Raychem XL-Trace Manual 

System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets H55838 2/12 www.tycothermal.com 1 of 44 Pipe Freeze Protection and Flow Maintenance This step-by-step design guide provides the tools necessary to design a Raychem XL-Trace pipe freeze protection or flow maintenance system. For other applications or for design assistance, contact your Tyco Thermal Controls representative or phone Tyco Thermal Controls at (800) 545-6258. Also, visit our web site at www.tycothermal.com. Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 How to Use this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 XL-Trace Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Self-Regulating Heating Cable Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pipe Freeze Protection Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Typical Pipe Freeze Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fire Sprinkler Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Flow Maintenance Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Typical Flow Maintenance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Greasy Waste Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pipe Freeze Protection and Flow Maintenance Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Design Step by Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 1 Determine design conditions and pipe heat loss . . . . . . . . . . . . . . . . . . . . . 13 Step 2 Select the heating cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Step 3 Determine the heating cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Step 4 Determine the electrical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Step 5 Select the connection kits and accessories . . . . . . . . . . . . . . . . . . . . . . . . 26 Step 6 Select the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Step 7 Select the power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Step 8 Complete the Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet . . . . . . 37 Introduction Raychem XL-Trace is designed for pipe freeze protection and flow maintenance in the following applications: •� Freeze protection of general water piping (aboveground and buried) •� Freeze protection of fire sprinkler systems (aboveground and buried supply pipes) •� Flow waste lines (aboveground and buried) •� Flow maintenance of fuel lines (aboveground) XL-Trace System

2 of 44 www.tycothermal.com H55838 2/12 This guide does not cover applications in which any of the following conditions exist: •� Hazardous locations, as defined in the national electrical codes •� Pipe temperature other than specified in Table 1 on page 3 •� Pipe maintenance temperatures above 150°F (65°C) •� Supply voltage other than 120 V or 208–277 V If your application conditions are different, or if you have any questions, contact your Tyco Thermal Controls representative or contact Tyco Thermal Controls directly at (800) 545-6258 . How to Use this Guide This design guide presents Tyco Thermal Controls’ recommendations for designing an XL-Trace pipe freeze protection or flow maintenance system . It provides design and performance data, electrical sizing information, and application configuration suggestions . Following these recommendations will result in a reliable, energy-efficient system . OTHER REquIRED DOCuMEnTS This guide is not intended to provide comprehensive installation instructions . For complete XL-Trace pipe freeze protection and flow maintenance system installation instructions, please refer to the following additional required documents: •� XL-Trace System Installation and Operation Manual (H58033) •� Additional installation instructions are included with the connection kits, thermostats, controllers, and accessories If you do not have these documents, you can obtain them from the Tyco Thermal Controls web site at www .tycothermal .com . For products and applications not covered by this design guide, please contact your Tyco Thermal Controls representative or call Tyco Thermal Controls directly at (800) 545-6258 . Safety Guidelines As with any electrical equipment, the safety and reliability of any system depends on the quality of the products selected and the manner in which they are installed and maintained . Incorrect design, handling, installation, or maintenance of any of the system connection kits could damage the system and may result in inadequate performance, overheating, electric shock, or fire . To minimize these risks and to ensure that the system performs reliably, read and carefully follow the information, warnings, and instructions in this guide . This symbol identifies important instructions or information . This symbol identifies particularly important safety warnings that must be followed . WARnInG: To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit . Arcing may not be stopped by conventional circuit protection .

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets System Overview Warranty Tyco Thermal Controls’ standard limited warranty applies to all products . An extension of the limited warranty period to ten (10) years from the date of installation is available if a properly completed online warranty form is submitted within thirty (30) days from the date of installation . You can access the complete warranty on our web site at www .tycothermal .com . System Overview The XL-Trace system provides freeze protection and flow maintenance for aboveground and buried pipe applications . The XL-Trace system is based on self-regulating heating cable technology . Tyco Thermal Controls offers the option of three self-regulating heating cables with the XL-Trace system: 5XL, 8XL, and 12XL (208–277 V only) for applications using 120 and 208–277 V power supplies . The cable’s output is reduced automatically as the pipe warms, so there is no possibility of failure due to overheating . An XL-Trace system includes the heating cable, power connection, splice, tee connections, controls, contactors, power distribution panels, accessories, and the tools necessary for a complete installation . XL-Trace Applications Identify which of the standard XL-Trace applications below pertain to your installation . Proceed to the appropriate design sections that follow . Table 1 XL-Trace Applications Application Description Specific application requirements Pipe freeze protection General water piping Freeze protection (40°F [4°C] minimum) of insulated, metal or plastic water piping “Aboveground piping,” page 6 “Buried piping,” page 7 Sprinkler piping Freeze protection (40°F [4°C] minimum) of standpipes up to 20", supply pipes and branch lines with sprinklers “Standpipes, supply pipes, and branch lines with sprinklers” on page 8 . Also see “XL-Trace System for Fire Sprinkler Freeze Protection Design Guide” (H58489) . Flow maintenance Greasy waste lines Flow maintenance (110°F [43°C] minimum) for insulated greasy waste lines “Aboveground piping” on page 10 “Buried piping” on page 11 Fuel lines Flow maintenance (40°F [4°C] minimum) for insulated metal piping containing #2 fuel oil “For aboveground piping only,” page 12 note: If your application does not fit these guidelines, contact your local Tyco Thermal Controls representative or call (800) 545-6258 .

4 of 44 www.tycothermal.com H55838 2/12 Self-Regulating Heating Cable Construction Raychem XL-Trace self-regulating heating cables are comprised of two parallel nickel-coated bus wires in a cross-linked polymer core, a tinned copper braid, and a fluoropolymer or polyolefin outer jacket . These cables are cut to length, simplifying the application design and installation . Fig. 1 XL-Trace heating cable construction With self-regulating technology, the number of electrical paths between bus wires changes in response to temperature fluctuations . As the temperature surrounding the heater decreases, the conductive core contracts microscopically . This contraction decreases electrical resis- tance and creates numerous electrical paths between the bus wires . Current flows across these paths to warm the core . As the temperature rises, the core expands microscopically . This expansion increases electrical resistance and the number of electrical paths decreases . The heating cable automatically reduces its output . At low temperature, there are many conducting paths, resulting in high output and rapid heat-up. Heat is generated only when it is needed and precisely where it is needed. At high temperature, there are few conducting paths and output is correspondingly lower, conserving energy during operation. At moderate temperature, there are fewer conducting paths because the heating cable efficiently adjusts by decreasing output, eliminating any possibility of overheating. The following graphs illustrate the response of self-regulating heating cables to changes in temperature. As the temperature rises, electrical resistance increases, and our heaters reduce their power output. Temperature Resistance Power Temperature Constant wattage Constant wattage Self-regulating Self-regulating Fig. 2 Self-regulating heating cable technology Nickel-plated copper bus wire Self-regulating conductive core Modified polyolefin inner jacket Tinned-copper braid Polyolefin or fluoropolymer outer jacket

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection Applications Pipe Freeze Protection Applications A pipe freeze protection system is designed to maintain water temperature at a minimum of 40°F (4°C) to prevent freezing . Typical Pipe Freeze Protection System A typical pipe freeze protection system includes the XL-Trace self-regulating heating cables, connection kits, ambient temperature control, and power distribution . Fig. 3 Typical XL-Trace pipe freeze protection system Lighted End Seal Heating Cable End Seal Kit Tee Kit Power Distribution Panel Power Connection Kit Splice Kit Cross Kit Ambient RTD

6 of 44 www.tycothermal.com H55838 2/12 General Water Piping General water piping is defined as metal or plastic water piping located in nonhazardous locations . AbOvEGROunD PIPInG Fig. 4 Typical aboveground piping system Application Requirements The system complies with Tyco Thermal Controls requirements for aboveground general water piping when: •� The heating cable is permanently secured to insulated metal pipes with GT-66 glass tape, or to plastic pipes using AT-180 aluminum tape . •� A 30-mA ground-fault protection device (GFPD) is used . •� The heating cable is installed per manufacturer’s instructions with approved Raychem connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Other Required Documents” page 14 . Approvals UL Listed, FM Approved, and c-CSA-us Certified for nonhazardous locations . RayClic-PC power connection Junction box XL-Trace heating cable RayClic-S splice RayClic-T tee Insulation RayClic-LE lighted end seal (optional) RayClic-E end seal DigiTrace C910 Electronic controller 5XL1-CR, -CT 5XL2-CR, -CT 8XL1-CR, -CT 8XL2-CR, -CT 5XL1-CR, -CT 5XL2-CR, -CT 8XL1-CR, -CT 8XL2-CR, -CT 12XL2-CR, -CT -w

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection Applications buRIED PIPInG Fig. 5 Typical buried piping system Application Requirements The system complies with Tyco Thermal Controls requirements for use on buried insulated metal or plastic pipe when: •� The pipeline is buried at least 2 feet deep . •� All heating cable connections (power, splice, tee, and end termination) are made above- ground . no buried or in-conduit splices or tees are allowed . •� The heating cable has a fluoropolymer outer jacket (-CT) . •� The power connection and end seal are made in UL Listed and CSA Certified junction boxes above grade . •� The heating cable is protected from the pipe to the power connection box in UL Listed and CSA Certified water-sealed conduit (minimum 3/4-inch diameter) suitable for the location . •� A 30-mA ground-fault protection device (GFPD) is used . •� Closed-cell, waterproof thermal insulation with fire-retardant, waterproof covering is used . •� The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 15 on page 29 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Pipe Heat Loss Calculations,” page 14 . Approvals UL Listed, FM Approved, and c-CSA-us Certified for nonhazardous locations . RTD10CS Insulation Conduit XL-Trace heating cable with -CT jacket Ground Alternate power connection Alternate end seal Ground Wall RayClic-LE* RayClic-PC* Junction box RayClic-E end seal Conduit Wall with wall mounting bracket with wall mounting bracket FTC-XC power connection *To protect the heating cable run it inside Convolex tubing between the conduit and the RayClic connection kits. DigiTrace C910 Electronic controller Conduit for temperature sensor 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 12XL2-CT -w

8 of 44 www.tycothermal.com H55838 2/12 Fire Sprinkler Systems XL-Trace is designed to maintain fire suppression system standpipes, supply piping, mains, feeders, branch lines and sprinklers at 40°F (4°C) in areas subject to freezing . STAnDPIPES, SuPPLy PIPES, AnD bRAnCH LInES WITH SPRInkLERS Fig. 6 Standard sprinkler standpipe heating system layout Refer to the Fire Sprinkler System Freeze Protection Design Guide (H58489) for detailed in- structions to design XL-Trace heating cable circuits to freeze protect aboveground or buried supply pipe, feeders, mains standpipes, branch lines and sprinklers . Approvals The 2007 edition of nFPA 13 (Standard for the Installation of Sprinkler Systems) allows List- ed electrical heat tracing to freeze protect fire suppression systems including supply lines, standpipes and branch lines containing sprinklers . XL-Trace is c-CSA-us Certified for use on fire suppression systms under CSA C22 .2 no . 130-03 for Canada and Ieee 515 .1-2005 for the US . The system covered in this manual includes supply lines, standpipes, branch lines and sprinkler heads . XL-Trace systems are also UL and ULC Listed for freeze-protecting sprinkler supply lines, standpipes up to 20 inches in diameter and branch lines not containing sprinklers . Standpipe Thermal insulation Control valves in heated enclosure RayClic-PC power connection RayClic-S splice RayClic-LE lighted end seal Ambient sensing RTD Ground XL-Trace Power distribution panel Fire alarm panel DigiTrace C910 electronic controller Refer to Branch Lines with Sprinkler section for information on heat tracing sprinkler heads. Line sensing RTD 5XL1-CR, -CT 5XL2-CR, -CT 8XL1-CR, -CT 8XL2-CR, -CT 5XL1-CR, -CT 5XL2-CR, -CT 8XL1-CR, -CT 8XL2-CR, -CT 12XL2-CR, -CT (not for branch lines with sprinklers and sprinkler heads) -w

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Flow Maintenance Applications Flow Maintenance Applications A flow maintenance system is designed to maintain cooking greasy waste lines and #2 fuel oil lines above the temperature at which the viscosity inhibits fluid flow . Typical Flow Maintenance System A typical flow maintenance system includes the XL-Trace self-regulating heating cables with a fluoropolymer outer jacket, connection kits, line-sensing temperature control and power distribution . Splice Kit Powered Tee Kit Heating Cable Lighted End Seal Power Distribution Panel Grade Electronic Controller RTD Fig. 7 Typical XL-Trace flow maintenance system

10 of 44 www.tycothermal.com H55838 2/12 Greasy Waste Lines Greasy waste lines are defined as piping used for the disposal of waste oils and fats created in the cooking process . Typical applications include greasy waste lines from commercial restaurants . A grease-line flow maintenance system is designed to maintain a 110°F (43°C) minimum fluid temperature . AbOvEGROunD PIPInG Fig. 8 Typical aboveground piping system Application Requirements The system complies with Tyco Thermal Controls requirements for aboveground greasy waste lines when: •� The heating cable is permanently secured to metal pipes with GT-66 glass tape, or to plastic pipes using AT-180 aluminum tape . •� The heating cable must have a fluoropolymer outer jacket (-CT) . •� A 30-mA ground-fault protection device (GFPD) is used . •� Tees and splices are installed using pipe mounting brackets, not in direct contact with piping . •� The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Pipe Heat Loss Calculations,” page 14 . Approvals XL-Trace systems (-CT only) are UL Listed, FM Approved, and c-CSA-us Certified for nonhazardous locations . RayClic-PC power connection Junction box RayClic-S splice Insulation RayClic-LE lighted end seal RayClic-E Alternate end seal XL-Trace heating cable with -CT jacket RayClic-SB-04 pipe mounting bracket DigiTrace C910 Electronic controller RTD10CS 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 12XL2-CT -w

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Flow Maintenance Applications buRIED PIPInG Fig. 9 Typical buried greasy waste line Application Requirements The system complies with Tyco Thermal Controls requirements for buried greasy waste lines when: •� The heating cable is permanently secured to metal pipes with GT-66 glass tape, or to plastic pipes using AT-180 aluminum tape . •� The heating cable must have a fluoropolymer outer jacket (-CT) . •� The pipeline is buried at least 2 feet deep . •� All heating cable splices or tees are made aboveground . no buried or in-conduit splices or tees are allowed . •� The power connection and end seal are made in UL Listed and CSA Certified junction boxes above grade . •� The heating cable is protected from the pipe to the power connection box in UL Listed and CSA Certified conduit (minimum 3/4-inch diameter) suitable for the location . •� A 30-mA ground-fault protection device (GFPD) is used . •� Closed-cell, waterproof thermal insulation with fire-retardant, waterproof covering is used . •� The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 15 on page 29 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Heating Cable Catalog number” on page 18 . Approvals XL-Trace systems (-CT only) are UL Listed, FM Approved, and c-CSA-us Certified for nonhazardous locations . RTD10CS Insulation Conduit XL-Trace heating cable with -CT jacket Ground Alternate power connection Alternate end seal Ground Wall RayClic-LE* RayClic-PC* Junction box RayClic-E end seal Conduit Wall with wall mounting bracket with wall mounting bracket FTC-XC power connection *To protect the heating cable run it inside Convolex tubing between the conduit and the RayClic connection kits. DigiTrace C910 Electronic controller Conduit for temperature sensor 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 12XL2-CT -w

12 of 44 www.tycothermal.com H55838 2/12 Fuel Lines Fuel lines are defined as those carrying #2 fuel oil . A fuel line flow maintenance system is designed to maintain a 40°F (4°C) minimum fluid temperature to maintain flow . FOR AbOvEGROunD PIPInG onLy Fig. 10 Typical aboveground piping system Application Requirements The system complies with Tyco Thermal Controls requirements for aboveground #2 fuel oil piping when: •� The heating cable is permanently secured to metal pipes with GT-66 glass tape, or to plastic pipes using AT-180 aluminum tape . •� The heating cable must have a fluoropolymer outer jacket (-CT) . •� Tees and splices are installed using pipe mounting brackets, not in direct contact with piping . •� A 30-mA ground-fault protection device (GFPD) is used . •� The heating cable is installed per manufacturer’s instructions with approved Tyco Thermal Controls connection kits . See Table 13 on page 27 and the XL-Trace System Installation and Operation Manual (H58033) . Cable Selection See “Pipe Heat Loss Calculations,” page 14 . Approvals XL-Trace systems (-CT only) are UL Listed, FM Approved, and c-CSA-us Certified for nonhazardous locations . RayClic-S splice XL-Trace heating cable with -CT jacket RTD10CS RayClic-LE lighted end seal Junction box Insulation RayClic-PC power connection RayClic-SB-04 pipe mounting bracket DigiTrace C910 Electronic controller 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 5XL1-CT 5XL2-CT 8XL1-CT 8XL2-CT 12XL2-CT -w

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Pipe Freeze Protection and Flow Maintenance Design This section details the design steps necessary to design your application . The examples provided in each step are intended to incrementally illustrate the project parameter output for two sample designs from start to finish . As you go through each step, use the “XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet,” page 37, to document your project parameters, so that by the end of this section you will have the information you need for your Bill of Materials . XL-erate, the commercial pipe freeze protection and flow maintenance design software is available at http://www .tycothermal .com to assist with your design . Design Step by Step Your system design requires the following essential steps . �Determine design conditions and pipe heat loss �Select the heating cable  Determine the heating cable length  Determine the electrical parameters  Select the connection kits and accessories  Select the control system  Select the power distribution  Complete the Bill of Materials Pipe Freeze Protection and Flow Maintenance 1. Determine design conditions and heat loss 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials Step  Determine design conditions and pipe heat loss Collect the following information to determine your design conditions: •� XL-Trace application (from Table 1Location – Indoors – Outdoors – Aboveground – Buried •� Maintain temperature (Tm) •� Maximum system temperature (Tmax) •� Minimum ambient temperature (Ta) •� Pipe diameter and material •� Pipe length •� Thermal insulation type and thickness •� Supply voltage Example: Pipe Freeze Protection – Water Piping Location Aboveground, outdoor Maintain temperature (Tm) 40°F (4°C) Maximum system temperature (Tmax) 80°F (27°C) Minimum ambient temperature (Ta) –20°F (–29°C) Pipe diameter and material 2-inch plastic Pipe length 300 ft (91 m) Thermal insulation type and thickness 1-inch fiberglass Supply voltage 120 V

14 of 44 www.tycothermal.com H55838 2/12 Example: Pipe Freeze Protection – Greasy Waste Line Location Buried Maintain temperature (Tm) 110°F (43°C) Maximum system temperature (Tmax) 125°F (52°C) Minimum ambient temperature (Ta) 50°F (10°C) (soil temperature) Pipe diameter and material 4-inch metal Pipe length 200 ft (61 m) Thermal insulation type and thickness 1-inch rigid cellular urethane Supply voltage 208 V PIPE HEAT LOSS CALCuLATIOnS To select the proper heating cable you must first determine the pipe heat loss . To do this you must first calculate the temperature differential (DT) between the pipe maintain temperature and the minimum ambient temperature . Fig. 11 Pipe heat loss Calculate temperature differential DT To calculate the temperature differential (DT), use the formula below: DT = Tm – Ta Example: Pipe Freeze Protection – Water Piping Tm 40°F (4°C) Ta –20°F (–29°C) DT = 40°F – (–20°F) = 60°F DT = 4°C – (–29°F) = 33°C Example: Flow Maintenance – Greasy Waste Line Tm 110°F (43°C) Ta 50°F (10°C) DT = 110°F – (50°F) = 60°F DT = 43°C – (10°C) = 33°C Determine the pipe heat loss Match the pipe size, insulation thickness, and temperature differential (DT) from Table 2 to determine the base heat loss of the pipe (Qb) . Example: Pipe Freeze Protection – Water Piping Pipe diameter 2 inch 20 40 60 80 −40 −20 0 +20 +40 Maintain temperature °F °F Minimum ambient temperature Thermal insulation thickness Pipe or tubing diameter

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Insulation thickness 1 inch DT 60°F (33°C) Heat loss (Qb) for 60°F must be calculated through interpolation between DT at 50°F and DT at 100°F from Table 2 . For difference between the DT of 50°F and the DT of 100°F: Qb-50 3 .2 W/ft (from Table 2) Qb-100 6 .8 W/ft (from Table 2) DT interpolation DT 60°F is 20% of the distance between DT 50°F and DT 100°F Qb-60 Qb-50 + [0 .20 x (Qb-100 – Qb-50)] = 3 .2 + [0 .20 x (6 .8 – 3 .2)] = 3 .9 W/ft Pipe heat loss (Qb) 3.9 W/ft @ Tm 40°F (12.9 W/m @ Tm 4°C) Example: Flow Maintenance – Greasy Waste Line Pipe diameter 4 inch Insulation thickness 1 inch DT 60°F (33°C) Qb for 60°F must be calculated through interpolation between DT at 50°F and DT at 100°F from Table 2 . For difference between the DT of 50°F and the DT of 100°F: Qb-50 5 .4 W/ft (from Table 2) Qb-100 11 .2 W/ft (from Table 2) DT interpolation DT 60°F is 20% of the distance between DT 50°F and DT 100°F Qb-60 Qb-50 + [0 .20 x (Qb-100 – Qb-50)] = 5 .4 + [0 .20 x (11 .2 – 5 .4)] = 6 .6 W/ft Pipe heat loss Qb 6.6 W/ft @ Tm 110°F (21.5 W/m @ Tm 43°C) Compensate for insulation type and pipe location The base heat loss is calculated for a pipe insulated with thermal insulation with a k-factor ranging from 0 .2 to 0 .3 BTU/hr–°F-ft2/in (fiberglass or foamed elastomer) in an outdoor, or buried application . To get the heat loss for pipes insulated with alternate types of thermal insulation and for pipes installed indoors, multiply the base heat loss of the pipe (Qb) from Step 3 by the insulation multiple from Table 4 and the indoor multiple from Table 3 to get the corrected heat loss: Qcorrected = Qb x Insulation multiple x Indoor multiple Example: Pipe Freeze Protection – Water Piping Location Aboveground, outdoor Thermal insulation thickness and type 1-inch fiberglass Pipe heat loss Qb 3 .9 W/ft @ Tm 40°F (12 .9 W/m @ Tm 4°C) Qcorrected 3 .9 W/ft x 1 .00 x 1 .00 = 3.9 W/ft @ Tm 40°F (12.9 W/m @ Tm 4°C) Example: Flow Maintenance – Greasy Waste Line Location Buried Thermal insulation type and thickness 1-inch rigid cellular urethane Pipe heat loss Qb = 6 .6 W/ft @ Tm 110°F (21 .5 W/m @ Tm 43°C) Qcorrected = 6 .6 W/ft x 0 .6 x 1 .00 = 4.0 W/ft @ Tm 110°F (13.1 W/m @ Tm 43°C)

16 of 44 www.tycothermal.com H55838 2/12 Table 2 Pipe Heat Loss (qb) for Outdoor or buried Pipe (W/ft) for 1/2 to 3-1/2 inches Insulation thickness (DT) Pipe diameter (IPS) in inches (in) °F °C 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 0 .5 20 11 1 .0 1 .2 1 .4 1 .6 1 .8 2 .2 2 .5 3 .0 3 .4 50 28 2 .5 2 .9 3 .5 4 .1 4 .6 5 .5 6 .5 7 .7 8 .6 100 56 5 .2 6 .1 7 .2 8 .6 9 .6 11 .5 13 .5 16 .0 18 .0 150 83 8 .1 9 .5 11 .2 13 .4 14 .9 17 .9 21 .1 25 .0 28 .1 1 .0 20 11 0 .6 0 .7 0 .8 1 .0 1 .1 1 .3 1 .5 1 .7 1 .9 50 28 1 .6 1 .9 2 .2 2 .5 2 .8 3 .2 3 .8 4 .4 4 .9 100 56 3 .4 3 .9 4 .5 5 .2 5 .8 6 .8 7 .8 9 .1 10 .2 150 83 5 .3 6 .1 7 .0 8 .2 9 .0 10 .6 12 .2 14 .2 15 .9 1 .5 20 11 0 .5 0 .6 0 .7 0 .8 0 .8 1 .0 1 .1 1 .3 1 .4 50 28 1 .3 1 .5 1 .7 1 .9 2 .1 2 .4 2 .8 3 .2 3 .6 100 56 2 .8 3 .1 3 .5 4 .0 4 .4 5 .1 5 .8 6 .7 7 .4 150 83 4 .3 4 .8 5 .5 6 .3 6 .9 8 .0 9 .1 10 .5 11 .6 2 .0 20 11 0 .5 0 .5 0 .6 0 .6 0 .7 0 .8 0 .9 1 .0 1 .1 50 28 1 .1 1 .3 1 .4 1 .6 1 .8 2 .0 2 .3 2 .6 2 .9 100 56 2 .4 2 .7 3 .0 3 .4 3 .7 4 .2 4 .8 5 .5 6 .0 150 83 3 .7 4 .2 4 .7 5 .3 5 .8 6 .6 7 .5 8 .5 9 .4 2 .5 20 11 0 .4 0 .5 0 .5 0 .6 0 .6 0 .7 0 .8 0 .9 1 .0 50 28 1 .0 1 .2 1 .3 1 .4 1 .6 1 .8 2 .0 2 .3 2 .5 100 56 2 .2 2 .4 2 .7 3 .0 3 .3 3 .7 4 .2 4 .7 5 .2 150 83 3 .4 3 .7 4 .2 4 .7 5 .1 5 .8 6 .5 7 .4 8 .1 3 .0 20 11 0 .4 0 .4 0 .5 0 .5 0 .6 0 .6 0 .7 0 .8 0 .9 50 28 1 .0 1 .1 1 .2 1 .3 1 .4 1 .6 1 .8 2 .0 2 .2 100 56 2 .0 2 .2 2 .4 2 .7 2 .9 3 .3 3 .7 4 .2 4 .6 150 83 3 .1 3 .4 3 .8 4 .3 4 .6 5 .2 5 .8 6 .6 7 .1 4 .0 20 11 0 .3 0 .4 0 .4 0 .5 0 .5 0 .5 0 .6 0 .7 0 .7 50 28 0 .9 0 .9 1 .0 1 .1 1 .2 1 .4 1 .5 1 .7 1 .8 100 56 1 .8 2 .0 2 .1 2 .4 2 .5 2 .9 3 .2 3 .5 3 .8 150 83 2 .8 3 .0 3 .4 3 .7 4 .0 4 .4 4 .9 5 .5 6 .0 note: Multiply the W/ft heat loss values by 3 .28 for W/m .

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 1.2 continued Pipe Heat Loss (qb) for Outdoor or buried Pipe (W/ft) for 4 to 20 inches Insulation thickness (DT) Pipe diameter (IPS) in inches (in) °F °C 4 6 8 10 12 14 16 18 20 0 .5 20 11 3 .8 5 .3 6 .8 8 .4 9 .9 10 .8 12 .2 13 .7 15 .2 50 28 9 .6 13 .6 17 .4 21 .4 25 .2 27 .5 31 .3 35 .0 38 .8 100 56 20 .0 28 .4 36 .3 44 .6 52 .5 57 .4 65 .2 73 .0 80 .8 150 83 31 .2 44 .3 56 .6 69 .6 81 .9 89 .5 101 .7 113 .8 126 .0 1 .0 20 11 2 .1 2 .9 3 .7 4 .5 5 .3 5 .8 6 .5 7 .3 8 .0 50 28 5 .4 7 .5 9 .4 11 .5 13 .5 14 .7 16 .6 18 .6 20 .5 100 56 11 .2 15 .6 19 .7 24 .0 28 .1 30 .6 34 .7 38 .7 42 .8 150 83 17 .5 24 .3 30 .7 37 .4 43 .8 47 .8 54 .1 60 .4 66 .7 1 .5 20 11 1 .5 2 .1 2 .6 3 .2 3 .7 4 .0 4 .5 5 .0 5 .5 50 28 3 .9 5 .3 6 .7 8 .1 9 .4 10 .2 11 .5 12 .9 14 .2 100 56 8 .1 11 .1 13 .9 16 .8 19 .6 21 .3 24 .0 26 .8 29 .5 150 83 12 .7 17 .3 21 .6 26 .2 30 .5 33 .2 37 .5 41 .8 46 .1 2 .0 20 11 1 .2 1 .7 2 .1 2 .5 2 .9 3 .1 3 .5 3 .9 4 .3 50 28 3 .1 4 .2 5 .2 6 .3 7 .3 7 .9 8 .9 9 .9 10 .9 100 56 6 .6 8 .8 10 .9 13 .1 15 .2 16 .5 18 .6 20 .7 22 .8 150 83 10 .2 13 .8 17 .0 20 .5 23 .8 25 .8 29 .0 32 .3 35 .5 2 .5 20 11 1 .1 1 .4 1 .7 2 .1 2 .4 2 .6 2 .9 3 .2 3 .5 50 28 2 .7 3 .6 4 .4 5 .2 6 .1 6 .6 7 .4 8 .2 9 .0 100 56 5 .6 7 .4 9 .1 10 .9 12 .6 13 .7 15 .3 17 .0 18 .7 150 83 8 .7 11 .6 14 .2 17 .0 19 .7 21 .3 23 .9 26 .5 29 .1 3 .0 20 11 0 .9 1 .2 1 .5 1 .8 2 .0 2 .2 2 .5 2 .7 3 .0 50 28 2 .4 3 .1 3 .8 4 .5 5 .2 5 .6 6 .3 7 .0 7 .6 100 56 4 .9 6 .5 7 .9 9 .4 10 .8 11 .7 13 .1 14 .5 15 .9 150 83 7 .7 10 .1 12 .4 14 .7 16 .9 18 .3 20 .5 22 .6 24 .8 4 .0 20 11 0 .8 1 .0 1 .2 1 .4 1 .6 1 .7 1 .9 2 .1 2 .3 50 28 2 .0 2 .5 3 .1 3 .6 4 .1 4 .4 5 .0 5 .5 6 .0 100 56 4 .1 5 .3 6 .4 7 .5 8 .6 9 .3 10 .3 11 .4 12 .4 150 83 6 .4 8 .3 10 .0 11 .8 13 .4 14 .5 16 .1 17 .8 19 .4 note: Multiply the W/ft heat loss values by 3 .28 for W/m . Table 3 Indoor Pipe Heat Loss Multiples Fiberglass thickness (in) Indooor multiple 0 .5 0 .79 1 0 .88 1 .5 0 .91 2 0 .93 2 .5 0 .94 3 0 .95 4 0 .97 Table 4 Insulation Heat Loss Multiples k factor at 50°F (10°C) (bTu/hr–°F-ft2/in) Insulation multiple Examples of preformed pipe insulation 0 .1–0 .2 0 .6 Rigid cellular urethane (ASTM C591) 0 .2–0 .3 1 .0 Glass fiber (ASTM C547) Foamed elastomer (ASTM C534) 0 .3–0 .4 1 .4 Cellular glass (ASTM C552) Mineral fiber blanket (ASTM C553)

18 of 44 www.tycothermal.com H55838 2/12 Pipe Freeze Protection and Flow Maintenance 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials 1. Determine design conditions and heat loss Step  Select the heating cable To select the appropriate XL-Trace heating cable for your application, you must determine your cable supply voltage, power output, and outer jacket . Once you select these, you will be able to determine the catalog number for your cable . HEATInG CAbLE CATALOG nuMbER Before beginning, take a moment to understand the structure underlying heating cable cata- log numbers . You will refer to this numbering convention throughout the product selection process . Your goal is to determine the catalog number for the product that best suits your needs . Fig. 12 Heating cable catalog number Select the heating cable from Fig . 13 that provides the required power output to match the corrected heat loss for your application . Fig . 13 shows the power output for the heating cables on metal pipe at 120/208 volts . To correct the power output for other applied voltage or plastic pipes multiply the power output at the desired maintain temperature by the factors listed in Table 5 . If the pipe heat loss, Qcorrected, is between the two heating cable power output curves, select the higher-rated heating cable . 5XL1-CR and 5XL1-CT (120 V) 5XL2-CR and 5XL2-CT (208 V) 8XL1-CR and 8XL1-CT (120 V) 8XL2-CR and 8XL2-CT (208 V) 12XL2-CR and 12XL2-CT (208 V)    Pipe temperature Power W/ft 50 (10) 30 (–1) 40 (5) 60 (15) 70 (21) 80 (27) 90 (32) 100 (38) 110 (43) 120 (49) 130 (54) °F (°C)    10 8 14 12 6 4 2 0 Fig. 13 Heating cable power output on metal pipe Catalog number: 5, 8 or 12 XL 1 or 2 -CR -CT Power output (W/ft) Product family Voltage 1 = 120 V (only available for 5 or 8) 2 = 208, 240, 277 V (available for 5, 8, or 12) Jacket type: Polyolefin Fluoropolymer (required for buried pipes, grease and fuel lines) or

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 5 Power Output Correction Factors voltage correction factors 5XL1 8XL1 5XL2 8XL2 12XL2 120 V 1 .00 1 .00 – – – 208 V – – 1 .00 1 .00 1 .00 240 V – – 1 .12 1 .12 1 .14 277 V – – 1 .29 1 .27 1 .30 Plastic pipe correction factor (With AT-180 Aluminum tape) 0 .75 0 .75 0 .75 0 .75 0 .75 Confirm that the corrected power output of the heating cable selected is greater than the corrected pipe heat loss (Qcorrected) . If Qcorrected is greater than the power output of the highest-rated heating cable, you can: •� Use two or more heating cables run in parallel •� Use thicker insulation to reduce heat loss •� Use insulation material with a lower k factor to reduce heat loss Example: Pipe Freeze Protection – Water Piping Pipe maintain temperature (Tm) 40°F (4°C) (from Step 1) Qcorrected Qcorrected = 3 .9 W/ft @ Tm 40°F (13 .1 W/m @ Tm 4°C) Supply voltage 120 V (from Step 1) Pipe material Plastic (from Step 1) Select heating cable: Qb = 3 .9 W/ft @ Tm 40°F (from Step 1) 5XL1= 5 .6 W/ft @ 40°F (from Fig. 13) Supply voltage correction factor 1 .00 (from Table 5) Pipe material correction factor Plastic = 0 .75 (from Table 5) Corrected heating cable power 5 .6 W/ft x 1 .00 x 0 .75 = 4 .2 W/ft Selected heating cable 5XL1 Example: Flow Maintenance – Greasy Waste Line Pipe maintain temperature (Tm) 110°F (43°C) (from Step 1) Qcorrected 3 .9 W/ft @ Tm 110°F (13 .1W/m @ Tm 43°C) Supply voltage 208 V (from Step 1) Pipe material Metal (from Step 1) Select heating cable: Qb = 3 .9 W/ft @ Tm 110°F (from Step 1) 12XL2= 7 .0 W/ft @110°F (from Fig. 13) Supply voltage correction factor 1 .00 (from Table 5) Pipe material correction factor Metal = 1 .00 Corrected heating cable power 7 .0 x 1 .00 x 1 .00 = 7 .0 W/ft Selected heating cable 12XL2

20 of 44 www.tycothermal.com H55838 2/12 COnFIRM EXPOSuRE TEMPERATuRE RATInG FOR THE HEATInG CAbLE Refer to Table 6 to verify that the maximum system temperature does not exceed the expo- sure temperature of the selected heating cable . Table 6 Heating Cable Temperature Ratings 5XL1 5XL2 8XL1 8XL2 12XL2 Maximum maintain temperature (Tm) 150°F (65°C) 150°F (65°C) 150°F (65°C) 150°F (65°C) 150°F (65°C) Maximum exposure temperature (Texp) 150°F (65°C) 150°F (65°C) 150°F (65°C) 150°F (65°C) 185°F (85°C) Example: Pipe Freeze Protection – Water Piping Maximum system temperature (Tmax) 80°F (27°C) (from Step 1) Selected heating cable 5XL1 (from previous step) Maximum heating cable exposure temperature (Texp) 150°F (65°C) (from Table 6) Tmax < Texp yes Example: Flow Maintenance - Greasy Waste Line Maximum system temperature (Tmax) 125°F (52°C) (from Step 1) Selected heating cable 12XL2 (from previous step) Maximum heating cable exposure temperature (Texp) 185°F (85°C)(from Table 6 Tmax < Texp yes SELECT OuTER JACkET Select the appropriate heating cable outer jacket for the application . Jacket options are: -CR Compatible with most XL-Trace applications -CT Required for grease and fuel line flow maintenance; may be used in other XL-Trace applications for improved mechanical strength and chemical resistance . Example: Pipe Freeze Protection – Water Piping Selection: 5XL1-CR Example: Flow Maintenance - Greasy Waste Line Selection: 12XL2-CT Pipe Freeze Protection and Flow Maintenance 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials 1. Determine design conditions and heat loss Step  Determine the heating cable length In Step 2 you selected the appropriate heating cable and the number of runs of heating cable required for the pipe . Multiply the length of the pipe by the number of heating cable runs for the heating cable length . Additional heating cable will be required for heat sinks and connection kits . Use Table 7 and Table 8 to determine the additional footage required for heat sinks (valves, flanges, and pipe supports) . You will determine the additional heating cable for connection kits in Step 5 . Round up fractional lengths to ensure heating cable lengths are sufficient . Heating cable length = Pipe length x No. heating cable runs Total heating cable length required (Pipe length x No. heating cable runs) Additional heating cable for heat sinks (valves, pipe supports, and flanges) = +

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 7 Additional Heating Cable for valves Pipe diameter (IPS) (inches) Heating cable (feet (meters)) 1/2 0 .8 (0 .24) 3/4 1 .3 (0 .4) 1 2 .0 (0 .6) 1-1/4 3 .3 (1 .1) 1-1/2 4 .3 (1 .3) 2 4 .3 (1 .3) 3 4 .3 (1 .3) 4 4 .3 (1 .3) 6 5 .0 (1 .5) 8 5 .0 (1 .5) 10 5 .6 (1 .7) 12 5 .9 (1 .9) 14 7 .3 (2 .2) 18 9 .4 (2 .9) 20 10 .5 (3 .2) Table 8 Additional Heating Cable for Pipe Supports and Flanges Support Additional cable Pipe hangers (insulated) no additional heating cable Pipe hangers noninsulated and U-bolt supports Add 2x pipe diameter Welded support shoes Add 3x the length of the shoe Flanges Add 2x pipe diameter note: For applications where more than one heating cable is required per foot of pipe, this correction factor applies for each cable run . Example: Pipe Freeze Protection – Water Piping Pipe length 300 ft (91 m) (from Step 1) Pipe diameter 2-inch plastic (from Step 1) number of heating cable runs 1 (from Step 2) Valves 3 gate valves 4 .3 ft x 3 gate valves = 12 .9 ft (3 .9 m) Pipe supports 5 pipe hangers with U-bolts 2-inch pipe diameter = 2 / 12 = 0 .17 ft [0 .17 ft pipe diameter x 2] x 5 pipe supports = 1 .7 ft (0 .5 m) Flanges 0 Total heating cable for heat sinks 12 .9 ft (3 .9 m) + 1 .7 ft (0 .5 m) = 14 .6 ft (4 .4 m) Rounded up to 15 ft (5 m) Total heating cable length required 300 ft (91 m) x 1 run + 15 ft = 315 ft (96 m) of 5XL1-CR (note: AT-180 Aluminum tape is required for installing heating cable on plastic pipe .)

22 of 44 www.tycothermal.com H55838 2/12 Example: Flow Maintenance – Greasy Waste Line Pipe length 200 ft (61 m) (from Step 1) Pipe diameter 4-inch metal (from Step 1) number of heating cable runs 1 (from Step 2) Valves 2 gate valves [4 .3 ft x 2 gate valves] x 1 run = 8 .6 ft (2 .6 m) Pipe supports 2 non-insulated hangers 4-inch pipe diameter = 4 /12 = 0 .33 ft [(0 .33 ft pipe diameter x 2) x 2 pipe supports] x 1 run = 1 .3 ft (0 .4 m) Flanges 2 4-inch pipe diameter = 4 /12 = 0 .33 ft [(2 x 0 .33 ft (pipe diameter)) x 2 flanges] x 1 run = 1 .3 ft (0 .4 m) Total heating cable for heat sinks 8 .6 ft (2 .6 m) + 1 .3 ft (0 .4 m) + 1 .3 ft (0 .4 m) = 11 .2 ft (2 .2 m) Rounded up to 12 ft (3 m) Total heating cable length required 200 ft x 1 run + 12 ft = 212 ft (65 m) of 12XL2-CT Pipe Freeze Protection and Flow Maintenance 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials 1. Determine design conditions and heat loss Step  Determine the electrical parameters To determine the electrical requirements for your application, you must determine the number of circuits and calculate the transformer load . DETERMInE nuMbER OF CIRCuITS To determine the number of circuits, you need to know: •� Total heating cable length •� Supply voltage •� Minimum start-up temperature Use Table 9 to determine the maximum circuit length allowed . If the total heating cable length exceeds the maximum circuit length for the expected start-up temperature, more than one circuit will be required . number of circuits = Heating cable length required Maximum heating cable circuit length Important: Select the smallest appropriate ground-fault circuit breaker size . WARnInG: To minimize the danger of fire from sustained electrical arcing if the heat- ing cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equip- ment protection must be used on each heating cable branch circuit . Arcing may not be stopped by conventional circuit protection .

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 9 Maximum Circuit Length in Feet 40°F / 110°F Maintain* Start-up temperature (°F) Cb size (A) 5XL1 8XL1 5XL2 8XL2 12XL2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 v –20°F 15 101 76 174 178 183 131 138 146 111 114 117 20 134 101 232 237 245 175 184 194 148 151 156 30 201 151 349 356 367 262 276 291 223 227 234 40 270 201 465 474 478 349 368 388 297 303 312 0°F 15 115 86 199 203 209 149 157 166 120 122 126 20 153 115 265 271 279 199 209 221 160 163 168 30 230 172 398 406 419 298 314 331 239 244 252 40 270 210 470 490 530 370/399 390/420 420/443 319 326 336 20°F 15 134 100 232 237 244 173 182 192 126 129 133 20 178 133 309 315 325 231 243 257 169 172 177 30 270 200 464 473 488 346 365 385 253 258 266 40 270 210 470 490 530 370/462 390/486 420/513 340/349 344 355 40°F 15 160 119 278 283 292 206 217 229 142 145 150 20 214 159 370 378 390 275 290 306 190 194 200 30 270 210 470 490 530 370/416 390/438 420/462 285 291 300 40 270 210 470 490 530 370/554 390/584 420/616 340/398 360/406 380/419 50°F (buried) 15 – – – – – 228 240 254 152 155 160 20 – – – – – 304 320 338 203 207 213 30 – – – – – 457 481 507 304 310 320 40 – – – – – 609 641 676 405 414 427 65°F (indoors grease) 15 – – – – – 272 286 302 169 172 178 20 – – – – – 362 381 402 225 230 237 30 – – – – – 543 572 603 338 345 356 40 – – – – – 610 660 720 430 460 490 * When maximum circuit length is listed in: •�black�type,�the�value�is�for�applications�with�a�40°F�maintain •�red italic type, the value is for applications with a 110°F maintain

24 of 44 www.tycothermal.com H55838 2/12 Table 10 Maximum Circuit Length in Meters 4°C / 43°C Maintain* Start-up temperature (°C) Cb size (A) 5XL1 8XL1 5XL2 8XL2 12XL2 120 v 120 v 208 v 240 v 277 v 208 v 240 v 277 v 208 v 240 v 277 v –29°C 15 31 23 53 54 56 40 42 44 34 35 36 20 41 31 71 72 75 53 56 59 45 46 48 30 61 46 106 108 112 80 84 89 68 69 71 40 82 61 142 145 149 106 112 118 90 92 95 –18°C 15 35 26 61 62 64 45 48 51 36 37 38 20 47 35 81 83 85 61 64 67 49 50 51 30 70 52 121 124 128 91 96 101 73 74 77 40 82 64 143 149 162 113/122 119/128 128/135 97 99 102 –7°C 15 41 31 71 72 74 53 56 59 39 39 41 20 54 41 94 96 99 70 74 78 51 52 54 30 82 61 141 144 149 106 111 117 77 79 81 40 82 64 143 149 162 113/141 119/148 128/156 104/106 105 108 4°C 15 49 36 85 86 89 63 66 70 43 44 46 20 65 48 113 115 119 84 88 93 58 59 61 30 82 64 143 149 162 113/127 119/134 128/141 87 89 91 40 82 64 143 149 162 113/169 119/178 128/188 104/121 110/124 116/128 10°C (buried grease) 15 – – – – – 70 73 77 46 47 49 20 – – – – – 93 98 103 62 63 65 30 – – – – – 139 147 155 93 95 98 40 – – – – – 186 195 206 124 126 130 18°C (indoors grease) 15 – – – – – 83 87 92 52 53 54 20 – – – – – 110 116 123 69 70 72 30 – – – – – 166 174 184 103 105 108 40 – – – – – 186 201 220 131 140 149 * When maximum circuit length is listed in: •�black�type,�the�value�is�for�applications�with�a�4°C�maintain •�red italic type, the value is for applications with a 43°C maintain Example: Pipe Freeze Protection – Water Piping Total heating cable length 315 ft of 5XL1-CR (from Step 3) Supply voltage 120 V (from Step 1) Minimum start-up temperature –20°F (–29°C) (from Step 1) number of circuits 315 ft / (210 ft max CL) = 1 .8 circuits Round up to 2 circuits Example: Flow Maintenance – Greasy Waste Line Total heating cable length 223 ft of 12XL2-CT (from Step 3) Supply voltage 208 V (from Step 1) Minimum start-up temperature 50°F (10°C) (from Step 1) number of circuits 223 ft / 428 ft = 0 .8 circuits Round up to 1 circuit

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design DETERMInE TRAnSFORMER LOAD Transformers must be sized to handle the load of the heating cable . Use the following tables to calculate the total transformer load . Table 11 Transformer Sizing (Amperes/foot) Minimum start-up temperature (°F) 5XL1 8XL1 5XL2 8XL2 12XL2 120 120 208 240 277 208 240 277 208 240 277 –20 0 .119 0 .159 0 .069 0 .067 0 .065 0 .092 0 .087 0 .082 0 .108 0 .106 0 .102 0 0 .105 0 .139 0 .060 0 .059 0 .057 0 .080 0 .076 0 .072 0 .100 0 .098 0 .095 20 0 .090 0 .120 0 .052 0 .051 0 .049 0 .069 0 .066 0 .062 0 .095 0 .093 0 .090 40 0 .075 0 .101 0 .043 0 .042 0 .041 0 .058 0 .055 0 .052 0 .084 0 .083 0 .080 50 – – – – – 0 .053 0 .050 0 .047 0 .079 0 .077 0 .075 65 – – – – – 0 .044 0 .042 0 .040 0 .072 0 .070 0 .067 Table 12 Transformer Sizing (Amperes/meter) Minimum start-up temperature (°C) 5XL1 8XL1 5XL2 8XL2 12XL2 120 120 208 240 277 208 240 277 208 240 277 –20 0 .391 0 .521 0 .226 0 .221 0 .215 0 .301 0 .286 0 .270 0 .354 0 .347 0 .336 –18 0 .343 0 .457 0 .198 0 .194 0 .188 0 .264 0 .251 0 .238 0 .329 0 .322 0 .312 –7 0 .294 0 .394 0 .170 0 .166 0 .161 0 .227 0 .216 0 .205 0 .311 0 .305 0 .296 4 0 .246 0 .331 0 .142 0 .139 0 .135 0 .191 0 .181 0 .172 0 .276 0 .271 0 .263 10 – – – – – 0 .172 0 .164 0 .155 0 .259 0 .254 0 .246 18 – – – – – 0 .145 0 .138 0 .130 0 .233 0 .228 0 .221 Use Table 11 or Table 12 to determine the applied voltage and the maximum A/ft (A/m) at the minimum start up temperature to calculate the transformer load as follows: Example: Pipe Freeze Protection – Water Piping Total heating cable length 315 ft of 5XL1-CR (from Step 3) Minimum start-up temperature –20°F (–29°C) (from Step 1) Circuit breaker sizing 30 A 1000 = Transformer load (kW) Max A/ft at minimum start-up temperature x Heating cable length (ft) x Supply voltage = (0.119 A/ft x 315 ft x 120 V) / 1000 = 4.5 kW Transformer load (kW) 1000 Max A/ft at –20°F x Total feet x Supply voltage

26 of 44 www.tycothermal.com H55838 2/12 Example: Flow Maintenance – Greasy Waste Line Total heating cable length 212 ft of 12XL2-CT (from Step 3) Supply voltage 208 V Minimum start-up temperature 50°F (10°C) (from Step 1) Maximum circuit length Tm = 110°F, 304 ft Pipe Freeze Protection and Flow Maintenance 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials 1. Determine design conditions and heat loss Step  Select the connection kits and accessories All XL-Trace systems require a power connection and end seal kit . Splice and tee kits are used as required . Use Table 13 on page 27 (for aboveground applications) and Table 15 on page 29 (for buried applications) to select the appropriate connection kits . note: Add extra cable on your Bill of Materials for power connections, tees, and end seals . See Table 13 on page 27, Table 15 on page 29, and Table 16 on page 30 for more information . WARnInG: Approvals and performance are based on the use of Tyco Thermal Controls-specified parts only . Do not substitute parts or use vinyl electrical tape . AbOvEGROunD PIPInG Fig. 14 RayClic connection system Use the following table for general piping, standpipe sprinkler piping, and greasy waste and fuel lines . Develop a bill of materials from the connection kits listed in this table . note: Connection kits must be off the pipe when installed on greasy waste, fuel oil, or pipes exceeding 150°F (65°C) . = (0.079 A/ft x 212 ft x 208 V) / 1000 = 3.5 kW Transformer load (kW) 1000 Max A/ft at 50°F x Total feet x Supply voltage RayClic-PT powered tee RayClic-PC powered connection RayClic-S splice RayClic-X cross tee RayClic-T tee RayClic-PS powered splice RayClic-LE lighted end seal RayClic-E end seal Alternate lighted end seal Alternate connection kits XL-Trace heating cable

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 13 Connection kits and Accessories for Aboveground Piping Catalog number Description Standard packaging usage Heating cable allowance1 Connection kits RayClic-PC Power connection and end seal (RayClic-SB-04 pipe mounting bracket included) 1 1 per circuit 2 ft (0 .6 m) RayClic-PS Powered splice and end seal (RayClic-SB-04 pipe mounting bracket included) 1 1 per circuit 4 ft (1 .2 m) RayClic-PT Powered tee and end seal (RayClic-SB-04 pipe mounting bracket included) 1 1 per circuit 6 ft (1 .8 m) FTC-P2 Power connection and end seal note: FTC-P is required for circuits requiring 40 A circuit breakers . 1 1 per circuit 3 ft (0 .9 m) RayClic-S Splice 1 As required 2 ft (0 .6 m) RayClic-T Tee kit with end seal 1 As required 3 ft (0 .9 m) R RayClic-X Cross connection to connect four heating cables 1 As required 8 ft (2 .4 m) FTC-HST3 Low-profile splice/tee 2 As required 3 ft (0 .9 m) RayClic-Le Lighted end seal (RayClic-SB-04 pipe mounting bracket included) 1 Alternate end seal 2 ft (0 .6 m) RayClic-e extra end seal 1 Additional end seal 0 .3 ft (0 .1 m)

28 of 44 www.tycothermal.com H55838 2/12 Table 13 Connection kits and Accessories for Aboveground Piping Catalog number Description Standard packaging usage Heating cable allowance1 Accessories RayClic-SB-04 Pipe mounting bracket 1 As required – RayClic-SB-02 Wall mounting bracket 1 As required – eTL “electric-Traced” label 1 1 label per 10 feet (3 m) of pipe – GT-66 Glass cloth adhesive tape 66 ft (20 m) See Table 14 – GS-54 Glass cloth adhesive tape 54 ft (20 m) See Table 14 – AT-180 Aluminum tape - required for installing heating cable on plastic pipe 180 ft (55 m) 1 ft/ft [0 .3 m/m] of heating cable – 1 Allow extra heating cable for ease of component installation . 2 Junction box not included . 3 One RayClic-e end seal is required for each FTC-HST used as a tee kit . Table 14 quantity of Glass Cloth Adhesive Tape Required (attach at 1-foot intervals) Pipe size (in) <2 3 4 6 8 10 Feet of pipe per GT-66 roll 60 (18 m) 50 (15 m) 40 (12 m) 25 (8 m) 20 (6 m) 15 (5 m) Feet of pipe per GS-54 roll 49 (15 m) 41 (13 m) 33 (10 m) 20 (6 m) 16 (5 m) 12 (4 m) (Continued)

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design buRIED PIPInG Fig. 15 Typical buried piping system Use the following for buried water piping and greasy waste lines . note that all connections must be aboveground and that no splices/tees are allowed . Develop a bill of materials from the connection kits in this table . Table 15 Connection kits and Accessories for buried Piping Catalog number Description Standard packaging usage Heating cable allowance1 RayClic-PC Power connection and end seal (RayClic-SB-04 pipe mounting bracket included) 1 1 per circuit 2 ft (0 .6 m) FTC-XC The FTC-XC power connection and end seal kit is for use with XL-Trace heating cable that is run through conduit to a junc- tion box . Materials for one power connec- tion and end seal is included in the kit . note: FTC-XC is required for circuits requiring 40 A circuit breakers . 1 1 per circuit 2 ft (0 .6 m) RayClic-Le Lighted end seal (RayClic-SB-04 pipe mounting bracket included) 1 Alternate end seal 2 ft (0 .6 m) RayClic-e extra end seal 1 Additional end seal 0 .3 ft (0 .1 m) RTD10CS Insulation Conduit XL-Trace heating cable with -CT jacket Ground Alternate power connection Alternate end seal Ground Wall RayClic-LE* RayClic-PC* Junction box RayClic-E end seal Conduit Wall with wall mounting bracket with wall mounting bracket FTC-XC power connection *To protect the heating cable run it inside Convolex tubing between the conduit and the RayClic connection kits. DigiTrace C910 Electronic controller Conduit for temperature sensor

30 of 44 www.tycothermal.com H55838 2/12 Table 15 Connection kits and Accessories for buried Piping Catalog number Description Standard packaging usage Heating cable allowance1 Accessories RayClic-SB-04 Pipe mounting bracket 1 As required – RayClic-SB-02 Wall mounting bracket 1 As required – eTL “electric-Traced” label 1 1 label per 10 feet (3 m) of pipe – GT-66 Glass cloth adhesive tape 66 ft (20 m) See Table 16 – GS-54 Glass cloth adhesive tape 54 ft (20 m) See Table 16 – AT-180 Aluminum tape - required for installing heating cable on plastic pipe 180 ft (55 m) 1 ft/ft [0 .3 m/m] of heating cable – 1 Allow extra heating cable for ease of component installation . Table 16 quantity of Glass Cloth Adhesive Tape Required (attach at 1-foot intervals) Pipe size (in) <2 3 4 6 8 10 Feet of pipe per GT-66 roll 60 (18 m) 50 (15 m) 40 (12 m) 25 (8 m) 20 (6 m) 15 (5 m) Feet of pipe per GS-54 roll 49 (15 m) 41 (13 m) 33 (10 m) 20 (6 m) 16 (5 m) 12 (4 m) (Continued)

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Pipe Freeze Protection and Flow Maintenance 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials 1. Determine design conditions and heat loss Pipe Freeze Protection and Flow Maintenance Step  Select the control system Temperature controls save energy by ensuring that the system is energized only when necessary . Tyco Thermal Controls offers a wide variety of monitoring and control options, including: •� Mechanical thermostats provide a cost effective control solution . •� electronic thermostats provide higher accuracy of the heating cable circuit with thermistor sensors . •� electronic controllers provide superior accuracy with RTD temperature sensors, built-in ground-fault protection, monitoring and alarm output . •� Modbus® protocol communication over RS-485 system is supported using DigiTrace Protonode multi-protocol gateways . note: Fire sprinkler standpipe freeze protection requires DigiTrace C910, DigiTrace C910-485 or ACCS-30 controllers with alarm relays connected to the fire control panel . note: Greasy waste flow maintenance requires line sensing controllers such as the DigiTrace eC-TS or DigiTrace C910, or the DigiTrace ACCS-30 . Use the following table to identify the control system suitable for your application . Contact your Tyco Thermal Controls representative or contact Tyco Thermal Controls directly at (800) 545-6258 for more information . Table 17 Temperature Control Options Application Electronic thermostat Electronic controllers Single-point Multipoint EC-TS DigiTrace C910* ACCS-30 Ambient sensing x x x Line sensing x x x Buried pipe x x x Fire sprinklers – x x Sensor Thermistor See data sheet See data sheet Sensor length – 10 ft " Set point range 30°F to 110°F (–1°C to 43°C) –76°F to 1058°F (–60°C to 570°C) " enclosure neMA 4X neMA 4X " Differential 3°F (1 .6°C) 3°F (1 .6°C) " Set point repeatability 3°F (1 .6°C) 3°F (1 .6°C) " enclosure limits –40°F to 140°F (–40°C to 60°C) –40°F to 140°F (–40°C to 60°C) " Switch rating 30 A 30 A " Switch type SPST DPST " electrical rating 100–277 V 100–277 V " Approvals c-UL-us c-CSA-us " Ground-fault protection – 20 mA to 250 mA " Alarm outputs " AC relay – 100–277 V, 0 .75 A max . " Dry contact relay – 48 Vac/dc, 500 mA max . " * The C910-485 is available to provide RS-485 communication capability . Connect to the BMS using DigiTrace Protonode multi-protocol gateways

32 of 44 www.tycothermal.com H55838 2/12 Table 18 Control Systems Catalog number Description Electronic Thermostats and Accessories eC-TS electronic thermostat housed in a neMA 4X enclosure with 2 x 1/2-in conduit entries for power and one gland entry for the sensor . The temperature set point and LeD indicators for alarm, power, and heating cable status can be visually checked through the clear lid . electrical rating is 30 A at 100–277 V, 50–60 Hz, SPST switch . eC-TS includes a 25 ft (7 .6 m) sensor . SB-110 Pipe mounting bracket for eC-TS Electronic Controllers and Sensors C910 C910-485 The C910 is a compact, full-featured microprocessor-based single-point heat-trace control- ler . The C910 provides control and monitoring of electrical heat-tracing circuits for both freeze protection and temperature maintenance, and can be set to monitor and alarm for high and low temperature, high and low current, ground-fault level, and voltage . The DigiTrace C910 controller is available with an electromechanical relay (eMR) for use in ordinary areas . The C910-485 comes with an RS-485 communication module . ACCS-UIT2 ACCS-PCM2-5 The DigiTrace ACCS-30 Advanced Commercial Control System is a multipoint electronic control and monitoring system for heat-tracing used in commercial freeze protection and flow maintenance applications . The DigiTrace ACCS-30 system can control up to 260 circuits with multiple networked ACCS-PCM2-5 panels, with a single ACCS-UIT2 user interface ter- minal . The ACCS-PCM2-5 panel can directly control up to 5 individual heat-tracing circuits using electromechanical relays rated at 30 A up to 277 V . By FieldServer Technologies www.ProtoCessor.com PROTOCESSOR SERIAL ETHERNET PROTONODE FRAME GND - PWR +PWR RS 485+ RS 485 - RS 485 GND S3 S2 S1 S0 B3 B2 B1 B0 A7 A6 A5 A4 A3 A2 A1 A0 Protonode-LeR Protonode-ReR The DigiTrace Protonode is an external, high performance multi-protocol gateway for customers needing protocol translation between Building Management Systems (BMS) and the DigiTrace ACCS-30 or C910-485 controllers . The Protonode-LeR is for LonWorks® systems; and the Protonode-ReR is for BACnet® or Metasys® n2 systems . RTD-200 RTD3CS RTD10CS Three-wire RTD (Resistance Temperature Device) used with DigiTrace C910 and ACCS-30 controllers . RTD-200: 6-ft (1 .8 m) fluoropolymer with 1/2-in nPT bushing RTD3CS: 3-ft (0 .9 m) flexible armor with 1/2-in nPT bushing RTD10CS: 10-ft (3 m) flexible armor with 1/2-in nPT bushing

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials Pipe Freeze Protection and Flow Maintenance 1. Determine design conditions and heat loss Pipe Freeze Protection and Flow Maintenance Step  Select the power distribution Once the heating cable circuits have been defined, you must select how to provide power to them . Power to the XL-Trace heating cables can be provided in several ways: directly through the temperature control, through external contactors, or through HTPG power distribution panels . SInGLE CIRCuIT COnTROL Heating cable circuits that do not exceed the current rating of the selected temperature control device shown in Table 18 can be switched directly (see Fig . 16) . GROuP COnTROL If the current draw exceeds the switch rating, or if the controller will activate more than one circuit (group control, an external contactor must be used (see Fig . 16 on page 33) . Large systems with many circuits should use an HTPG power distribution panel . The HTPG is a dedicated power-distribution, control, ground-fault protection, monitoring, and alarm panel for freeze protection and broad temperature maintenance heat-tracing applications . This enclosure contains an assembled circuit-breaker panelboard . Panels are equipped with ground-fault circuit breakers with or without alarm contacts . The group control package al- lows the system to operate automatically in conjunction with an ambient-sensing thermostat, individual electronic, or duty cycle controller . Fig. 16 Single circuit and group control Single circuit control Group control Temperature controller 1-pole GFEP breaker 1 N G Heating cable ø ø supply C Temperature controller Contactor 1-pole GFEP breaker N G (Typ 3) ø2 ø1 ø3 3-phase 4-wire supply (WYE) 3-pole main breaker ø ø 1 supply N Heating cable sheath, braid or ground Heating cable sheath, braid or ground

34 of 44 www.tycothermal.com H55838 2/12 Fig. 17 HTPG power distribution panel Fig. 18 HTPG power schematic A COMMON ALARM PUSH TO ACKNOWLEDGE HAND/OFF/AUTO 1 2 3 4 5 6 7 8 9 10 11 12 Main circuit breaker Main contactor Distribution panelboard Fuse holder C POWER ON TB 1 TB 2 AR R Ground bus bar Selector switch Alarm relay (optional) Terminals (optional) Push button for light testing Alarm horn (optional) Alarm option shown above Door disconnect (optional) N Ø1 Three-pole main circuit breaker Panel energized Contactor coil C NC External controller/ thermostat* Hand Auto Off Three-pole main contactor Ø3 Ø2 Power connection Heating cable One-pole with 30-mA ground-fault trip (120/277 Vac) Two-pole with 30-mA ground-fault trip (208/240 Vac) Alarm remote annunciation (with alarm option) Heating cable circuit Heating cable circuit G End seal Heating cable shealth, braid or ground Three-phase, 4 wire supply (Wye)

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets Pipe Freeze Protection and Flow Maintenance Design Table 19 Power Distribution Catalog number Description Power Distribution A COMMON ALARM PUSH TO ACKNOWLEDGE HAND/OFF/AUTO C POWER ON HTPG Heat-tracing power distribution panel with ground-fault and monitoring for group control . Contactors e104 Three-pole, 100 Amp per pole, 600 V maximum contactor housed in UL Listed, CSA Certified, neMA 4X enclosure with two 1-inch conduit entries . When ordering, select coil voltage (110–120, 208–240, 277 V) . enclosure dimensions: 13-1/2 in x 9-1/5 in x 6-11/16 in (343 mm x 234 mm x 170 mm) . e304 Three-pole, 40 Amp per pole, 600 V maximum contactor housed in UL Listed, CSA Certified neMA 4X enclosure with two 1-inch conduit entries . When ordering, select coil voltage (110–120, 208–240, 277 V) . enclosure dimensions: 9-1/2 in x 7-1/5 in x 6-11/16 in (241 mm x 183 mm x 170 mm) .

36 of 44 www.tycothermal.com H55838 2/12 2. Select the heating cable 3. Determine the heating cable length 4. Determine the electrical parameters 5. Select the connection kits and accessories 6. Select the control system 7. Select the power distribution 8. Complete the Bill of Materials Pipe Freeze Protection and Flow Maintenance 1. Determine design conditions and heat loss Pipe Freeze Protection and Flow Maintenance Step  Complete the bill of Materials If you used the Design Worksheet to document all your design parameters, you should have all the details necessary complete your Bill of Materials .

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step  Determine design conditions and pipe heat loss Design conditions XL-Trace application Location Maintain temp. (Tm) Max. system temp. (Tmax) Min. ambient temp. (Ta) Pipe diameter and material Pipe length Thermal insulation type and thickness Pipe freeze protection  Water piping  Indoors  Outdoors  Aboveground  Buried ______ ______ ______ ____ in  Metal  Plastic _____ ft (m)  Fiberglass  ________ ____ in  Sprinkler piping  Indoors  Outdoors  Aboveground  Buried ______ ______ ______ ____ in  Metal  Plastic _____ ft (m)  Fiberglass  ________ ____ in Flow maintenance  Greasy waste lines  Indoors  Outdoors  Aboveground  Buried ______ ______ ______ ____ in  Metal  Plastic _____ ft (m)  Fiberglass  ________ ____ in  Fuel lines  Indoors  Outdoors  Aboveground  Buried ______ ______ ______ ____ in  Metal  Plastic _____ ft (m)  Fiberglass  ________ ____ in Example: 0 Water piping 0 Aboveground 0 Outdoor 40°F 80°F –20°F 2 in 0 Plastic 300 ft 0 Fiberglass 1 in Pipe heat loss Calculate temperature differential DT Pipe maintain temperature (TM) °F (°C) Ambient temperature (TA) °F (°C) TM ∆T − = Example: Pipe Freeze Protection − Water Piping TA Pipe maintain temperature (TM) °F (from Step 1) (from Step 1) Ambient temperature (TA) °F TM ∆T 40 °F 40 °F −20 °F −20 °F 60 °F − = TA

38 of 44 www.tycothermal.com H55838 2/12 Determine the pipe heat loss: See Table 2 for the base heat loss of the pipe (Qb) . If the DT for your system is not listed, interpolate between the two closest values . QB-50 ∆T1 W/ft (W/m) QB-100 ∆T2 W/ft (W/m) QB W/ft (W/m) in in °F (°C) W/ft (W/m) W/ft (W/m) Example: Pipe Freeze Protection − Water Piping Pipe diameter 2 in 1 in 60°F Insulation thickness 3.2 W/ft 6.8 W/ft ∆T QB-50 QB-100 Pipe diameter Insulation thickness ∆T QB-50 QB-50 ∆T 60°F is 20% of the distance between ∆T 50°F and ∆T 100°F QB-50 + [0.20 x (QB-100 − QB-50)] ∆T interpolation 3.2 + [0.20 x (6.8 − 3.2)] = 3.9 W/ft QB-60 3.9 W/ft @ TM 40°F Pipe heat loss (QB-60)

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Compensate for insulation type and pipe location See Table 2 for the pipe heat loss (Qb) . If the DT for your system is not listed, interpolate between the two closest values . See Table 3 for indoor multiple See Table 4 for insulation multiple QB QCORRECTED QB x = W/ft (W/m) Insulation multiple Indoor multiple (if applicable) Location Insulation thickness and type Insulation multiple x Indoor multiple (if applicable) Example: Pipe Freeze Protection − Water Piping Location Aboveground, indoor 1-in fiberglass Thermal insulation thickness and type 3.9 W/ft @ TM 40°F Indoor multiple 1.00 Insulation multiple N/A 3.9 W/ft 1.00 3.9 W/ft @ TM 40°F QCORRECTED QB x == = Insulation multiple QB

40 of 44 www.tycothermal.com H55838 2/12 Step  Select the heating cable Power output data: See Fig . 13 Power output correction factors: See Table 5 Heating cable temperature ratings: See Table 6 Select outer jacket  -CR  -CT Example: Pipe Freeze Protection – Water Piping 5XL1-CR Power at rated V factor x Pipe maintain temperature (TM) (from Step 1) (from Step 1) (from Step 1) (from Step 1) (from Step 1) (from Step 1) (from Step 1) (from Step 1) Corrected heat loss (QCORRECTED) Supply voltage Pipe material (metal or plastic) XL-Trace application (water, fuel oil, or greasy waste) Pipe freeze protection: general water piping, sprinkler piping Flow maintenance: greasy waste lines, fuel lines Maximum system use temperature (TMAX) Plastic pipe correction factor = Corrected power Heating cable selected Power at TM (120/208 V) Power output correction factor Plastic pipe correction factor If No, then design with additional runs of heating cable or thicker thermal insulation. EYes No E Maintain temperature (TM) 40°F 3.9 W/ft @ TM 40°F 120 V plastic QB = 3.9 W/ft @ TM 40°F Select curve C: 5XL1 = 5.6 W/ft @ 40°F Power output correction factor: 120 V = 1.00 Pipe material correction factor: Plastic = 0.75 Corrected heating cable power: 5.6 @/ft x 1.00 x 0.75 = 4.2 W/ft Select: 5XL1 Maximum system temperature (TMAX): 80°F Maximum heating cable exposure temperature (TEXP): 150°F TMAX < TEXP: Yes Corrected heat loss (QCORRECTED) Supply voltage Pipe material (metal or plastic*) (*AT-180 aluminum tape required for installing heating cable on plastic pipes) Example: Pipe Freeze Protection − Water Piping CORRECTED

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step  Determine the heating cable length For additional heating cable allowance for valves: See Table 7 . For additional heating cable allowance for pipe supports and flanges: See Table 8 . Pipe length ( ) x + Total heating cable length required Number of heating cable runs Total heating cable length Heat sinks = Additional cable for valves, pipe supports, and flanges Type of valves x Total heating cable for valves How many = Additional heating cable Type of pipe supports x Total heating cable for pipe supports How many = Additional heating cable *2-in pipe diameter = 0.17 ft Type of flanges x Total heating cable for flanges How many = Additional heating cable Total heating cable for heat sinks: Pipe length ( ) x + Total heating cable length required 300 ft 1 15 ft 315 ft Number of heating cable runs Total heating cable length Heat sinks = Additional cable for valves, pipe supports, and flanges Type of valves x Total Gate valves 3 4.3 ft 12.9 ft How many = Additional heating cable Example: Type of pipe supports x Total Pipe hangers noninsulated and U-bolt supports 5 (0.17 ft* x 2 = 0.34 ft) 1.7 ft How many = Additional heating cable *2-in pipe diameter = 0.17 ft Type of flanges x Total n/a 0 0 0 ft How many = Additional heating cable 14.6 ft rounded up to 15 ft Total:

42 of 44 www.tycothermal.com H55838 2/12 Step  Determine the electrical parameters Determine maximum circuit length and number of circuits See Table 9 and Table 10 . Determine transformer load See Table 11 and Table 12 . 201 ft 315 ft 1.6 circuits, round up to 2 315 ft of 5XL1-CR −20°F 201 ft / = Number of circuits Maximum heating cable circuit length Total heating cable length required T 120 V T 208 V T 240 V T 277 V Total heating cable length required Supply voltage: T 15 A T 20 A T 30 A T 40 A Circuit breaker size: Minimum start-up temperature Maximum circuit length / = Number of circuits Maximum heating cable circuit length Total heating cable length required T 120 V T 208 V T 240 V T 277 V Total heating cable length required Supply voltage: T 15 A T 20 A T 30 A T 40 A Circuit breaker size: Minimum start-up temperature Maximum circuit length Example: 9 9 x / 1000 = Transformer load (kW) 0.119 A/ft 315 ft 120 V 4.5 kW Max A/ft at minimum start-up temperature Heating cable length x Supply voltage Example: x / 1000 = Transformer load (kW) Max A/ft at minimum start-up temperature Heating cable length x Supply voltage

2. Fire Sprinkler System Freeze Protection 1. Pipe Freeze Protection and Flow Maintenance 3. Roof and Gutter De-Icing 4. Surface Snow Melting – MI 5. Surface Snow Melting and Anti- Icing – ElectroMelt 6. Freezer Frost Heave Prevention 7. Floor Heating 8. Technical Data Sheets XL-Trace System Pipe Freeze Protection and Flow Maintenance Design Worksheet Step  Select the connection kits and accessories See Table 13 . Connection kits – Aboveground Description quantity Heating cable allowance  RayClic-PC  RayClic-PS  RayClic-PT  FTC-P  RayClic-S  RayClic-T  RayClic-X  FTC-HST  RayClic-Le  RayClic-e Power connection and end seal Power splice and end seal Powered tee and end seal Power connection and end seal Splice Tee kit with end seal Cross connection Low-profile splice/tee Lighted end seal extra end seal ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ Connection kits – buried Description quantity Heating cable allowance  RayClic-PC  FTC-XC  RayClic-Le  RayClic-e Power connection and end seal Power splice and end seal Lighted end seal extra end seal ____________ ____________ ____________ ____________ __________________ __________________ __________________ __________________ Accessories – Aboveground and buried Description quantity  RayClic-SB-04  RayClic-SB-02  eTL  GT-66  GS-54  AT-180 Pipe mounting bracket Wall mounting bracket “electric-Traced” label Glass cloth adhesive tape Glass cloth adhesive tape Aluminum tape (for plastic pipes) _____________ _____________ _____________ _____________ _____________ _____________ + = Total heating cable length required Total heating cable allowance for connection kits Total heating cable length Total heating cable allowance for connection kits

44 of 44 www.tycothermal.com H55838 2/12 Step  Select the control system See Table 18 . Thermostats, controllers and accessories Description quantity  eC-TS  SB-110  DigiTrace C910  ACCS-UIT2  ACCS-PCM2-5  Protonode-LeR  Protonode-ReR  RTD3CS  RTD10CS  RTD-200 electronic thermostat with 25-ft sensor Pipe mounting bracket for eC-TS Microprocessor-based single-point heat-tracing controller ACCS-30 user interface terminal ACCS-30 power control panel Multi-protocol gateway Multi-protocol gateway Resistance temperature device Resistance temperature device Resistance temperature device _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ Step  Select the power distribution See Table 19 . Power distribution Description quantity  HTPG Heat-tracing power distribution panel for group control _____________ Contactors Description quantity  e104  e304 Three-pole, 100 Amp per pole contactor Three-pole, 40 Amp per pole contactor _____________ _____________ Step  Complete the bill of Materials Use the information recorded in this worksheet to complete the Bill of Materials .

Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal Controls' only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to make changes—without notification to Buyer—to processing or materials that do not affect compliance with any applicable specification. Worldwide Headquarters Tyco Thermal Controls 7433 Harwin Drive Houston, TX 77036 USA Tel: 800-545-6258 Tel: 650-216-1526 Fax: 800-527-5703 Fax: 650-474-7711 [email protected] www.tycothermal.com Europe, Middle East, Africa Tyco Thermal Controls Romeinse straat 14 3001 Leuven België / Belgique Tel: +32 16 213 511 Fax: +32 16 213 603 Canada Tyco Thermal Controls 250 West St. Trenton, Ontario K8V 5S2 Canada Tel: 800-545-6258 Fax: 800-527-5703 Tel: 613-392-6571 Fax: 613-392-3999 Latin America Tyco Thermal Controls Al. Araguaia, 2044 – Sala.1101, Bloco B Edificio CEA – Alphaville Barueri – Sao Paulo – Brasil 06455-000 Tel: +55 11 2588 1400 Fax: +55 11 2588 1410 Asia Pacific Tyco Thermal Controls 20F, Innovation Building, 1009 Yi Shan Rd, Shanghai 200233, P.R.China Tel: +86 21 2412 1688 Fax: +86 21 5426 2937 / 5426 3167 Tyco, Alliance Integrated Systems, AMC, AutoMatrix, AutoSol, BTV, CapaciSense, Chemelex, DHSX, DigiTrace, DigiTrace logo, DigiTrace Supervisor, Duoterm, ElectroMelt, EM2XR, FHSM, FHSC, FlexFit, FlexiClic, Flowguard, FreezeTrace, FreezGard, Frostex, Frostex Plus, Frostguard, FroStop, FSE, Gardian, HAK, Handvise, HBTV, HCCL, HotCap, HQTV, HTPG, HTPI, HWAT, HXTV, IceStop, Interlock, JBM, JBS, K-Flex, K-Flex logo, KHE, KHH, KHL, KHP, KTV, Labsafe, LBTV, LHC, LHFV, LHRV, Metabond, Mini WinterGard, Miser WinterGard, MoniTrace, Multi-plus, NGC, PetroTrace, PLI, PolyMatrix, Pyro CiC, PyroFLX, Pyromaster, Pyropak, Pyrosil, PyroSizer, Pyrotenax, Pyrotenax Designer, Pyrotenax logo, QTVR, QuickNet, QuickNet logo, QuickStat, QuickTerm, RayClic, RaySol, RayStat, Retro WinterGard, RHS, RHSC, RHSM, RMM2, SBF, SBV, SC, SHC, Sheathmaster, ShowerGuard, SLBTV, Smart Heat for Comfort and Safety, SnoCalc, SnoCalc logo, STS, System 500, System 1850, System 1850-SE, System 2000, System 2200, T2, T2 logo, T2Blue, T2QuickNet, T2Red, T2Reflecta, TankCalc Plus, TempBus, Thermoheat, ThermoLimit, Thermo- Line, Total Care in Heat-tracing, Touch, Trac-Loc, Trac Calc, TraceCalc Net, TraceCalc Net logo, TraceCalc Pro logo, TraceGuard 277, TraceMaster, Tracer, Tracer logo, TRACERLYNX, TRACERLYNX logo, TraceStat, TraceTek, TraceTek logo, TruckPak, VLBTV, VLKTV, VPL, We manage the heat you need, WinterGard, WinterGard logo, WinterGard Plus, WinterGard Wet, XL-ERATE, XL-ERATE logo, XL-Trace, XTV and Zero EMI are registered and/or unregistered trademarks of Tyco Thermal Controls LLC or its affiliates. All other trademarks are the property of their respective owners.