Design Guide Iecex Final

Design Guide
Self-regulating trace heating systems

for hazloc / industrial applications
Design guide
Self-regulating trace heating systems
for pipes and tanks in hazardous locations
with BARTEC self-regulating trace heaters
Table of contents
Overview 4
Applications 5
Personnel requirements 5
Safety 5
Certifications / Approvals 5
Technical data 5
System design 6
Trace heater selection 6
Determination of the required trace heater length 15
Determination of the required number of heating circuits 16
Selection of the required components for power connection,
control and monitoring, end termination etc. 18
Trace heaters 23
Power connection, splice and junction components 24
Control and monitoring units 25
Splice kits 26
End termination 26
Accessories 27
Temperature sensors 29
Spare parts 30
Installation 31
Preparation 31
Required tools / equipment 31
Unrolling the trace heater 31
Installation on pipes 31
Fastening 32
Trace heater routing 32
Installation on tanks and vessels 34
Tests and commissioning 36
Measurement of the insulation resistance 36
Acceptance test and acceptance test report 37
Commissioning 37
Operation 37
System documentation 37
Maintenance 37
Visual and functional inspection 37
Electrical inspection 37
Inspection intervals 38
Personnel training courses 38
Repairwork on piping or thermal insulation 38
Troubleshooting 39
Acceptance report / Record of inspection 40
EC Declaration of conformity 41
Limited Product warranty 45
Self regulating trace heating systems Design Guide for Hazloc / Industrial
Overview
This manual covers the design, installation and operation of BARTEC Self regulating trace heating systems for use in hazardous locations using
the following self-regulating trace heaters:
▪ BARTEC PSB
▪ BARTEC MSB
▪ BARTEC HSB
▪ BARTEC HTSB
The self-regulating trace heater features a temperature-dependent resistive element between two parallel copper conductors that regulates and
limits the heat output of the trace heater according to the ambient temperature. If the ambient temperature rises, the power output of the trace
heater is reduced. This self-regulating property prevents overheating which would cause damage to the trace heater. Even crossing or overlap-
ping with other trace heaters (or other portions of the same trace heater) are possible.
cold pipe warm pipe hot pipe
high power output high temperature
low temperature low power output
The trace heaters are fixed equipment heating systems for pipes in ordinary and hazardous areas. Thanks to the parallel design the trace heater
can be cut and installed to any required length (up to the maximum heating circuit length as shown on page 17).
Multiple options for connection, splicing and end termination of the heating circuit are available to meet the individual requirements on site. A large
variety of accessories allows for easy customization and extensibility. The following illustration shows a typical electric trace heating system:
Power distribution
wiring (3rd party) Transformer
Power distribution panel

(incl. ground fault protection)
End seal
Warning label
Power connection kit
Trace heater
Attachment tape
01-5800-7N0012/- Notice Technical data subject to change without notice. Page 4 / 46

05/2019-EHT-432712 No claims for damage arising from alternations, errors or misprints shall be allowed.
Applications Safety
Trace heating compensates for the heat loss through the thermal insula- For safe installation and operation of BARTEC Self regulating trace
tion to maintain the pipe and fluid at temperatures above the freezing or heating systems the technical requirements and instructions given in
solidification point in systems that are expected to have stagnant fluids for this manual must be followed.
prolonged durations.
Freeze protection: WARNING
Risk of fire or electrical shock. Follow these guidelines to avoid
Water, and fluids containing significant water, expand as they freeze. personal injury or material damage.
This expansion can cause the pipe to be blocked or break leading to:
▪ Economic losses: A frozen water pipe leading to a critical process ▪ All electrical systems and installations must comply with BARTEC
like a frozen pipe in a waste water treatment plant or cooling tower GmbH requirements and be installed in accordance with the relevant
can shut down the operation causing high economic losses. electrical codes and any other applicable national and local codes.
▪ Safety issues: A frozen pipe to safety showers can jeopardize ▪ BARTEC GmbH and many international electrical and safety codes
personnel safety in the event of hazardous chemical exposure. require ground fault protection to be provided for all trace heating
circuits.
Temperature maintenance: ▪ Install the trace heater circuit carefully.
▪ Use the trace heater in accordance with the intended purpose and
A process temperature maintenance system can maintain the tem-
strictly comply with the operational data specified in section Tech-
perature of the fluid in a pipe to the desired level over a broad range
nical Data.
of temperatures.
▪ The bending radius of the trace heater must be at least 25 mm (for
Maintaining liquids within the specified temperature range allows you HTSB 35 mm). Do not bend on the narrow axis.
to cost-effectively transport the fluids from one location to another, ▪ To avoid short circuits, do not connect the trace heater bus wires
operate your processes at maximum efficiencies, and safely start/shut together.
down your operations. ▪ Keep all components and the trace heaters dry before and during
installation.
Personnel requirements ▪ Each heating circuit must be marked with electrical warning labels.
▪ Keep these instructions for future reference. If applicable, leave
The personnel executing installation and maintenance tasks must have them with the end user.
acquired the skills and specialized knowledge relating to the types of ▪ De-energize before installation or servicing.
protection and types of devices concerned. At least, the personnel must ▪ Use only original BARTEC accessories.
have:
▪ a general understanding of the relevant electrical engineering Certifications / Approvals
▪ a practical understanding of the principles and techniques of explo-
sion protection KEMA 08 ATEX 0111 X
PSB
▪ a working knowledge and understanding of the relevant standards IECEx KEM 09.0084X
of explosion protection KEMA 08 ATEX 0110 X
HSB/MSB
a basic knowledge of quality assurance, including the principles of IECEx KEM 09.0083X
auditing documentation, traceability of measurements and calibration Sira 10 ATEX 3268
HTSB
of measurement instruments. IECEx SIR 16.0035
(see BARTEC website for additional information)
Technical data
PSB MSB HSB HTSB
Max. exposure temperature 65 °C 110 °C 120 °C 250 °C
power on
Max. withstand temperature 85 °C 130 °C 200 °C 250 °C

power off
Min. operation temperature -40 °C -40 °C -60 °C -65 °C
Min. installation temperature -55 °C -50 °C -60 °C -40 °C
Operating voltage max. 254 Vac max. 254 Vac max. 254 Vac max. 277 Vac
Heat output1 10 to 33 W/m 10 to 40 W/m 10 to 60 W/m 15 to 75 W/m
Braid resistance < 18.2 Ω/km < 18.2 Ω/km < 18.2 Ω/km < 18.2 Ω/km
II 2G Ex e IIC T5, II 2G Ex e IIC 150 °C (T3), II 2G Ex e IIC 200 °C (T2), II 2G Ex e IIC T2, T3 Gb
T6 Gb T4 Gb T3, T4 Gb
Protection classification
II 2D Ex tb IIIC T95 °C, II 2D Ex tb IIIC T150 °C, II 2D Ex tb IIIC T200 °C, II 2D Ex t IIIC T200 °C,
T 80 °C Db T130 °C Db T195 °C, T130 °C Db T300 °C IP 6x Db
Temperature classes2 T5, T6 T3, T4 T2, T3, T4 T2, T3
Minimum bending radius 25 mm 25 mm 25 mm 35 mm
1 nominal heat output at 10 °C

2 according to IEC/IEEE 60079-30-1:2015, refer to page 7 for further information

System design
For the design of trace heating systems with BARTEC self-regulating trace heaters, the following steps are necessary:
▪ Trace heater selection
▪ Determination of the total required trace heater length
▪ Determination of the required number of trace heating circuits
▪ Selection of the required components and accessories for power connection, control and monitoring, end termination etc.
The following sections provide step-by-step instructions.
Trace heater selection
Step 1: Familiarize yourself with the trace heater types and their properties
BARTEC self-regulating trace heaters are available in various types to suit different applications. Each trace heater is marked with a product
code that contains relevant information as shown in the following example:
Trace heater family

PSB (07-5801)
MSB (07-5804)
HSB (07-5803)
HTSB (07-5819)
BARTEC® 10PSB2-CT...PSB33...Type 07-5801-2335

Trace heater output
in W/m @ 10 °C
Outer jacket
CT(5, Y, A or 2) = fluoropolymer
CR (6) = polyolefin
Voltage rating
1 = 120 Vac nominal
2 = 230 Vac nominal
Trace heater output in W/ft @ 10 °C

→ Example
A trace heater that bears the marking 10PSB2-CT...PSB33...Type 07-5801-2335 has the following specifications:
▪ Trace heater output @ 10 °C: 33 W/m (10 W/ft)
▪ Trace heater family: PSB
▪ Voltage rating: 230 Vac
▪ Outer jacket: fluoropolymer
Step 2: Determine the heat loss of your pipe setup

For proper system design it is essential to know the effective heat loss of your pipe setup. To determine it, the following data will be required:
▪ Pipe diameter ▪ Maintain temperature
▪ Insulation thickness ▪ Minimum ambient temperature
▪ Insulation material ▪ Temperature differential ΔT: ΔT = maintain temperature - minimum ambient temperature
minimum
ambient temperature
insulation thickness
pipe diameter maintain

temperature

Next, obtain the basic heat loss in W/m using the following table3:
Table A: Basic heat loss in W/m
Pipe ø in
DN (inch) DN8 DN10 DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150 DN200 DN250 DN300
(1/4") (3/8") (1/2") (3/4") (1") (1 1/4") (1 1/2") (2") (2 1/2") (3") (4") (5") (6") (8") (10") (12")
ΔT in °C
25 4.3 4.9 5.7 6.7 7.8 9.3 10.3 12.4 14.9 17.2 21.4 25.7 30.4 38.9 47.9 56.4
35 6.2 7.2 8.2 9.7 11.4 13.5 15.0 17.9 21.6 24.9 31.0 37.2 44.1 56.4
45 8.2 9.5 10.9 12.8 15.1 18.0 19.9 23.8 28.7 33.1 41.2 49.4 58.6
15
75 15.0 17.4 20.0 23.5 27.6 32.8 36.4 43.5 52.4
100 21.5 24.9 28.6 33.6 39.5 47.0 52.1
125 28.7 33.3 38.2 44.9 52.8
25 3.6 4.2 4.7 5.5 6.4 7.5 8.3 9.8 11.7 13.4 16.6 19.8 23.4 29.8 36.5 42.9
35 5.3 6.0 6.8 7.9 9.2 10.9 12.0 14.2 17.0 19.5 24.1 28.7 33.9 43.1 52.9
45 7.0 8.0 9.1 10.5 12.3 14.5 15.9 18.9 22.6 25.9 32.0 38.2 45.1 57.3
20
75 12.8 14.6 16.6 19.3 22.5 26.4 29.1 34.5 41.2 47.3 58.6
100 18.3 20.9 23.8 27.6 32.2 37.9 41.7 49.4 59.0
125 24.4 28.0 31.8 36.9 42.9 50.6 55.7
25 3.2 3.7 4.1 4.8 5.5 6.4 7.0 8.3 9.8 11.2 13.8 16.3 19.2 24.3 29.7 34.8
35 4.7 5.3 6.0 6.9 8.0 9.3 10.2 12.0 14.2 16.2 19.9 23.6 27.8 35.2 43.0 50.4
45 6.2 7.1 8.0 9.1 10.6 12.3 13.5 15.9 18.9 21.5 26.5 31.4 36.9 46.8 57.1
25
75 11.3 12.9 14.5 16.7 19.3 22.6 24.7 29.1 34.5 39.4 48.4 57.4
100 16.2 18.5 20.8 24.0 27.7 32.3 35.4 41.7 49.4 56.4
125 21.7 24.7 27.8 32.0 36.9 43.1 47.3 55.7
Insulation thickness in mm
25 2.9 3.3 3.7 4.3 4.9 5.7 6.2 7.2 8.5 9.7 11.8 14.0 16.4 20.6 25.1 29.4
35 4.3 4.8 5.4 6.2 7.1 8.2 9.0 10.5 12.3 14.0 17.1 20.2 23.7 29.9 36.4 42.6
45 5.7 6.4 7.2 8.2 9.4 10.9 11.9 13.9 16.4 18.6 22.8 26.9 31.5 39.7 48.4 56.5
30
75 10.4 11.7 13.1 15.0 17.2 19.9 21.8 25.4 30.0 34.1 41.6 49.2 57.6
100 14.8 16.8 18.8 21.5 24.6 28.5 31.2 36.4 42.9 48.8 59.6
125 19.8 22.4 25.1 28.7 32.9 38.1 41.6 48.7 57.3
25 2.6 2.9 3.2 3.6 4.1 4.7 5.1 5.9 6.9 7.8 9.4 11.0 12.8 16.0 19.4 22.6
35 3.7 4.2 4.6 5.2 5.9 6.8 7.4 8.6 10.0 11.3 13.6 16.0 18.6 23.2 28.1 32.8
45 5.0 5.5 6.2 7.0 7.9 9.1 9.8 11.4 13.3 15.0 18.1 21.2 24.7 30.9 37.4 43.5
40
75 9.1 10.1 11.3 12.7 14.5 16.6 18.0 20.8 24.3 27.4 33.1 38.8 45.2 56.5
100 13.0 14.5 16.1 18.2 20.7 23.7 25.8 29.8 34.8 39.2 47.4 55.6
125 17.4 19.4 21.6 24.4 27.6 31.7 34.4 39.8 46.4 52.4
25 2.3 2.6 2.9 3.2 3.6 4.1 4.5 5.1 5.9 6.6 7.9 9.2 10.7 13.3 16.0 18.6
35 3.4 3.8 4.2 4.7 5.2 6.0 6.4 7.4 8.6 9.6 11.5 13.4 15.5 19.2 23.2 26.9
45 4.5 5.0 5.5 6.2 7.0 7.9 8.6 9.8 11.4 12.8 15.3 17.8 20.6 25.6 30.8 35.7
50
75 8.3 9.2 10.1 11.3 12.8 14.5 15.7 18.0 20.8 23.3 28.0 32.5 37.7 46.7 56.3
100 11.8 13.1 14.5 16.2 18.3 20.8 22.4 25.7 29.8 33.4 40.0 46.6 53.9
125 15.8 17.5 19.3 21.7 24.4 27.7 30.0 34.4 39.8 44.6 53.5
25 1.8 2.0 2.1 2.3 2.6 2.9 3.1 3.4 3.9 4.2 4.9 5.6 6.4 7.7 9.1 10.38
35 2.6 2.9 3.1 3.4 3.7 4.1 4.4 4.9 5.6 6.1 7.2 8.1 9.2 11.2 13.2 15.0
45 3.5 3.8 4.1 4.5 5.0 5.5 5.9 6.6 7.4 8.2 9.5 10.8 12.3 14.8 17.5 20.0
100
75 6.4 6.9 7.5 8.2 9.1 10.1 10.7 12.0 13.6 14.9 17.4 19.8 22.4 27.1 32.0 36.5
100 9.1 9.9 10.7 11.8 13.0 14.4 15.4 17.2 19.4 21.3 24.9 28.3 32.1 38.8 45.8 52.3
125 12.2 13.3 14.4 15.8 17.4 19.3 20.5 23.0 25.9 28.5 33.2 37.8 42.9 51.8 61.1 69.9
3 Heat loss calculations are based on IEC/IEEE 60079-30-1:2015 Annex C and IEC/IEEE 60079-30-2:2015 Annex E. The following assumptions have been made:
▪ Medium not in motion
▪ Single layer insulation
▪ No gap between pipe and insulation layer
▪ No gap between insulation layer and weather shielding
▪ Ambient temperature: -20 °C
▪ Outdoor installation, wind speed: 20 m/s
▪ Application of a safety factor of +10 %
For other values contact your local BARTEC distributor.

Finally, you must apply the following correction factors depending on your insulation material:
Table B: Insulation Correction Factors
thermal conductivity at 20 °C
Correction Factor
in W/m×K
Rockwool / Mineral Fibre (ASTM C547-15 Type II) 1.00 0.0370
Calcium Silicate (ASTM C547-13 Type I) 1.72 0.0567
Cellular glass (ASTM C552-15 Type II) 1.46 0.0481
Insulation
Rigid cellular urethane (ASTM C591-13 Type I) 0.83 0.0275
material
Foamed elastomer Grade 2 (ASTM C534-14) 1.29 0.0425
Expanded perlite (ASTM C610-15) 2.06 0.0678
Pyrogel XT (ASTM C1728-12) 0.56 0.0206
→ Example
▪ Pipe diameter: DN25
▪ Insulation thickness: 20 mm
▪ Insulation material: calcium silicate
▪
▪
Minimum ambient temperature: -20 °C
Maintain temperature: 25 °C } ΔT = 25 °C - (-20 °C) = 45 °C
We obtain the basic heat loss in W/m from Table A on page 7:
basic heat loss: 12.3 W/m
Now, the correction factors from Table B must be checked and, if necessary, applied:
correction factor insulation: 1.72
The effective heat loss of the setup is determined as follows:

effective heat loss = basic heat loss × correction factor insulation
= 12.3 W/m × 1.72
= 21.2 W/m

Step 3: Choose a trace heater family
Determine the requirements for your trace heating application:
▪ Maximum exposure temperature (power on / power off)
▪ Minimum operation / installation temperature
▪ Required heat output to compensate for the effective heat loss as calculated in Step 2
▪ Required temperature class (“T-Rating”)
Select the trace heater family that meets your requirements using the following table:
Table C: Trace heater family selection
PSB MSB HSB HTSB
Maximum exposure temperature 65 °C 110 °C 120 °C 250 °C
power on
Maximum withstand temperature 85 °C 130 °C 200 °C 250 °C
power off
Minimum operation temperature -40 °C -40 °C -60 °C -65 °C
Minimum installation temperature -55 °C -50 °C -60 °C -40 °C
Power output4 10, 15, 26, 33 W/m 10, 15, 30, 40 W/m 10, 15, 30, 45, 60 W/m 15, 30, 45, 60, 75 W/m
Supply voltage 110 to 120 Vac / 208 to 254 Vac 208 to 254 Vac 110 to 120 Vac / 208 to 254 Vac 110 to 120 Vac / 208 to 277 Vac
Braid resistance / < 18.2 Ω/km / < 18.2 Ω/km / < 18.2 Ω/km / < 18.2 Ω/km /
Minimum percent coverage > 70 % > 70 % > 70 % > 70 %
Braid material Tinned copper Nickel-plated copper Nickel-plated copper Nickel-plated copper
25 mm 25 mm 25 mm 35 mm
Minimum bending radius
(Do not bend on the narrow axis.) (Do not bend on the narrow axis.) (Do not bend on the narrow axis.) (Do not bend on the narrow axis.)
Cable weight 10.9 kg/100 m 12.5 kg/100 m 12.5 kg/100 m 14.6 kg/100 m
fluoropolymer
11.6 x 5.6 mm 10.2 x 4.8 mm 10.2 x 4.8 mm 12.1 x 5.4 mm
Heater outer jacket
dimensions polyolefin outer n/a
jacket 11.8 x 5.8 mm n/a n/a
10, 15 W/m → T6 10, 15, 25 W/m → T4 15, 30, 45 W/m → T3 15, 30, 45, 60 W/m → T3
Temperature classes5
26, 33 W/m → T5 30, 40 W/m → 150 °C (T3) 60 W/m → 200 °C (T2) 75 W/m → T2
II 2G Ex e IIC T5, T6 Gb II 2G Ex e IIC 150°C (T3), T4 Gb II 2G Ex e IIC 200°C (T2), T3, T4 Gb II 2G Ex e IIC, T2, T3 Gb
Protection classification
II 2D Ex tb IIIC T95°C, T 80°C Db II 2D Ex tb IIIC T150°C, T130°C Db II 2D Ex tbIIICT200°C, T195°C, T130°CDb II 2D Ex t IIIC T200°C, T300°C, IP 6x Db
NOTICE
If you want to use plastic piping within your installation, contact your local BARTEC distributor for verification that the design does not exceed the
maximum withstand temperature of the pipe material. Also, adjustments in heat loss calculations may be required.
→ Example
▪ Maximum exposure temperature: 50 °C (“power on”), 70 °C (“power off”)
▪ Minimum operation temperature: -10 °C
▪ Required heat output: 21.2 W/m
▪ Required temperature class: T5
Trace heater family that meets the requirements: PSB
4 nominal heat output at 10 °C

5 applies for the trace heater models with 230 Vac nominal rated voltage, temperature classes according to IEC/IEEE 60079-30-1:2015 (max. surface temperature). For other
voltages or temperatures contact your local BARTEC distributor.

Step 4: Determine the required power rating

Since the power output of self-regulating trace heaters depends on the pipe temperature, the conditions within your application must be consid-
ered when choosing the trace heater:
▪ Determine the maintain temperature (= pipe temperature) of your application and the effective heat loss as calculated in Step 2.
▪ Find the required power output in the graph that contains the trace heater type and voltage you use (see tables on pages 11 to 13).
▪ If the required power output is between 2 trace heater types, choose the one with the higher rating.
▪ If the required power output exceeds the output of the trace heater with the highest rating, you may:
 Use 2 or more trace heaters on the same pipe.
 Use a thicker insulation or insulation material with a lower thermal conductivity.
 Contact your local BARTEC distributor for further assistance.
→ Example
▪ Trace heater family as determined in Step 3: PSB
▪ Power supply voltage: 230 V
▪ Maintain temperature: 25 °C
▪ Effective heat loss: 21.2 W/m
Trace heater that meets the required power output: 10PSB / PSB33
21.2 W/m
25 °C

Table D: PSB 230 V
For MSB trace heaters see page 12.

For HSB trace heaters see page 13.
For HTSB trace heaters see page 14.

Table E: MSB 230 V
For PSB trace heaters see page 11.


Table F: HSB 230 V


Table G: HTSB 230 V


Step 5: Select the appropriate outer jacket material
BARTEC self-regulating trace heaters are available with 2 different types of outer jackets. Choose the outer jacket that suits the chemical envi-
ronment it will be exposed to. For questions regarding the chemical resistance please contact your local BARTEC distributor.
Table H: Chemical resistance of outer jackets
Application Catalog No. Type key (example)

Polyolefin outer jacket exposure to aqueous, inorganic chemicals …-CR 07-5801-2336 (PSB only)
07-5801-2335 (PSB)
07-5804-225Y (MSB)
Fluoropolymer outer jacket exposure to organic chemicals …-CT
07-5803-230A (HSB)
07-5819-7452 (HTSB)
→ Example
▪ Trace heating systems for process applications in the oil industry: fluoropolymer outer jacket
▪ Trace heater catalog no. that meets the required power output and environmental conditions: 10PSB2-CT, Type 07-5801-2335
Determination of the required trace heater length

The total required trace heater length is determined by taking into account the trace heater length for piping as well as allowances for valves,
pumps, flanges, pipe supports and connection kits.
trace heater allowance for valves, allowance for allowance for

on piping pumps and flanges pipe supports connection kits
Step 6: Determine the required trace heater length for the piping:
The required trace heater length for piping corresponds to the pipe length.
→ Example
50 m of piping = 50 m of trace heater
Step 7: Determine the required allowance for connection kits:

The required trace allowance for connection kits is 0.5 m for each kit.
→ Example
▪ Heating circuit with 1 power connection kit and 1 end of line lamp
The total required allowance is calculated as follows:
total required allowance = no. of connection kits × 0.5 m
= 2 × 0.5 m
= 1.0 m

Step 8: Determine the required allowance for pumps, valves, flanges and pipe supports:
Determine the required allowances for pumps, valves, flanges and pipe supports using the following table:
Table I: Allowance values and pipe support intervals
Pipe diameter DN8 DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN150 DN200 DN250 DN300
in DN / inch 1/4" 1/2" 3/4" 1" 11/4" 11/2" 2" 21/2" 3" 4" 6" 8" 10" 12"
Allowance for pumps
1.5 2 2 2.1 2.3 2.3 2.4 2.4 2.4 2.6 3 3.5 4 4
in m
Allowance for valves
0.5 0.5 0.5 0.6 0.6 0.7 0.7 1 1 1.3 1.5 1.6 1.8 2
in m
Allowance for flanges
0.2 0.2 0.3 0.3 0.3 0.3 0.4 0.4 0.5 0.7 0.9 1 1.2 1.2
in m
Allowance for pipe supports
0.2 0.2 0.3 0.3 0.3 0.3 0.4 0.4 0.5 0.7 0.9 1 1.2 1.2
in m
Typical pipe support interval
1 1.5 1.5 2 2 2.5 3.1 4 4 5 6 7 8 8
in m
→ Example
▪ Pipe diameter: DN25
▪ 1 pump
▪ 2 valves
▪ 6 flanges
▪ 24 pipe supports
The total required allowance is calculated as follows:
total required allowance = no. of pumps × pump allowance value +
no. of valves × valve allowance value +
no. of flanges × flange allowance value +
no. of pipe supports × pipe support allowance value
= 1 × 2.1 m + 2 × 0.6 m + 6 × 0.3 m + 24 × 0.3 m
= 12.3 m
Step 9: Add all lengths / allowances together:

Add the lengths for piping (as determined in step 6) and allowances (as determined in step 7 and step 8) together to obtain total required trace
heater length.
→ Example
▪ required trace heater length for piping (step 6): 50 m
▪ required allowances for connection kits (step 7): 1.0 m
▪ required allowances for pumps, valves, flanges and pipe supports (step 8): 12.3 m
total required trace heater length = required trace heater length for piping + required allowances
= 50 m + 1.0 m + 12.3 m
= 63.3 m
Determination of the required number of heating circuits

Step 10: Confirm the number of electrical circuits required for the application:
Using Table J on page 17, compare the required heater length and start up temperature to the available circuit breaker allowances to determine
the number of electrical circuits that will be required.
→ Example
▪ total required trace heater length: 63.3 m
▪ circuit breaker voltage: 230 Vac
▪ selected trace heater: 10 PSB
▪ circuit breaker amperage: 20 A
▪ required start-up temperature: -15 °C
allowable trace heater length from table below = maximum of 64 m at -15 °C on 20 A circuit breaker at 230 Vac
= 63.3 m calculated < 64 m maximum allowable for 20 A
= 1 circuit

The following table shows the maximum circuit length for one continuous length of cable, not the sum of segments of cable. If feeding multiple cable
segments from the single circuit breaker, please refer to BARTEC HELOC design software or contact BARTEC technical support. Breaker sizing
should be based on international electric codes or any other local or applicable code. Use only circuit breakers with type C tripping characteristics.
WARNING
Risk of fire, electrical shock or dysfunction. Observe the maximum amperage of all components of the trace heating circuit. If the required trace
heater length exceeds the maximum heating circuit length you must install multiple heating circuits.
Table J: Maximum heating circuit length for circuit breakers with Type C tripping characteristics
PSB trace heaters

Circuit Start-up
Operating voltage: 230 Vac
breaker size temperature
3 PSB / PSB 10 5 PSB / PSB 15 8 PSB / PSB 26 10 PSB / PSB 33
+10 °C 205 m 145 m 88 m 70 m
16 A -15 °C 139 m 93 m 58 m 49 m
-30 °C 120 m 77 m 45 m 43 m
+10 °C 205 m 162 m 117 m 90 m
20 A -15 °C 186 m 125 m 75 m 64 m
-30 °C 150 m 106 m 64 m 52 m
+10 °C 205 m 162 m 120 m 98 m
25 A -15 °C 190 m 142 m 95 m 80 m
-30 °C 170 m 135 m 82 m 65 m
+10 °C 205 m 162 m 126 m 108 m
32 A -15 °C 195 m 160 m 117 m 95 m
-30 °C 195 m 160 m 100 m 82 m
MSB trace heaters

Circuit Start-up
3 MSB / MSB 10 5 MSB / MSB 15 8 MSB / MSB 25 10 MSB / MSB 30 12 MSB / MSB 40
+10 °C 200 m 165 m 120 m 85 m 70 m
16 A -25 °C 175 m 117 m 88 m 69 m 49 m
-50 °C 165 m 110 m 80 m 65 m 45 m
+10 °C 235 m 189 m 140 m 114 m 82 m
20 A -25 °C 235 m 152 m 120 m 92 m 66 m
-50 °C 225 m 144 m 114 m 86 m 62 m
+10 °C 235 m 189 m 140 m 114 m 82 m
32 A -25 °C 235 m 189 m 140 m 114 m 82 m
-50 °C 235 m 189 m 136 m 110 m 78 m
HSB trace heaters

Circuit Start-up
3 HSB / HSB 10 5 HSB / HSB 15 10 HSB / HSB 30 15 HSB / HSB 45 20 HSB / HSB 60
+10 °C 200 m 165 m 85 m 70 m 50 m
16 A -25 °C 175 m 117 m 69 m 49 m 38 m
-60 °C 165 m 110 m 65 m 45 m 35 m
+10 °C 235 m 189 m 114 m 82 m 64 m
20 A -25 °C 235 m 152 m 92 m 66 m 52 m
-60 °C 225 m 144 m 86 m 62 m 48 m
+10 °C 235 m 189 m 114 m 82 m 64 m
25 A -25 °C 235 m 170 m 100 m 75 m 58 m
-60 °C 230 m 160 m 92 m 70 m 52 m
+10 °C 235 m 189 m 114 m 82 m 64 m
32 A -25 °C 235 m 189 m 114 m 82 m 64 m
-60 °C 235 m 189 m 110 m 78 m 60 m
HTSB trace heaters

Circuit Start-up
5 HTSB / HTSB 15 10 HTSB / HTSB 30 15 HTSB / HTSB 45 20 HTSB / HTSB 60 25 HTSB / HTSB 75
+10 °C 126 m 82 m 62 m 50 m 42 m
16 A 0 °C 120 m 78 m 58 m 46 m 40 m
-20 °C 108 m 70 m 52 m 42 m 36 m
+10 °C 154 m 102 m 78 m 62 m 52 m
20 A 0 °C 150 m 96 m 74 m 58 m 48 m
-20 °C 136 m 88 m 66 m 52 m 44 m
+10 °C 154 m 108 m 88 m 76 m 64 m
25 A 0 °C 154 m 108 m 88 m 72 m 60 m
-20 °C 154 m 108 m 82 m 66 m 54 m
+10 °C 172 m 108 m 88 m 76 m 82 m
32 A 0 °C 172 m 108 m 88 m 76 m 78 m
-20 °C 172 m 108 m 88 m 76 m 70 m

Selection of the required components for power connection, control and monitoring, end termination etc.
A typical heating circuit with self-regulating trace heaters consists of:
▪ Power supply / cold lead cable connection
▪ Trace heater splices / junctions (optional)
▪ Control and monitoring units (optional)
▪ End termination
Step 11: Determine the required trace heater power connection kit:
→ Example
▪ From Step 10: 1 Heating circuit with 1 power connection kit = PBS-200-E
Step 12: Determine if control equipment is required:

BARTEC provides a variety of control products, from simple mechanical thermostats to sophisticated digital controllers and control and monitor-
ing systems designed specifically for use with our trace heating products. This section will help you select and specify the right control products
for your application.
General design considerations for temperature control:
When designing your trace heating system, you should consider the following factors.
▪ Adding control elements increases the installation and maintenance costs of the heating system, but allows tighter temperature control, energy
savings and more efficient use of plant maintenance personnel’s time.
▪ The thermal environment of a trace heating system varies greatly, especially at valves, pipe supports, and other heat sinks. It is therefore
seldom possible to achieve very tight temperature control.
▪ The temperature of a heat tracing system is based on ambient temperature and can vary by as much as 20 °C when the system is uncon-
trolled. You can choose between 2 approaches for temperature control:
Ambient sensing control:

▪ uses an on-off thermostat that senses ambient tem-
Ambient temperature sensor perature
▪ is more energy efficient than self-regulating control
because the heating circuit is energized only when the
Ambient sensing control temperature drops below the set-point
▪ is most suitable for freeze-protection applications
where multiple circuits can be controlled by a single
sensing point
▪ flow path considerations (flowing or non-flowing) are
not required with ambient control.
Line sensing control:

▪ regulates the desired maintain temperature by turning
the heating circuit on if the pipe temperature falls be-
low the set-point and turning it off if it exceeds the set-
Line temperature sensor
point
▪ the most energy-efficient method for controlling heat
Line sensing control tracing is a line-sensing thermostat, because a flowing
pipe will typically not need any additional heat to keep
it at the proper temperature
▪ needs a separate circuit controlled by a line-sensing
Line temperature sensor
thermostat for each flow path
▪ where a piping system has tees and therefore multiple
flow paths, more than one thermostat may be re-
quired.
NOTICE
Line sensing provides tighter temperature control than ambient sensing but flow paths may require additional controllers.

Overview of control equipment:
DTW
▪ Fixed set point mechanical thermostat with a 5 °C set point
▪ IP65 in coated cast aluminium enclosure
▪ SPDT switch rated 480 Vac, 22 A
BSTW II
▪ Adjustable set point mechanical thermostat with
Mechanical thermostats -20 °C to 50 °C or 0 °C to 190 °C range
▪ IP65 rating in a GRP enclosure suitable for mounting off of
the pipe
▪ SPDT switch, load path rated 400 Vac,16 A / 230 Vac, 25 A
PBTW-200-E
▪ Adjustable set point mechanical thermostat with
-20 °C to 50 °C or 0 °C to 190 °C range
▪ IP 65 rating in a GRP enclosure suitable for mounting on pipe
▪ SPDT switch, load path rated 230 Vac, 25 A
DETU-300-CN
▪ Adjustable set point electronic thermostat with a
-4 °C to 600 °C range
▪ IP 65 rating in a GRP enclosure suitable for mounting off of
the pipe or on adjacent structure
▪ RS485 communications interface, Modbus RTU
▪ SPDT switch rating 230 Vac, 22 A/25 A/30 A @ 55 °C/50 °C/40 °C
Electronic controllers
ESTM-30
▪ Continuous monitoring technology for heat-tracing faults
▪ Internal diagnostics and monitoring of the heat tracing current
▪ Integral ground fault monitoring
▪ DPDT switch rated 30 A
▪ RS485 communications interface, Modbus RTU
▪ Bluetooth communication
Recommendations for selecting the appropriate control equipment:

Base your selection on the number and type of trace heating circuits to be installed, the type of control you need, and the area classification.
TABLE K: Control Equipment Selection Recommendations
Heating circuit type Application Control options Suitable BARTEC control product Quantity required
Self-regulating heating circuits on pipes Freeze protection Ambient-sensing DTW (on panel) 1 per control panel
BSTW (off pipe , local only)
Temperature maintenance or
Self-regulating heating circuits on pipes Line-sensing PBTW-200-E (on pipe, local only) 1 per circuit
tight temperature control
DETU-300-CN (off pipe, local and remote)
Multiple self-regulating heating circuit(s) Freeze protection or wide band
Ambient-sensing DTW (on panel) 1 per control panel
for frost protection on tanks temperature control
BSTW (off tank, local only)
Single self-regulating heating circuit(s) Temperature maintenance or
Point-sensing DETU-300-CN (off tank, local and remote) 1 per circuit
on temperature sensitive tanks tight temperature control
ESTM-20-E (local and remote indication)
→ Example
▪ The application is temperature maintain for the pipe in a hazardous area. The ambient temperature is below the maintain temperature for
only a few months every year and the customer wants to conserve energy. No remote indication or communication is required.
appropriate control equipment = PBTW-200-E
Note: Since the PBTW-200-E includes the power connection enclosure the PBS-200-E kit (from Step 11) is not required.

Step 13: Determine if monitoring equipment is required:

Monitoring increases system reliability by detecting faults before they become a major problem. Consider the following points when planning
heating circuit monitoring:
▪ While you may select only one method of control for each trace heating circuit, you can make use of various monitoring options. The use of
monitoring increases overall system reliability because failures in the heating and power distribution systems get reported to operations per-
sonnel.
▪ BARTEC recommends to always use, at a minimum, ground-fault monitoring. For the small additional cost, you get a monitoring system that
reliably reports physical damage to the trace heating system, which is a common failure mode.
▪ For sensitive applications, add end of line monitoring with either a high profile end seal or an end of line light. The end of line light gives the
most direct visual feedback on system performance.
Conventional system layout with monitoring panel and ground fault equipment protection device
Maintenance access through a high profile end seal

The high profile end seal is used to quickly locate the end of the heating circuit for troubleshooting in the field. It provides a convenient way to
locate the end of the circuit and for testing of voltage presence at the end of the circuit.
ELS-200
Continuity monitoring using an end of line light

Continuity monitoring is used to verify that the trace heater circuit has voltage present at the termination end. This is often assured by an end of line
light installed as part of the end seal. In addition to the visual feedback at the end of the trace heater circuit it provides easy maintenance accessibility.
ELL-200

Table L: Selecting the appropriate monitoring equipment:
Base your selection on the number and type of trace heating circuits to be installed, the type of continuity monitoring you need, and the area
classification:
TABLE L: Monitoring Equipment Selection Recommendations
Heating circuit type Application Monitoring options Suitable BARTEC monitoring product Quantity required
High profile end seal or ELS-200
Self-regulating heating circuits on pipes Freeze protection 1 per circuit
signal light for indication ELL-200
Temperature maintenance or
Self-regulating heating circuits on pipes High profile end seal ELS-200 1 per circuit
tight temperature control
→ Example
▪ The application is temperature maintenance (25 °C) of a pipe in a hazardous area.
▪ The maintenance team wants to be able to quickly locate the end seal.
appropriate monitoring equipment = ELS-200
Step 13: Finalize the required Materials List (BOM):

Accessories including the glass tape for attachment and pipe straps for the components and electrical traced warning labels
→ Example
▪ Heating cable catalog no. (see Step 1-5 beginning on page 6) and required length (see Step 9 on page 16) = 10PSB2-CT 64 m
▪ Temperature control device including power connection enclosure (see Step 12 on page 18) PBTW-200-E 1 pc.
▪ High profile end seal for ease of maintenance (see Step 12 on page 18) = ELS-200 1 pc.
▪ Accessories (see section Accessories on page 27-30):
Glass cloth tape (see selection table in section Accessories) GT-164 2 rolls
Pipe straps (see selection table in section Accessories) PC-01 4 pcs.
Electrically traced warning labels HTWL-EN 10 pcs.

The following figure shows a sample heating circuit including typical components:
PBS splice kit End of line lamp
Pipe insulation Trace heater

(3rd party)
Power supply
(3rd party)
Power junction box
High profile end seal

Electrically traced
warning label
Silicone
end seal
PLEXO Plug-in splice kit
Adhesive tape
The following pages list compatible components for BARTEC Self regulating trace heating systems in hazardous locations. The respective instal-
lation instructions are included in the scope of delivery.

Trace heaters
PSB trace heater with polyolefin outer jacket W/m Catalog No.: Order No.: Part No.:
Self regulating trace heater for installation on 10 W/m 3PSB2-CR 101766 07-5801-2106
pipes, tanks etc. 15 W/m 5PSB2-CR 104866 07-5801-2156
Polyolefin outer jacket: suitable for exposure to aqueous
26 W/m 8PSB2-CR 106466 07-5801-2266
chemicals 33 W/m 10PSB2-CR 108266 07-5801-2336
Maximum maintain temperature (“power on”): 65 °C
Maximum withstand temperature (“power off”): 85 °C
Approved for Zone 1 and Zone 2 areas. See data sheet for
full details.
PSB trace heater with fluoropolymer outer jacket W/m Catalog No.: Order No.: Part No.:
Self regulating trace heater for installation on 10 W/m 3PSB2-CT 101566 07-5801-2105
pipes, tanks etc. 15 W/m 5PSB2-CT 104766 07-5801-2155
Fluoropolymer outer jacket: suitable for exposure to organic
26 W/m 8PSB2-CT 106066 07-5801-2265
chemicals 33 W/m 10PSB2-CT 107966 07-5801-2335
full details.
MSB trace heater W/m Catalog No.: Order No.: Part No.:
Self regulating trace heater for installation on 10 W/m 3MSB2-CT 320845 07-5804-210Y
pipes, tanks etc. 15 W/m 5MSB2-CT 320846 07-5804-215Y
25 W/m 8MSB2-CT 320847 07-5804-225Y
chemicals 30 W/m 10MSB2-CT 320849 07-5804-230Y
Maximum maintain temperature (“power on”): 110 °C 40 W/m 12MSB2-CT 320851 07-5804-240Y
full details.
HSB trace heater W/m Catalog No.: Order No.: Part No.:
Self regulating trace heater for installation on 10 W/m 3HSB2-CT 109366 07-5803-210A
pipes, tanks etc. 15 W/m 5HSB2-CT 109766 07-5803-215A
30 W/m 10HSB2-CT 110666 07-5803-230A
chemicals 45 W/m 15HSB2-CT 111166 07-5803-245A
60 W/m 20HSB2-CT 111666 07-5803-260A
full details.
HTSB trace heater W/m Catalog No.: Order No.: Part No.:
Self regulating trace heater for installation on 15 W/m 5HTSB2-CT 302932 07-5819-7152
pipes, tanks etc. 30 W/m 10HTSB2-CT 302933 07-5819-7302
45 W/m 15HTSB2-CT 302934 07-5819-7452
chemicals 60 W/m 20HTSB2-CT 302945 07-5819-7602
Maximum maintain temperature (“power on”): 250 °C 75 W/m 25HTSB2-CT 302946 07-5819-7752
full details.

Power connection, splice and junction components

.
PBS-200-E/E10 Single power entry con- PBS-200-E:

nection kit "on pipe"
Catalog No.: PBS-200-E
For connection of a trace heater inside a junction Order No.: 430173
box. Includes a mounting stand for on-pipe instal- Part No.: 27-54P2-4212/1210
lation and a silicone end seal.
PBS-200-E10:
Maximum power conductor size:
PBS-200-E 6 mm² Catalog No.: PBS-200-E10
PBS-200-E10 10 mm² Order No.: 430174
2 pipe straps per stand required. Part No.: 27-54P2-4312/3B10
For a complete list of kit contents and approvals see
data sheet.
PBS-300-E/E10 Single power entry con- PBS-300-E:

nection kit "off pipe"
Catalog No.: PBS-300-E
For connection of a trace heater inside a Order No.: 430205
junction box. Includes a mounting stand for Part No.: 27-54P2-4211/1210
off-pipe installation and a silicone end seal.
PBS-300-E10:
PBS-300-E 6 mm² Catalog No.: PBS-300-E10
PBS-300-E10 10 mm² Order No.: 430206
data sheet.
PBM-200-E/E10 Multiple power entry con- PBM-200-E:

nection kit "on pipe"
Catalog No.: PBM-200-E
For connection of up to 3 trace heaters inside Order No.: 430210
a junction box. Includes a mounting stand for Part No.: 27-54P2-4433/1210
on-pipe installation and 2 silicone end seals.
PBM-200-E10:
PBM-200-E 6 mm² Catalog No.: PBM-200-E10
PBM-200-E10 10 mm² Order No.: 430211
data sheet.
PBM-300-E/E10 Multiple power entry con- PBM-300-E:

nection kit "off pipe"
Catalog No.: PBM-300-E
For connection of up to 3 trace heaters inside Order No.: 430212
a junction box. Includes a mounting stand for Part No.: 27-54P2-4431/1210
off-pipe installation and 2 silicone end seals.
PBM-300-E10:
PBM-300-E 6 mm² Catalog No.: PBM-300-E10
PBM-300-E10 10 mm² Order No.: 430213
For a complete list of kit contents and approvals see data
sheet.

Control and monitoring units
Mechanical thermostats for hazardous Catalog No.: DTW

locations Order No.: 246338
Part No.: 27-6CA2-2411/2000
Select this thermostat when the control unit
must be located in a hazardous location and
mechanical ruggedness is important and the
control device is separate from the power
connection.
Set point::-4 °C/163°C
PBTW Mechanical thermostat for hazard- Sensor temperature range -20 °C to 50 °C:
ous locations (on-pipe installation)
Catalog No.: PBTW-200-E050
Select this thermostat when the control unit Order No.: 427650
is located in a hazardous location, rugged- Part No.: 27-54D2-4422/C210
ness is important and the control device is
Sensor temperature range 0 °C to 190 °C:
integrated with the power connection and
can be mounted on the pipe. Catalog No.: PBTW-200-E190
For a complete list of temperature range options, kit
Order No.: 427651
contents and approvals see datasheet. Part No.: 27-54D2-4422/D210
BSTW II Mechanical thermostat for haz- Sensor temperature range -20 °C to 50 °C:
ardous locations (off-pipe installation)
Catalog No.: BSTW-300-E50
Select this thermostat when the control unit Order No.: 345675
is located in a hazardous location, rugged- Part No.: 27-6DF2-5232/1200
ness is important and the control device is
Sensor temperature range 0 °C to 190 °C:
integrated with the power connection and is
to be mounted off the pipe. Catalog No.: BSTW-300-E190
For a complete list of temperature range options, kit
Order No.: 413371
contents and approvals see datasheet. Part No.: 27-6DF2-5232/1C00
DETU Electronic control unit for hazard- Catalog No.: DETU-300-CN

ous locations Order No.: 392790
Part No.: 17-8887-2636/2221
The DETU-300-CN single-point electronic
controller senses pipe or tank temperatures
to provide tight temperature control for pro-
cess applications. It detects and alarms on
low and high temperatures and features
networking communication capabilities.
datasheet.
ESTM-30 Catalog No.: ESTM-30

Order No.: 420943
The BARTEC ESTM-30 single-point control-
Part No.: 17-88C1-F22H/1R10
ler senses pipe or tank temperatures to
provide tight temperature control for process
applications. It features continuous monitor-
ing technology to detect trace heating faults,
monitor trace heating current and provides
networking communication capabilities.
For a complete list of kit contents and approvals see datasheet.

Splice kits
PLEXO-TCS Low profile in-line splice Catalog No.: PLEXO-TCS

Order No.: 320724
In-line splice kit for connections below the
Part No.: 27-59P2-0110
insulation and cladding. The kit is re-
enterable for ease of maintenance at pumps
and vessels.. The kit is approved for Zone 1
and Zone 2 areas.
For a complete list of kit contents, approvals and additional
configurations see data sheet.
End termination
ELS-200 high profile end seal Catalog No.: ELS-200

Order No.: 430293
End seal for access above the insulation.
Part No.: 27-54E2-4012/A000
The kit is approved for Class I, II and III Div 2
areas.
2 pipe straps per stand required.
For a complete list of kit contents and approvals see data
sheet..
ELL-200 End of line lamp Green lens:

Catalog No.: ELL-200-E
End of line lamp for connection of a trace
Order No.: 430215
heater. Includes a mounting stand for on-pipe
Part No.: 27-54E2-4212/F210
installation. The kit is approved for Zone 1
and Zone 2 areas. Available with a Green or Red lens:
Red lens.
Catalog No.: ELL-200-A
Order No.: 407406
For a complete list of kit contents and approvals see Part No.: 27-54E1-4211/F010
data sheet.
ELL-300 End of line lamp Green lens:

Catalog No.: ELL-300-E
End of line lamp for connection of a trace
Order No.: 430216
heater. Includes a mounting stand for off-pipe
Part No.: 27-54E2-4211/F210
installation. The kit is approved for Zone 1
and Zone 2 areas. Available with a Green or Red lens:
Red lens.
Catalog No.: ELL-300-A
Order No.: 407406
For a complete list of kit contents and approvals see Part No.: 27-54E1-4211/F010
data sheet.
CAK-E5/E10 Cold applied end seal CAK-E5:

Catalog No.: CAK-E5
Silicone end seal for insulation of the end of
Order No.: 404126
the trace heater.
Part No.: 27-59CZ-90000001
CAK-E5 5 pcs. CAK-E10:
CAK-E10 10 pcs.
Catalog No.: CAK-E10
For a complete list of kit contents and approvals see data Order No.: 404128
sheet. Part No.: 27-59CZ-90000010

Accessories
Polyester adhesive tape Catalog No.: PT-164

Order No.: 100706
for use on pipes other than stainless steel Part No.: 02-5500-0005
19 mm x 50 m per roll
Minimum installation temperature (dry surface): 5 °C
Maximum withstand temperature: 100 °C
Tip: Refer to the following table to estimate the required number of tape rolls for your installation:
Pipe diameter DN8 DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN150 DN200 DN250 DN300 DN350 DN400 DN450 DN500 DN600
DN (inch) (1/4") (1/2") (3/4") (1") (1 1/4") (1 1/2") (2") (2 1/2") (3") (4") (6") (8") (10") (12") (14") (16") (18") (20") (24")
Required no. of
tape rolls per 1 1 1 1 1 1 2 2 2 3 4 5 6 7 7 8 9 10 12
30 m of piping
Glass cloth tape Catalog No.: GT-164

Order No.: 392328
for fixation of self-regulating trace heaters on
Part No.: 02-5500-0047
all pipes including stainless steel / required
during preparation of power limiting trace heat-
ers
Minimum installation temperature (dry surface): -10 °C
Tip: Refer to the following table to estimate the required number of tape rolls for your installation (for fixation of trace heaters on pipes only)
Pipe diameter DN8 DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN150 DN200 DN250 DN300 DN350 DN400 DN450 DN500 DN600
DN (inch) (1/4") (1/2") (3/4") (1") (1 1/4") (1 1/2") (2") (2 1/2") (3") (4") (6") (8") (10") (12") (14") (16") (18") (20") (24")
Required no. of
tape rolls per 1 1 1 1 2 2 2 3 3 4 5 7 9 10 11 12 14 15 18
30 m of piping
AT80:
Aluminum adhesive tape
Catalog No.: AT80-164
for use on all pipe materials Order No.: 100506
Part No.: 02-5500-0003
AT150:
AT80: Catalog No.: AT150-164
Order No.: 101606
Part No.: 02-5500-0014
AT150:

for pipe ø up to 3” / DN80:

Stainless steel pipe straps
Catalog No.: PC-1
stainless steel, for fixation of mounting stands Order No.: 435727
on pipes etc. No special tooling required.
for pipe ø up to 10” / DN250:
Catalog No.: PC-2
Order No.: 435729
Stainless steel cable ties SSC-03:

for installation of power limiting trace heaters, Catalog No.: SSC-03
mounting stands, etc. Order No.: 126227
SSC-03: pipe ø up to 3” / DN80
Part No.: 03-6510-0208
SSC-06: pipe ø up to 6” / DN150 SSC-06:
Pack of 100 pcs. Catalog No.: SSC-06
Order No.: 126228
Part No.: 03-6510-0209
Stainless steel strapping ribbon & SST-34/30:

buckles, 3/4"
Catalog No.: SST-34/30
for bulk installation of mounting stands on Order No.: 126227
pipes etc. Note: tensioning tool is required. Part No.: 03-6510-0208
SST-34/30: 19 mm x 30 m per roll SSB-34/100:
SSB-34/100: pack of 100 pcs.
Catalog No.: SSB-34/100
Order No.: 126228
Part No.: 03-6510-0209
Tensioning tool for stainless steel strap- Catalog No.: SST-TT

ping ribbon Order No.: 126207
Part No.: 03-5510-0003
Required for installation of stainless steel
strapping ribbon
Insulation entry bushing for PSB trace heaters:

for protection of trace heaters or sensor Catalog No.: IEB-P
cables at the point where they pass through Order No.: 234006
the thermal insulation outer cladding Part No.: 05-0020-0472
for HSB trace heaters:
Catalog No.: IEB-H
Order No.: 106730
Part No.: 05-0020-0091
for PT100 sensor:
Catalog No.: IEB-PT
Order No.: 122964
Part No.: 05-0020-0261

Electrically traced warning label German:
Warning label for trace heater circuits Catalog No.: HTWL-DE
Recommended: electrical warning label every 3 m on the
Order No.: 113450
outside of the thermal cladding on a clearly visible place. Part No.: 05-2144-0046
Packaged in rolls of 100 pcs. English:
Catalog No.: HTWL-EN
Order No.: 113550
Part No.: 05-2144-0047
French:
Catalog No.: HTWL-FR
Order No.: 120300
Part No.: 05-2144-0703
Russian:
Catalog No.: HTWL-RU
Order No.: 207439
Part No.: 05-2144-0860
Polyester fixing straps Catalog No.: PFS-850

Order No.: 117932
for installation of trace heaters on tanks and
Part No.: 03-6500-0100
vessels
for tank diameters up to 3 m
19 mm x 850 m on full roll
Tensioning buckle Catalog No.: TB-075

Order No.: 117939
for use with the PFS-850 polyester fixing
Part No.: 03-6515-0203
straps
Temperature sensors
Hazardous Area 100 Ohm Platinum RTD BRTD-D2:

Platinum RTD mounted inside a 316SS Catalog No.: BRTD-D2
sheath and includes a 20 mm radius mount- Order No.: 710148
ing pad with an Aluminum head assembly.
BRTD-D1:
BRTD-D2 has a Ex e Aluminum head, 480 °C
Catalog No.: BRTD-D1
BRTD-D1 has a Ex d Aluminum head, 480 °C
Order No.: 710149

PT100-with 300 mm sensor and 2 m lead:

PT-100 - 100 Ω Platinum RTD
Catalog No.: PT-100-300
This Pt100 Ex sheathed resistance thermom- Order No.: 289768
eter has been particularly designed for use in Part No.: 27-7125-1333/0220
potentially explosive areas. As it meets the
PT100 Ex e enclosure:
requirements of the Ex m type of protection,
intrinsically safe circuits can be dispensed Catalog No.: PT-100-Ex e
with. Order No.: 122629
Part No.: 07-5103-9024
Approved for Zone 1 and Zone 2 areas see data sheet for full
details as additional lengths are available for special order.
Spare parts
Catalog No.: CAK-SRS

On pipe cable gland kit and end seal
Order No.: 434968
Part No.: 27-59CX-7C01/0001
Spare parts kit for use with PBS/PBM-200 kits
for replacement of damaged or lost parts.
Off pipe cable gland kit and end seal Catalog No.: CAK-SRG
Order No.: 434969
Spare parts kit for use with PBS/PBM-300 kits Part No.: 27-59CX-7301/0001
for replacement of damaged or lost parts.
Splice adaptor kit Catalog No.: CAK-M25

Order No.: 434980
Provides the additional parts to use the PBS-
Part No.: 27-59CZ-9901/0000
200-E/E10 junction box as an above the
insulation splice kit.

Installation
Preparation
Before installing any electric trace heating, the person installing must check if the trace heating has been designed and planned correctly. It is
particularly essential to verify the following points:
▪ complete project planning documentation, operating instructions and installation instructions.
▪ correct selection of the trace heater and accessories with respect to:
 calculation of heat losses
 max. permissible operating temperature
 max. permissible ambient temperature
 temperature class
 heating circuit length
Before installing, make sure that all piping and equipment is properly installed and pressure tested.
Required tools / equipment Installation on pipes

The following tools are required for installation of the BARTEC Self This step is necessary for plastic pipes only since plastic pipes
regulating trace heating systems: conduct heat less efficiently than metal pipes do. For metal pipes
continue with step 4.
▪ Wire cutters
▪ Insulation resistance meter with a minimum testing voltage of ▪ Place aluminium tape where the trace heater will be attached for
500 Vdc and a maximum testing voltage of 2500 Vdc. better heat distribution.
CAUTION
Risk of injury and/or material damage. Never step on or drive over
the trace heater. Do not use it as a loop for stepping on.
1 ▪ Install the trace heater in a straight line along the pipe. This
saves time, helps to avoid installation mistakes and prevents
damage to the trace heater during the thermal insulation work.
Unrolling the trace heater
WARNING 4
Risk of short circuit and/or material damage. Keep the trace
heater ends dry before and during installation.
▪ Unroll the required trace heater in a straight line and cut to the ▪ Preferably install the trace heater in the lower half of the pipe,
correct length. Cut off the trace heater ensuring a straight cut. but not on the lowest point. This prevents mechanical damage
▪ Do not bend or pinch the trace heater, or pull it over sharp edg- and allows for better heat distribution.
es. ▪ If you use multiple trace heaters, position them with an offset of
90°.
2 5
Fastening Trace heater routing

Select the correct fastening material: ▪ On fittings, valves etc. you should leave a sufficiently large trace
heater loop to ensure that the equipment is easily accessible.
▪ Use polyester adhesive tape or glass cloth tape that suits the
This way, heating circuits do not have to be cut up for mainte-
expected temperatures.
nance or replacement works.
▪ Preferably use BARTEC adhesive tapes.
▪ Due to the higher heat losses from fittings, valves, flanges etc.
▪ Never use PVC electrical tape or self-adhesive tapes containing
an additional length of trace heater is required. This requirement
PVC or VC.
is specified in the project planning documents.
▪ Do not use metal wire or banding.
▪ The following illustrations show typical types of installation.
NOTICE
The bending radius of the trace heater must always be at least
25 mm (for HTSB 35 mm). Do not bend on the narrow axis.
6 9
▪ Fasten the trace heater with the adhesive tape at intervals of at ▪ Installation on bends:
least 300 mm on plastic pipes or 900 mm on steel pipes.
NOTICE
In order to ensure good heat transmission the trace heater must
have a flat, flush fit over the whole length. If necessary, reduce
10
the distances between the fixing points.
▪ Installation of service loops on components:
7
▪ Apply the pipe’s insulation according to the manufacturer’s in-
stallation instructions.
▪ Apply an electrical warning label every 3 m on a clearly visible
place.
8 11
▪ Installation on valves: ▪ Installation on pipe supports:
14
▪ Installation on pressure gauges:
12
▪ Installation on flanges:
15
▪ Installation on pumps:
13 16
Installation on tanks and vessels

▪ For tank diameters of up to 2 m the trace heater is attached using polyester fixing straps and tensioning buckles.
▪ To fasten the fixing straps thread the polyester straps through the tensioning buckle as shown and pull the ends of the straps.
17
▪ At first, install fixing straps around the beginning and end of the tank and fasten them with slight tension.
Upright tank
Horizontal tank
18
▪ Install the trace heater beginning at the supply point.
▪ Fix it at the distances specified in the project planning documentation. Use the pre-mounted fixing straps to hold the trace heaters in place.
▪ Allow for material addition for the bases.
19
▪ Align the trace heater exactly and fix it firmly to the bases and the cylinder using additional fixing straps.
▪ To avoid damage to the trace heater, make sure that the fixing straps are not tightened too firmly. It should be possible to move the trace heater
slightly under the fixing straps.
▪ The distances between the fixing straps should not exceed 250 mm.
20
▪ Finally, place aluminium tape on areas of loose contact of the trace heater.
▪ This step improves heat transfer and prevents insulating material being trapped between the trace heater and the tank.
21
Tests and commissioning

Measurement of the insulation resistance
The measurement of the insulation resistance is used to determine damage to the trace heater and possible installation faults. It must be carried
out at the following times:
▪ Preliminary test (on the reel, before installation of the trace heater on the construction site; refer to section Acceptance Report on page 40)
▪ Acceptance test (after installation of the heating circuit and before installation of the thermal insulation; refer to section Acceptance Report on
page 40)
▪ Final inspection (immediately after completion of work on the thermal insulation)
▪ Upon commissioning
▪ Before switching on the installation
Preparation of the measurement:

▪ De-energize the heating circuit.
▪ Disconnect the thermostat or controller, if installed.
▪ Disconnect the bus wires and PE wires from the terminal block, if installed.
▪ For the measurement you will need a megohmmeter with, at least, a minimum testing voltage of 500 Vdc and a maximum testing voltage of 2500 Vdc.
Test 1 - Conducting the measurement between the bus wires and the grounding braid:
▪ Set the test voltage to 0 Vdc.
▪ Connect the negative (-) lead to the grounding braid of the trace heater.
▪ Connect the positive (+) lead to both trace heater bus wires simultaneously.
▪ Turn on the megohmmeter and set the voltage to 500 Vdc.
▪ Apply the voltage for 1 minute. The meter reading should stabilize. Rapid changes in the reading indicate a breakdown of the insulation.
▪ Record the insulation resistance value in the Inspection Record.
▪ Repeat the measurement at 1000 and 2500 Vdc.
Test 2 - Conducting the measurement between the grounding braid and PE:
▪ Repeat the measurement between the grounding braid and PE (again, at 500, 1000 and 2500 Vdc).
Results:
▪ Properly installed dry and clean trace heater sets should measure thousands of megohms, regardless of the trace heater length or measuring
voltage (0-2500 Vdc). Even if optimum conditions may not apply, all insulation resistance values should be greater than the IEC 60079-30.1:2015
minimum recommendation of 20 megohms. However, BARTEC strongly recommends a minimum reading of 1000 megohms. If the reading is
lower or fluctuating, refer to section Troubleshooting on page 39.
▪ Insulation resistance values for Test 1 and 2; for any particular circuit, should not vary more than 25 percent as a function of measuring volt-
age. Greater variances may indicate a problem with your trace heating system; confirm proper installation and/or contact your local BARTEC
representative for assistance.
WARNING
Risk of fire or electrical shock. If the insulation resistance is insufficient you must fix the heating circuit before putting it into operation.
After the measurement:

If trace heater meets all resistance criteria:
▪ Reconnect the bus wires.
▪ Reconnect any thermostat or controller.
▪ Reenergize the circuit.

Acceptance test and acceptance test report
▪ After completion of the installation work (before installation of the thermal insulation) each heating circuit must be accepted, if possible in the
presence of the client.
▪ All further tests must also be documented in an acceptance test report (refer to section Acceptance report / Record of inspection on page 40).
NOTICE
Claims under warranty will not be considered if the acceptance report is not filled in completely.
▪ After completion of work on the thermal insulation final inspection and acceptance of the individual heating circuits is recommended. Usually,
this is the task of the client or the final customer (= final inspection).
Commissioning
Each heat tracing system can only be put into operation if the following conditions are fulfilled:
▪ The acceptance test reports for each heating circuit are complete and the trace heating system has been accepted.
▪ All components of the heating circuit are completely installed and are in working order.
▪ It has been ensured that the heating circuit is operated in conformance with the technical data specified by BARTEC.
NOTICE
Upon a cold start, additional heating power is required for heating up tanks and pipes. When starting the system you should allow sufficient time
for heat up. For further information on heat up calculations contact your local BARTEC representative.
Operation
During operation of the electric trace heating system you must ensure that all components of the system are operated within the operating data
specified by BARTEC.
This applies particularly to observation of the maximum temperature. Operation within these operating data is a precondition for possible later
warranty claims.
System documentation
Complete documentation must be carried out for each system, from the project planning stage, through installation and commissioning up to
periodic maintenance of the trace heating system.
This documentation should include the following:
▪ Project planning documents
▪ Manuals of all of the components of the heating system
▪ Heat loss calculation
▪ Selection of the trace heater
▪ Layout plans with division of heating circuits
▪ Circuit graphs
▪ Acceptance reports
▪ Reports on repairwork and any operations carried out on the tank/pipe system, trace heating system and thermal insulation
▪ Inspection reports
Maintenance
Visual and functional inspection

▪ Regularly check the thermal insulation for possible damage, missing seals, cracks, damage to the outer jacket, missing thermal insulation bushings
for trace heaters and cables, penetrated water or chemicals. If the thermal insulation is damaged the trace heater should be checked for possible
damage.
▪ Damaged trace heaters must be replaced.
▪ Parts subject to wear must be replaced (e.g. seals, locking plates etc).
▪ Check junction boxes, splices, end terminations etc. for corrosion and possible mechanical damage. Make sure that all enclosure covers are
properly in place.
▪ If present, check the temperature controller connecting cables and sensors for damage and that their installation is protected against mechani-
cal damage.
Electrical inspection
▪ Measurement of the insulation resistance should be seen as a permanent part of regular maintenance. For instructions on how to perform the
test refer to section Measurement of the insulation resistance on page 36.

Inspection intervals
▪ For frost protection installations inspections should be carried out annually before the heating period begins.
▪ For systems designed to maintain process temperatures, inspections should be carried out at regular intervals, but at least twice a year.
Personnel training courses

▪ Regular maintenance should be carried out by trained, experienced maintenance personnel.
▪ It is recommended that maintenance personnel is updated on new developments in application technology and maintenance.
Repairwork on piping or thermal insulation

▪ Ensure that all safety procedures and precautions in the area for repairs are followed.
▪ Take care that the heat tracing system is not damaged during repairwork on the pipes or insulation.
▪ After completion of the repairwork:
 Make sure that any repaired heating circuits are properly installed and tested according to the project planning documentation.
WARNING
Risk of fire or electrical shock due to damaged components. Remember that self-regulating trace heaters are designed to be installed only once.
 Carry out a visual, functional and electrical test (refer to section Tests and commissioning on page 36).

Troubleshooting
Problem Possible cause Remedy
Trace heater remains No power supply Check the power wiring for continuity to circuit breaker.
cold
Trace heater bus wires or power wiring Connect the trace heater and power wiring according to the installa-
not properly connected tion instructions.
Control unit adjusted incorrectly Adjust the control unit according to the installation instructions.
Automatic circuit breaker Automatic circuit breaker defective Replace the automatic circuit breaker.
tripped
Automatic circuit breaker has wrong trip- Install an automatic circuit breaker with Type-C tripping characteris-
ping characteristics, e. g. “B” instead of “C” tics or contact the factory for Type-B tripping characteristics.
Nominal circuit breaker size is insufficient Install an automatic circuit breaker with higher capacity. Observe the
maximum amperage of all components of the trace heating circuit!
Maximum heating circuit length has been Split the heating circuit into separate circuits.
exceeded
End seal has not been installed Install the end seal according to the installation instructions.
Short circuit Identify the cause and remedy the fault (e. g. ensure that trace heater
bus wires are not twisted together).
Humidity inside the connection system or Dry the components. For junction boxes, be sure that the cable gland
end seal is correctly installed and sealing properly.
Ground fault protection Trace heater damaged Replace the trace heater at the point where it is damaged.
is disengaged
Moisture in the components Dry the components. For junction boxes, be sure that the cable gland
is correctly installed and sealing properly.
Ground fault protection defective Replace the ground fault protection device(s).
Low or inconsistent Trace heater damaged Replace the trace heater at the point where it is damaged.
insulation resistance
Moisture in the components Dry the components. For junction boxes, be sure that the cable gland
is correctly installed and sealing properly.
Arcing due to damaged trace heater Replace the trace heater at the point where it is damaged.
insulation
Arcing due to inadequate stripping dis- Check the stripping distance between bus wires//heating element and
tance between heating element and grounding braid at all power, splice and end seal connections to
grounding braid ensure adequate separation.
Short-circuit between the grounding braid Check for cut or damaged cable or inadequate stripping length.
and the heating element or the grounding
braid and the pipe
Test leads touching the junction box Relocate test leads and retest.
Note: High pipe temperature may lower the insulation resistance reading relative to earlier readings on a cold pipe.

Acceptance report / Record of inspection

Protocol type
Inspection before commissioning Inspection after modification Periodic inspection
Visual inspection Close inspection Detailed inspection
Project information
Project / Customer
Order Comm. No. / BARTEC Order No.
Date
Installation details
Heating circuit type Electric Trace Heating of Pipes Electric Trace Heating of Tanks/Vessels
Ex version yes no Zone Temperature class T Ex group
Switchgear / Distribution panel Included in the scope of delivery UV Name ESS/LDP
yes no Test report
Thermal insulation Thermal insulation material Thermal insulation thickness in mm (inch)
Check before installation of the insulation Check after installation of the insulation
Date / Name / Signature Date / Name / Signature
Heating circuit data

Heating Circuit No.
Sub-Heating circuit yes no yes no yes no yes no
Pipe-/Vessel No.
Building
Product
Trace heater type
Lot No. of trace heater
Trace heater length ____________________ m ____________________ m _____________________ m _____________________ m
Serial No. connection kit
Serial No. junction box
Voltage _____________________ V _____________________ V ______________________ V ______________________ V
Current (Switch on / opera- ___________/__________ ___________/__________ ___________/__________ ___________/__________ A
tion) A A A
Output power trace heater __________________ W/m __________________ W/m ___________________ W/m ___________________ W/m
Trace heater resistance ____________________ Ω ____________________ Ω _____________________ Ω _____________________ Ω
Insulation resistance at ….. > __________________ MΩ > __________________ MΩ > __________________ MΩ > __________________ MΩ
V
Temperature settings °C yes no °C yes no °C yes no °C yes no
Controller ______ ______ ______ ______
Limiter ______ ______ ______ ______
Low temperature ______ ______ ______ ______
Remarks: __________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________
____________________________________ _____________________________________ _____________________________________

City/Date BARTEC Contractor Customer
Name / Signature Name / Signature
NOTICE
Claims under warranty will not be considered if the acceptance report is not filled in completely.

EC Declaration of conformity



Limited Product warranty
Scope
BARTEC warrants that all BARTEC products and accessories that are the subject of this manual will be free from defects in materials and work-
manship from and after its date of purchase for a period of 12 (twelve) months.
This limited product warranty does not cover any damage caused by:
▪ accidents,
▪ misuse, improper installation, operation, maintenance or repairs,
▪ neglect, or
▪ alteration.
Furthermore BARTEC cannot be held liable under this warranty for:
▪ installation or removal costs,
▪ loss or damage to property,
▪ indirect, special, incidental or consequential damages (including, without limitation, loss of revenue or anticipated profits), or
▪ any other damages or costs directly or indirectly related to the warranty issue.
If all warranty conditions are met (as set forth below), BARTEC will, at its sole discretion:
▪ repair the product,
▪ replace the product, or
▪ refund the purchase price paid for the product.
This warranty gives you specific legal rights, and you may also have other rights which vary by country, state or province. Except as specifically
provided otherwise in this limited product warranty, the BARTEC Group General Terms and Conditions shall apply.
General terms and conditions

BARTEC Global Terms and Conditions are available at: https://www.bartec.de/en/terms/
Conditions
The limited product warranty is subject to the following conditions:
▪ proper installation, operation and maintenance in compliance with the state of the technology and the product documentation, and
▪ presence of completely filled in acceptance reports for all installation, maintenance and repairwork operations.
How to claim the warranty

To file a claim under the limited product warranty:
▪ Notify BARTEC or your local BARTEC representative by written correspondence or email within 30 days after identification of a possible war-
ranty issue.
▪ If requested, you must provide any warranty-related information and documentation to BARTEC, including, without limitation:
 project planning documents, and
 acceptance reports for installation, operation, maintenance or repairwork.


BARTEC REGIONAL OFFICES
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Design Guide

Self-regulating trace heating systems

cold pipe warm pipe hot pipe

high power output high temperature

low temperature low power output

Power distribution panel

Power connection kit

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 4 / 46

Max. withstand temperature 85 °C 130 °C 200 °C 250 °C

1 nominal heat output at 10 °C

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 5 / 46

Trace heater family

BARTEC® 10PSB2-CT...PSB33...Type 07-5801-2335

Trace heater output in W/ft @ 10 °C

Step 2: Determine the heat loss of your pipe setup

pipe diameter maintain

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 6 / 46

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 7 / 46

basic heat loss: 12.3 W/m

correction factor insulation: 1.72

The effective heat loss of the setup is determined as follows:

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 8 / 46

4 nominal heat output at 10 °C

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 9 / 46

Step 4: Determine the required power rating

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 10 / 46

For MSB trace heaters see page 12.

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 11 / 46

Table E: MSB 230 V

For PSB trace heaters see page 11.

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 12 / 46

For PSB trace heaters see page 11.

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 13 / 46

Table G: HTSB 230 V

For PSB trace heaters see page 11.

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 14 / 46

Application Catalog No. Type key (example)

Determination of the required trace heater length

trace heater allowance for valves, allowance for allowance for

Step 7: Determine the required allowance for connection kits:

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 15 / 46

Step 9: Add all lengths / allowances together:

Determination of the required number of heating circuits

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 16 / 46

PSB trace heaters

MSB trace heaters

HSB trace heaters

HTSB trace heaters

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 17 / 46

Step 12: Determine if control equipment is required:

Ambient sensing control:

Line sensing control:

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 18 / 46

Recommendations for selecting the appropriate control equipment:

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 19 / 46

Step 13: Determine if monitoring equipment is required:

Maintenance access through a high profile end seal

Continuity monitoring using an end of line light

01-5800-7N0012/- Notice Technical data subject to change without notice. Page 20 / 46

__________________ _ ___________________