify as recommended.
5. Removable blankets to design. 5a. Verify that K factor is equal
5b. Installed properly and air gaps are sealed
with duct tape.
**The power output on lower resistance heater cables is temperature sensitive and requires a special procedure to determine its value.
When using 556K, 712K, 722K, 588B, 614B, 627B, 640B, 145K, 189K or 216K heating sections, please consult factory for assistance in
determining cable output.
18
Heat trace installation record
1. Pipe No. _________________________ Date________________________
DESIGN ACTUAL
2. Receiving Documentation
Heater Cat. Nos. ___________________ ____________________
3. Receiving Testing
Date_________________________
A. Check for physical damage.
O.K.______________ Damage______________
B. Continuity Check—Check for continuity
between power leads. O.K.______________ Open________________
C. 500VDC megger check between
leads and sheath, 20 megohms min.
Megohms________________________________
4. Post Installation Testing
Date_________________________

A. Continuity Check—Check for continuity

between cold leads. O.K.______________ Open________________
B. 500VDC megger check between
leads and sheath, 20 megohms min.
Megohms________________________________
C. Visually check cable installation
prior to release for thermal insulation.
O.K.______________ Open________________
5. Final Testing & Commissioning
Date_________________________
A. Circuit approved for testing by client.
Approved________________________________
B. 500VDC megger check between
leads and sheath, 20 megohms min.
Megohms________________________________
DESIGN ACTUAL
C. Energized Testing (All test data
to be within 10% of design data)
1. Circuit Voltage ___________________ ____________________
2. Intial Current ___________________ ____________________
3. Current after 15
mins. of operation ___________________ ____________________
6. Circuit Acceptance ________________ _________________

This circuit has been tested and documented in accordance with the above itemized
data. Ths circuit approved by:
Contractor_____________________________________ Date________________
Client_________________________________________ Date________________

Figure 24
T h e H e a t Tr a c e I n s t a l l a t i o n R e c o r d c a n b e u s e d t o m o n i t o r t h e i n i t i a l i n s t a l -
lation and check out process. This form can be used in conjunction with the
Periodic Inspection Record shown in figure 23.
 19
LIMITED WARRANTY AND LIABILITY
Easy Heat warrants that if there are any defects in material or workmanship in any
heating cable or accessory during the first year after the date of purchase, we will
provide new products to replace any defective items, or we will refund the purchase
price paid for the accessory or cable, not including any labor or other installation costs.
As an alternate, we may elect to repair the cable or accessory at our factory with all
shipping and other removal costs borne by the purchaser.

We further warrant that, for a period of twelve (12) months after the date of performance,
any services performed hereunder will be in a good and skillful manner, based on our
understanding of pertinent technical data as of the date of performance of such services.
Easy Heat’s sole responsibility and liability in the event of any defect, error, omission,
or failure in the services rendered hereunder shall be to provide corrected services
of the type provided for herein, designed to correct such defect, error, omissions, or
failure, and in no event shall Easy Heat’s liability with respect to such warranty exceed
the amount received by it from the Buyer on account of such services.

Our obligation to provide corrected services, new products, refund the purchase
price, or perform the repair described above is conditioned upon (a) the installation
of the accessory or cable conforming to the specifications set forth in our installation
instructions and (b) the accessory or cable not having been damaged by mechanical
or electrical activities unrelated to the operation of the accessory or cable.

A refund of your purchase price, provision of replacement products, repair of

the accessory or cable or provision of corrected services as described above,
shall be your sole and exclusive remedy for a breach of this warranty. THESE ARE
THE SOLE AND EXCLUSIVE WARRANTIES GIVEN BY EASY HEAT WITH RESPECT
TO THE GOODS AND SERVICES AND ARE IN LIEU OF AND EXCLUDE ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR
OTHERWISE, INCLUDING WITHOUT LIMITATION, MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE WHETHER OR NOT THE PURPOSE OR USE HAS
BEEN DISCLOSED TO EASY HEAT IN SPECIFICATIONS, DRAWINGS OR OTHERWISE,
AND WHETHER OR NOT EASY HEAT’S PRODUCTS ARE SPECIFICALLY DESIGNED
AND/OR MANUFACTURED BY EASY HEAT FOR YOUR USE OR PURPOSE.

This warranty does not extend to any losses or damages due to misuse, accident, abuse,
neglect, normal wear and tear, negligence, unauthorized modification or alteration, use
beyond rate capacity, or improper installation, maintenance or application. To the extent
that you or your agents have supplied specifications, information, representation of
operating conditions or other data to Easy Heat in the selection or design of the Goods
and the preparation of Easy Heat’s quotation, and in the event that actual operating
conditions or other conditions differ from those represented by you, any warranties or
other provisions contained herein which are affected by such conditions shall be null
and void. (continued on other page)
20
LIMITED WARRANTY AND LIABILITY (continued)
If within thirty (30) days after your discovery of any warranty defects within the warranty
period, you notify Easy Heat thereof in writing, Easy Heat shall, at its option, repair,
correct or replace F.O.B. point of manufacture, or refund the purchase price for, that
portion of the Goods found by Easy Heat to be defective. Failure by you to give such
written notice within the applicable time period shall be deemed an absolute and
unconditional waiver of your claim for such defects. Goods repaired or replaced during
the warranty period shall be covered by the foregoing warranty for the remainder of the
original warranty period or ninety (90) days from the date of shipment of the repaired
or replaced goods, whichever is longer.

This limited warranty does not cover any costs relating to the repair or
replacement of any accessory or cable at the installation site. Our accessories
and cables are not easily accessible. A failed accessory or cable usually cannot
be easily repaired. Replacement of a failed accessory or cable will require that the
materials under which it is installed be removed to permit replacement of the accessory
or cable. We will not reimburse any costs relating to the repair or replacement
of any accessory or cable at the installation site.

IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION

(WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY,
OTHER TORT OR OTHERWISE), SHALL EASY HEAT’S LIABILITY TO YOU AND/OR
YOUR CUSTOMERS EXCEED THE PRICE PAID BY YOU FOR THE SPECIFIC GOODS
PROVIDED BY EASY HEAT GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. YOU
AGREE THAT WE SHALL NOT BE LIABLE TO YOU OR YOUR CUSTOMERS FOR ANY
INCIDENTAL, SPECIAL OR CONSEQUENTIAL OR PUNITIVE DAMAGES. No agent,
employee or representative of ours has authority to bind us to any affirmation,
representation or warranty concerning the goods sold unless such affirmation,
representation or warranty is specifically incorporated by written agreement.

To obtain new products, arrange repair of existing product, or a refund under this
warranty, please contact Easy Heat with a description of the defect and proof of
purchase at the address noted herein.

ATTN: WARRANTY DEPARTMENT:

In US - EasyHeat Inc; 2 Connecticut South Drive, East Granby, CT 06026
In CANADA - EasyHeat Ltd; 99 Union Street, Elmira, ON N3B 3L7
US T. (800) 537-4732 / F. (888) 324-2440
CAN T. (800) 794-3766 / F. (800) 361-4574

©2008 Easy Heat www.easyheat.com 14035-001 Rev. 4