Electric Heat Tracing

INSTALLATION, MAINTENANCE,
& TROUBLESHOOTING
About These Instructions Safety and Site Practice
The installation instructions within this document • Installation shall be carried out under the
describe the installation of Thermon trace heating supervision of a qualified person.
systems in typical piping applications and are suitable • Persons involved in the installation and testing
for use with the flexible trace heating products listed of electric trace heating systems shall be suitably
on page 4. trained in all special techniques required, including:
These instructions are not intended for mineral-​ • the purpose and function of the electrical trace
insulated (MI) trace heaters. Instructions and heating system,
documentation for other products and applications
may be found at www.thermon.com. • its associated power supply and control
equipment, and
For translations of this document in languages other
than English, please contact Thermon. The English • how to recognise and avoid the hazards associated
language version of this document shall govern. with its operation and maintenance.
• All personnel shall use all appropriate personal
protective equipment (PPE), including protective
IMPORTANT: To maintain warranty coverage of the clothing, to protect against potential arc flash and
trace heating system, the steps in these installation shock hazards.
instructions, including testing, must be followed and
documented on the Installation Report (page 12), • All personnel shall comply with all applicable
wherever required in the text. safety and health guidelines, including Thermon
requirements, the regulations outlined in EN/
IEC 60079-14 and EN/IEC/IEEE 60079-30-2 for
hazardous areas (as applicable), and any other
applicable national and local electric codes.
• During installation, the trace heating system
parameters shall be verified. Tests shall be
performed in the field and documented in the
Installation Report (page 12) as instructed.

3
Thermon Flexible Polymer-Insulated Trace Heaters

Type1 Marking/Usage1, 6 Minimum Installation Temp. Minimum Bend Radius

Self-Regulating Trace Heaters
BSX™ 0344
II 2 G Ex eb IIC T5 or T6, –60 °C 10 mm @ –15 °C
II 2 D Ex tb IIIC T100°C or T85°C SIRA 19ATEX3074 32 mm @ –60 °C
IECEx CSA 19.0009 Ex eb IIC T5 or T6,
Ex tb IIIC T100°C or T85°C
RSX™ 2,3 0344
II 2 G Ex eb IIC T6...120°C (T4), –50 °C 10 mm @ –15 °C
II 2 D Ex tb IIIC T80°C...T120°C KEMA 07ATEX0179 32 mm @ –50 °C
IECEx KEM 07.0052 Ex eb IIC T6...120°C (T4),
With -FOJ option:
Ex tb IIIC T80°C...T120°C
–60 °C 10 mm @ –15 °C
32 mm @ –60 °C
HTSX™ 2,4 0344
II 2 G Ex 60079-30-1 IIC T2 or T3 Gb, –60 °C 10 mm @ –15 °C
II 2 D Ex 60079-30-1 IIIC T300°C or T200°C Db FM 12ATEX0014X 32 mm @ –60 °C
IECEx FMG 12.0004X Ex 60079-30-1 IIC T2...T3 Gb,
Ex 60079-30-1 IIIC T300°C...T200°C Db
KSX™ 2,4 0344
II 2 G Ex 60079-30-1 IIC T6...T3 Gb, –60 °C 10 mm @ –15 °C
II 2 D Ex 60079-30-1 T200°C...T85°C FM 07ATEX0027X 32 mm @ –60 °C
IECEx FMG 06.0009X Ex 60079-30-1 IIC T6...T3 Gb,
Ex 60079-30-1 T200°C...T85°C Db
USX™ 2,4 0344
II 2 G Ex 60079-30-1 IIC T2 or T3 Gb, –60 °C 10 mm @ –15 °C
II 2 D Ex 60079-30-1 IIIC T300°C or T200°C Db CSANe 20ATEX3059 32 mm @ –60 °C
IECEx IECEx CSA 20.0006 Ex 60079-30-1 IIC T2...T3 Gb, Ex
60079-30-1 IIIC T300°C...T200°C Db
VSX-HT™ 0344
II 2 G Ex 60079-30-1 IIC T6...T2 Gb, –60 °C 10 mm @ –15 °C
II 2 D Ex 60079-30-1 IIIC T85°C...T300°C Db FM 18ATEX0009X 32 mm @ –60 °C
IECEx FMG 18.0002X Ex 60079-30-1 IIC T6...T2 Gb,
Ex 60079-30-1 IIIC T85°C...T300°C Db
Power-Limiting Trace Heaters
HPT™ 5 0344
II 2 G Ex 60079-30-1 IIC T6...T2 Gb, –60 °C 10 mm @ –15 °C
II 2 D Ex 60079-30-1 IIIC T85 °C...T300 °C Db DEKRA 16ATEX0093 32 mm @ –60 °C
IECEx DEK 16.0046 Ex 60079-30-1 IIC T6...T2 Gb,
Ex 60079-30-1 IIIC T85°C...T300°C Db
Parallel Constant-Watt Trace Heaters
FP 0344
II 2 G Ex e II T3 to T6, –60 °C 10 mm @ –15 °C
II 2 D Ex tD A21 IP66/IP67 T200°C to T85°C FM 07ATEX0016 19 mm @ –60 °C
IECEx FMG 06.0008 Ex e II T3 to T6,
Ex tD A21 IP66/IP67 T200°C to T85°C
Series Constant-Watt Trace Heaters
HTEK™, 0344
II 2 G Ex eb IIC T260ºC (T2) to T6, –60 °C 22 mm @ –15 °C
TEK™ Ex tb IIIC T260°C to T85°C FM 11ATEX0050 32 mm @ –60 °C
IECEx CCVE 11.0002 Ex eb IIC T260ºC (T2) to T6,
Ex tb IIIC T260°C to T85°C
TESH™ 0344
II 2 G Ex e IIC T2 to T6 Gb, –60 °C 5 times the outside
II 2 D Ex tb IIIC IP6X T260°C to T80°C Db ISSeP 10ATEX015X diameter
Notes
1 Temperature ratings may vary within a trace heater product type. Always verify that the temperature ratings and markings of the trace heater are
appropriate for the specific installation location.
2 EN 60079-0, EN 60079-30-1, EN 60079-31, IEC 60079-0, IEC 60079-30-1, IEC 60079-31
3 For use with integral components: TBX-3LC, ET-6C, PETK-1, SCTK-1, SK-SX, HS-PBSK-HD, and HS-ET-6C-HD. Also for use with other suitably certified
connection kits such as Thermon Terminator series.
4 For use with integral components: ET-8C, PETK-2, SCTK-2, TBX-4LC, and SK-SX. Also for use with other suitably certified connection kits such as Thermon
Terminator series.
5 For use with integral components: ET (-6C, -7C, -8C), TBX-4LC, PETK kits (-3, -3D, -4, -HPTXR), SCTK (-3, -3D, -4, -HPTXR), HPEK, and HPSK. Also for use with
other suitably certified connection kits such as Thermon Terminator series.
6 Specific conditions of use, for insulated externally heated surfaces, lower T- class systems may be obtained by utilizing stabilised design of a trace
heating system using methods described in IEC/IEEE/EN 60079-30-1. Clause 4.5, using CompuTrace Electric Heat Tracing Design Software or by Thermon
Engineering. The system design parameters, including the resulting T-class, shall be retained as a record of system documentation for each stabilised
system design for as long as the system is in use. The parameters in the system documentation shall be checked during commissioning of the system.

4
About Electric Trace Heating Systems
Thermon electric trace heating systems are used 5a
for freeze protection or temperature maintenance 4
of piping, tanks, and instrumentation. They may be
installed in ordinary (nonclassified) and hazardous 5
(classified) locations, depending on the specific trace
heater options and approvals1.
A typical self-regulating electric trace heating system
(as depicted in Illustration A) may consist of the
following components:
8
1. Electric trace heater (may be self-regulating,
power-limiting, parallel constant-watt, or series 6
constant-watt)1.
2. Power connection kit2. 7

3. RTD sensor or control thermostat2.

4. In-line/T-splice kit (permitting two or three cables
to be spliced together).
5. Cable end termination. 1
3
5a. End of circuit light kit.
6. Attachment tape (use on 30cm intervals, or as
required by code or specification).
7. “Electric Heat Tracing - Caution” label.
8. Thermal insulation4 and vapor barrier. 2
The absence of any of these items can cause a system
to malfunction or represent a safety hazard.

Notes
1 See Page 3 for trace heater types and approvals. Illustration A: Typical Trace Heating Installation
2 Power connections must be used with correctly-installed certified
enclosures that are suitable for the application (such as Terminator™).
When connecting Ex e certified terminals using associated accessories,
the required creepage distances and clearances shall be observed.
3 Temperature control is recommended for all freeze-protection and
temperature-maintenance trace heating applications.
4 All heat-traced lines must be thermally insulated.

Trace Heating System Design

• The design of electrical resistance trace • The stabilised design method may be used for
heating systems shall be overseen by persons self-regulating, power-limiting, and constant-watt
knowledgeable of trace heating, following the heating cables without a limiting device.
design methodology for explosive atmospheres as • Series heating cable output and T-rating are
specified by Thermon Engineering or CompuTrace dependent upon several variables, including
Electric Heat Tracing Design Software. supply voltage, cable resistance, and temperature
• For insulated externally heated surfaces, lower conditions.
T-class systems may be obtained by utilizing
stabilised designs or controlled designs using
methods described in IEC/IEEE/EN 60079-30-1,
Clause 4.5, using CompuTrace Electric Heat Tracing
Design Software or by Thermon Engineering. The
system design parameters, including the resulting
T-class, shall be retained as a record of system
documentation for each design for at least as long
as the system is in use. The parameters in the
system documentation shall be checked during
commissioning of the system.

5
Upon Receiving the Trace Heater Insulation Resistance (IR) Testing
1. Make sure that the correct type (including the The insulation resistance (IR) test establishes the
correct nominal power output and voltage level) has electrical integrity of the trace heater. For the flexible
been received. trace heaters covered in this document, the IR test
All flexible trace heaters, of the types covered in this should be performed with a megger capable of
document, are printed with the catalog number, delivering a voltage of at least 500 Vdc.
voltage rating and power output (in W/m or W/ft) 1. If not done already, prepare the conductors of
on the jacket. To verify the year of construction, the trace heater according to the instructions
please contact Thermon with the batch code accompanying the power and end termination
number printed on the trace heater jacket. kit(s) provided with the system.
2. Record the reel number, reel length, trace heater 2. Connect the megger’s positive lead to the cable
type, and nominal power output and voltage in bus wires, shorted together.
the Pre-Installation section of the Installation 3. Connect the megger’s negative lead to the metallic
Report (page 12). braid.
3. Visually inspect cable for any damage incurred 4. Set the megger test voltage to 500 Vdc.
during shipment. Note any observed damage in the
Installation Report. 5. Energise the megger for 60 seconds.
4. Perform the Insulation Resistance (IR) Test, 6. Readings of at least 20 MΩ are acceptable.
described on this page, to confirm the trace heater’s Readings below 20 MΩ
electrical integrity. Record the reading in the usually indicate that the
Installation Report. electrical insulation of
5. Store the trace heater in a dry location. the trace heater has been
compromised.
Before Installing Check the trace heater for
signs of physical damage
• Be sure all piping and equipment to be traced have between the braid and the heating element. Small cuts
been completely installed and pressure-tested. or scuffmarks on the outer jacket will not affect the
• Ensure that all surface areas where the trace heater megger reading unless there is penetration through
is to be installed are reasonably clean. Remove any the braid and dielectric insulation jacket.
dirt, rust, and scale with a wire brush. Remove oil
and grease films with a suitable solvent.
• De-energise power sources before installation.
• Keep ends of trace heaters and kit components dry
before and during the installation.

6
Initial Trace Heater Installation
• Begin installing the trace heater at the proposed • Allow extra length of trace heater for power
end-of-circuit location, following the guidance in connections, splices, and any in-line heat
the isometric system diagrams (if provided). sinks, such as valves, flanges, and supports
• Lay out the trace heater on the pipe, at the 4 or 8 (Illustration C). See page 8 and page 9 for
o’clock position (Illustration B), securing it tightly details on how to properly install the trace heater
against the pipe with attachment tape. Wrap at these sites and the allowance of trace heater
bands of tape around the trace heater and pipe at required.
intervals of 30 cm or less, keeping the trace heater • Install temperature sensors at least 90° away from
in close contact with the pipe. trace heater locations.
• If accessibility is a problem, the trace heater may • CAUTION: For series constant-watt trace heaters
be installed at the 10 or 2 o’clock position. (HTEK, TEK, TESH), do not allow the heating
• Refer to Table 1 (page 8) to estimate the portion of the trace heater to touch, cross over, or
number of rolls of attachment tape required, overlap itself.
based on the pipe length and diameter1. • CAUTION: Do not exceed the trace heater’s
• A continuous covering of aluminum foil tape may specified minimum bend radius. Refer to page
also be required under special circumstances, 4 of this document for the minimum bend
including: radius of the specific trace heater type.
• where spray or foam2 thermal insulation will
Notes
be applied,
1 Table 1 assumes circumferential bands every 30 cm along the length of
• where nonmetallic piping is used, or the piping.
2 Verify that the curing temperature of the insulation is less than the
• design requirements dictate the use of exposure temperature of the trace heater.
aluminum tape.

Illustration B: Heating Cable vs. Sensor Location Temperature Sensor

(Typical)

45° Pipe Wall

90°

45°
45°
90° 45° 45° 45° 45°
Heating Cable
(Typical)
Single Cable Installation Dual Cable Installation Triple Cable Installation

Proposed End-of-Circuit
Illustration C: Temporary Installation Location

Pipe Support

Notes . . .
1. Termination kits to fabricate a heat tracing circuit are not
addressed in detail in these installation procedures. Refer
Cable Allowance for
to installation instructions included with cable termination
In-Line Heat Sinks kits or contact Thermon for specific instructions to
Proposed Power fabricate heating cable.
Connection Location

7
 Table 1: Attachment Tape (Approximate Linear Pipe Length Allowance Per Roll)
Pipe Size
12-25 32 40 50 80 100 150 200 250 300 350 400 450 500 600 750
mm
Length of Pipe/
Roll of Tape 109.7 79.2 67.0 54.9 45.7 36.6 27.4 21.3 18.2 15.2 12.2 10.7 9.1 7.6 6.0 4.6
m

Installation on Elbows, Pipe Supports, and

Flanges
• Elbows: Locate the trace heater on the outside • Flanges: Loop the trace heater around the pipe
radius of the elbow (Illustration D). Secure the on each side of, and adjacent to, the flange
trace heater to the pipe with attachment tape on (Illustration F). Be sure to keep the trace heater
each side of the elbow. in close contact with the flange throughout the
• Pipe Supports: For uninsulated pipe supports, length of the bend.
allow twice the length of the support, plus an Refer to Table 2 (page 9) for typical flange
additional 40 cm of trace heater. Install the trace allowances.
heater in a loop, following Illustration E as a guide.
Insulated pipe supports do not require additional
length of trace heater.

Illustration D: Pipe Elbow Illustration E: Uninsulated Pipe Support

Attachment Tape
(Typical)
Heating Cable
Heating Cable

Attachment Tape
(Typical)

8 cm

Support
Illustration F: Pipe Flange 8 cm Length
Attachment Tape
(Typical)

Heating Cable
Circuit Layout on Support

Note . . .
1. Only applicable for pipe ≥ 50mm.

30 cm
Note: Flange allowance will vary based on method of
insulating flange and adjacent piping.

8
Installation on Valves and Pumps Table 2: Typical Valve, Pump, and Flange Allowances1
Valve Allowance (M) Pump Allowance (M) Flange
• Valves, pumps, and other miscellaneous equipment Pipe
Size Screwed or Allowance
require additional passes of trace heater to offset (mm) Welded Flanged Butterfly Screwed Flanged (M)
the increased heat loss that occurs at these sites.
12 0.20 0.30 0.00 0.30 0.61 0.38
• Refer to the isometric system drawings, provided 20 0.20 0.46 0.00 0.46 0.91 0.46
by Thermon Engineering, for allowances specific to 25 0.30 0.61 0.30 0.61 1.22 0.46
each line and circuit. 32 0.50 0.61 0.30 0.91 1.37 0.61
Allowances for typical valves and pumps are 40 0.50 0.76 0.46 0.91 1.52 0.61
provided in Table 2. 50 0.60 0.76 0.61 1.22 1.68 0.69
80 0.80 1.07 0.76 1.52 2.13 0.69
• Install the trace heaters using a looping technique,
100 1.20 1.52 0.91 2.44 3.05 0.84
using Illustrations G and H as a guide, such that the
150 2.10 2.44 1.07 4.27 4.88 0.99
valve or pump may be removed for required service
200 2.90 3.35 1.22 5.79 6.71 1.14
and maintenance.
250 3.80 4.27 1.22 7.62 8.53 1.30
• Keep the trace heater in close contact with the pipe 300 4.60 5.03 1.52 9.14 10.06 1.52
and heat sink areas, to compensate for additional 350 5.50 5.94 1.68 10.97 11.89 1.68
heat loss. 400 6.60 7.01 1.83 13.11 14.02 1.83
450 7.80 8.23 1.98 15.54 16.46 1.98
500 8.70 9.14 2.13 17.37 18.29 2.21
550 10.40 10.97 2.44 20.73 21.95 2.51
600 12.20 12.80 3.05 24.38 25.60 3.05
1 Allowance is the total length of additional trace heater to be installed.
If multiple passes are used, total allowance may be divided among the
individual passes.

Valve allowances are based on 150-pound class valves; more passes are
required for higher-rated valves.

Illustration G: Typical Valve Detail Illustration H: Typical Pump Detail

Heating Cable #2
Heating Cable #3
Heating Cable #2
Heating Cable #3

Heating Cable #1 Heating Cable #1

Heating Cable Serpentined on Valve

Heating Cable Serpentined on Pump

Heating Cable #3 Heating Cable #2

Heating Cable #2

Heating Cable #3

Heating Cable #1

Single Circuit Layout on Valve Multiple Circuit Layout on Valve 2

Heating Cable #1
Single Circuit Layout on Pump
Multiple Circuit Layout on Pump 2

9
Completing the Trace Heater Installation
1. Secure the end-of-circuit termination kit and work 6. Connect the metallic braid of the trace heater to a
back toward the power supply (Illustration I). suitable earthing/ground terminal.
2. Keep the trace heater in secure contact with the 7. Before completing the power connections, perform
pipe, using bands of attachment tape at least every an Insulation Resistance (IR) Test (page 6) and
30 cm. record the result in the After Installation section
3. Secure any required temperature sensors to the of the Installation Report (page 12). The recorded
pipe using attachment tape. value shall not be less than 20 MΩ.
4. Complete any required splice connections in 8. Record the line number and all other associated
accordance with the installation instructions circuit information in the After Installation section
provided with the splice kit. of the Installation Report.
5. Install any power connection kits in accordance with
the detailed installation instructions provided with
the kit.

Illustration I: Final Cable Attachment

Proposed End of Circuit

Attachment Tape

Proposed Power Supply

Installing Thermal Insulation After Installing Thermal Insulation

Properly installed and well-maintained thermal The presence of trace heaters shall be made evident
insulation is critical to the performance of the trace by posting of caution signs or markings at appropriate
heating system. Without proper insulation, heat losses locations and/or at frequent intervals along the circuit.
are generally too high to be offset by a conventional 1. Apply the provided peel-and-stick “Electric Heat
heat tracing system. Tracing - Caution” labels along the pipe, on the
1. Properly insulate all heat sinks, including pipe outermost surface of the thermal insulation or
supports, hangers, flanges, and in most cases, valve vapor barrier, at intervals of 3 m or less.
bonnets. 2. Apply the caution labels at any other appropriate
2. Install a protective vapor barrier over the insulation, locations, such as valves.
regardless of the type or thickness of insulation
used. The vapor barrier protects the insulation from
moisture intrusion and physical damage and ensures
the proper performance of the trace heating system.
3. Seal all penetrations around the vapor barrier.
4. After ensuring that the insulation is weather-tight,
document the completion of the insulation in the
After Installation of Thermal Insulation section of
the Installation Report (page 12).

10
Circuit Protection Requirements Final Inspection
• Each branch circuit must use over-current protection 1. After installing the thermal insulation and vapor
that isolates all appropriate power conductors from barrier BUT BEFORE ENERGIZING THE CIRCUIT,
the supply (typically circuit breakers). repeat the IR test to verify that the trace heater has
• Earth fault equipment protection is required for not been damaged during installation. Record the IR
each circuit. value in the After Installation of Thermal Insulation
section of the Installation Report (page 12).
• For typical installations (with TT and TN grounding
systems), the means of protection must include a 2. For Series Heating Cables, measure the electric loop
residual current protective device for each branch resistance and record the resistance values in the
circuit. Installation Report.
• For fixed-level earth/ground-fault circuit 3. Ensure that all junction boxes, temperature
interrupters, a minimum 30 mA trip level is controllers, cable glands, etc., are properly secured.
recommended. The preferred trip level for 4. If a temperature controller is used, force the circuit
adjustable devices is 30 mA above any inherent on and energise the circuit at the rated voltage.
capacitive leakage characteristic of the heater, as 5. After 5 minutes, measure the voltage, current, pipe
specified by Thermon Engineering. temperature, and ambient temperature. Record
• Where conditions of maintenance and supervision these values in the Final Commissioning section of
ensure that only qualified persons will service the the Installation Report.
installed systems, and continued circuit operation is 6. If a control device is used, verify its settings to
necessary for the safe operation of the equipment ensure that the maximum surface temperature does
or processes, earth-fault detection without not exceed the system T-rating, in accordance with
interruption is acceptable if alarmed in a manner to IEC/IEEE/EN 60079-30-1, Clause 4.
assure an acknowledged response.
• For IT grounding systems, a means of protection Documentation Retention
against earth faults is required that includes an
electrical insulation monitoring device that shall The trace heating system documentation shall be
disconnect the supply whenever the electrical retained for each trace heating circuit for as long as the
resistance is not greater than 50 ohms/volt of rated system is in use. This includes:
voltage. • System Design Parameters And T-Class
• Isometric Circuit Diagrams
• Maintenance Records
• Operating History
• These Instructions
• All Other Documentation Provided By Thermon

11
Installation Report

Project Information
Project No. Installer
Unit No.
Customer Reference No. Inspector
Thermon Reference No.
Pre-Installation
Reel No. Insulation Resistance (IR)
Reel Length m/ft Single-Phase: MΩ/GΩ
Trace Heater Type 3-Phase L1 MΩ/GΩ
Power Output (nom.) W/m/W/ft (for Series L2 MΩ/GΩ
Trace Heaters):
Voltage (nom.) V L3 MΩ/GΩ
Notes Tested By/Date
Witnessed By/Date
After Installation
Line No. Braid Connected to Ground?
Equipment No. Unused Entries Plugged Off?
Circuit/Heater No. Insulation Resistance (IR)
Circuit Switch No. Single-Phase: MΩ/GΩ
Thermostat No. 3-Phase L1 MΩ/GΩ
Junction Box No. (for Series L2 MΩ/GΩ
Trace Heaters):
Panel No. L3 MΩ/GΩ
Breaker No.
Trace Heater Line Length m/ft
Notes Tested By/Date
Witnessed By/Date
After Installation of Thermal Insulation
Insulation Weather-Tight? Insulation Resistance (IR)
Caution Labels Placed? Single-Phase: MΩ/GΩ
L-L Ω 3-Phase L1 MΩ/GΩ
Electrical Loop L1-L2 Ω (for Series L2 MΩ/GΩ
Resistance (for Trace Heaters):
Series Trace Heaters) L2-L3 Ω L3 MΩ/GΩ
L3-L1 Ω
Notes Tested By/Date
Witnessed By/Date
Final Commissioning
Perform final measurements after energising circuit for 5 minutes.
Ambient Temperature °C/°F Voltage V
Pipe Temperature °C/°F Current A
Notes Tested By/Date
Witnessed By/Date
NOTE: All Insulation Resistance (IR) values shall be at least 20 MΩ for a successful installation.

12
Maintenance and Repair Before maintenance, repair, or modification
• Once the system has been successfully installed, an CAUTION: Consult the trace heating system
ongoing preventive maintenance program should be documentation prior to maintenance, repair, or
implemented, using qualified personnel. The trace modification.
heating system should be inspected and tested on a 1. Identify the circuit or equipment to be de-energised
regular basis, at least once per year. and all possible sources of electrical energy supplies
• Keep records of the operating and maintenance to the specific circuit and equipment.
history for each circuit, including all test results 2. De-energise all power sources.
performed during maintenance and inspection.
Record-keeping during scheduled maintenance will 3. Apply lockout/tagout devices according to
help to establish a “normal” range of operation. established procedures.
Insulation resistance readings that deviate from the 4. Test for the absence of voltage with an approved
normal range may indicate problems with a circuit. voltmeter (where the voltmeter is tested on a
• If the system fails any test, refer to the known circuit voltage prior to and immediately
troubleshooting guide below to address the issue. following application).
De-energise the affected circuits and make the 5. For protection against the accidental energizing of
necessary repairs immediately. supply conductors, apply temporary jumpers rated
for the available fault duty between each supply
conductor and earth/ground.
NOTE: In the event of an earth fault or over-current
interruption, devices shall not be reset until the
cause of the trip has been investigated by qualified
personnel.

After maintenance, repair, or modification

1. Test the operation of each affected circuit.
2. The insulation resistance of the trace heater shall be
measured and recorded and shall not be less than
20 MΩ.
3. Visually verify that all circuit-disconnect devices are
open before reconnecting power.

Troubleshooting Guide
This troubleshooting guide aims to help to diagnose • Physical damage incurred from recent repairs and
and resolve many issues on-site. maintenance to any in-line or nearby equipment.
Many problems with electric trace heating systems can Other possible causes are listed below, with their
be attributed to two causes: symptoms and potential remedies.
• Wet, damaged, or missing insulation. Visually If any circuit is suspected to be damaged, de-energise
inspect the insulation along the entire length of the circuit and perform the Insulation Resistance Test
the circuit, making sure that it is intact and dry outlined on page 6. Readings below 20 MΩ indicate
throughout. that the trace heater may be physically damaged.

Symptom Possible Cause Remedy

No heat/no current • Loss of power/voltage • Check the circuit breaker and electrical
connections
• Controller setpoint too low • Verify/adjust setpoint
• High-temperature limit switch • May require manual reset to re-enable
activated trace heating circuit
• “Open” series heating circuit • Repair or replace circuit1
• Controller failure • Repair sensor or controller2

13
 Symptom Possible Cause Remedy
Low system • Controller setpoint too low • Verify/adjust setpoint
temperature • Temperature sensor located too close • Relocate sensor
to trace heater or other heat source;
may be accompanied by excessive
cycling of control relays/contacts
• Insulation material and/or thickness • Replace insulation; increase insulation
different than designed thickness (if dry); review design3
• Ambient temperature lower than • Install higher-output trace heater; increase
designed insulation thickness; review design3
• Low voltage (check at power • Adjust voltage to meet design
connection point) requirements3
Low temperature in • Wet, damaged, or missing insulation • Repair or replace insulation and barrier
sections • Trace heater damaged • Repair or replace section; splice kits are
available from Thermon
• Heat sinks (valves, pumps, pipe • Insulate heat sinks or increase passes of
supports, etc.) tracing on heat sinks
• Significant changes in elevation along • Consider dividing heating circuit into
length of the heat-traced pipe separate, independently controlled
segments
High system • Controller “on” continuously • Adjust setpoint or replace sensor2
temperature • Controller fails with contacts closed • Replace sensor or controller2
• Sensor located on uninsulated pipe or • Relocate sensor to an area representative
too close to heatsink of conditions along length of pipe
• Backup heating circuit controller “on” • Adjust setpoint or replace backup
continuously controller
Excessive cycling • Temperature sensor located too close • Relocate sensor
to trace heater or other heat source;
may be accompanied by low system
temperature
• Ambient temperature near controller • Temporarily alter controller setpoint
setpoint
• Connected voltage too high • Lower voltage
• Trace heater output too high • Install lower-output trace heater or lower
(overdesign) the voltage
• Controller differential too narrow • Widen the differential or replace controller
to avoid premature contact failure
Temperature variations • Inconsistent trace heater installation • Check consistency of trace heater
along pipe along pipe installation, especially at heat sinks
• Inconsistent trace heater • Compare calculated power per unit length
performance (W x A/length) for the measured pipe
temperature with designed trace heater
output for the same temperature; regional
damage to trace heater can cause partial
failure
• Unanticipated flow patterns or • Redistribute heating circuits to
process operating temperatures accommodate existing flow patterns;
confirm process conditions

Notes
1 Flexible, polymer-jacketed trace heaters (such as those covered in this document) may be field-spliced. Mineral-insulated (MI) trace heaters typically
require replacement.
2 Mechanical thermostat sensors cannot be repaired or replaced. RTD and thermocouple sensors may be replaced. Some controllers have replaceable
contacts/relays or may require a manual reset if a “trip-off” condition was detected.
3 Before making any changes to system parameters, consult Thermon for the impact on trace heater performance.

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Form PN50207U-0220 © Thermon, Inc. • Printed in U.S.A. • Information subject to change.