DESIGN GUIDESystem Components . . .A system with Type FLX heating cable for frost heave protectionwill typically include the following components:1. FLX 8 self-regulating heating cable2. TBX-3LC power connection kit3. ET-6C end termination kit4. JB-K nonmetallic junction box5. Adjustable Thermostat (not shown)6. RTD-500-3 resistance temperature detector7. HeatChek control and monitoring system8. CL “Electric Heat Tracing” caution labels peel and stick tojunction boxes, power distribution and control panel(s), oras required by code or specification (not shown)1FLX Self-Regulating He423<strong>Frost</strong> <strong>Heave</strong> Protection Bill of Materials . . .Use the design outline steps on page 3 and the detailed stepson pages 4 through 6 to assemble an FLX bill of materials. It isrecommended that some additional heating cable per circuitbe allowed to compensate for variations between the existingdrawings and the actual installation area.7Quantity DescriptionFLX 8-1 OJ or FLX 8-2 OJ Self-Regulating Heating Cable(refer to Table 3.0 on page 5 for proper cable type)TBX-3LC Power Connection KitET-6C End Termination KitJB-K Nonmetallic Junction Box (for cable termination)CL “Electric Heat Tracing” Caution Labels (peel-andsticklabels attach to junction boxes, power distributionand control panel(s), or as required by code orspecification)Adjustable Thermostat (not shown)RTD-500-3 Resistance Temperature Detector (for usewith the HeatChek system)HeatChek Control and Monitoring System67
Freezer General <strong>Frost</strong> Specification <strong>Heave</strong> ProtectionPart 1 . . . GeneralFurnish and install a complete UL Listed system of heaters andcomponents approved specifically for freezer floor frost heaveprotection. The heat tracing system shall conform to IEEEStandard 515.1-1995.Part 2 . . . Products1. The self-regulating heating cable shall be of parallel constructionand shall consist of two nickel-plated copper buswires embedded in a radiation cross-linked semiconductivepolymer core. The heater shall include a tinned copperbraid to provide grounding and polyolefin outer jacket foradditional mechanical protection for the cable2. The heater shall operate on line voltage of (select: 110-120,208, 220, 240, 277 or 480) Vac without the use of transformers.3. The heating cable shall be suitable for use with metallic andnonmetallic conduit.4. Power connections and end seal terminations shall be madein junction/pull boxes as described under Part 5, Installation.5. For additional energy conservation, the heating cable shallbe controlled by (select):a. An adjustable thermostat based on current loads foreach circuit.b. A resistance temperature detector (RTD) used in conjunctionwith a microprocessor-based temperature controland monitoring module. Control and monitoringshall be capable of switching up to 30 amps per circuit at120/208/220/240/277 Vac.c. When the load of the heating cable exceeds the ratingof the temperature controller, the heating cable shall becontrolled through an appropriately sized contactor.6. All heating cable core will be permanently marked with themanufacturer’s identification number for traceability.7. Acceptable products and manufacturers are:a. FLX 8 Self-Regulating heating cable and accessories asmanufactured by <strong>Thermon</strong> Industries, Inc.b. HeatChek ® systems and components as manufacturedby <strong>Thermon</strong> Industries, Inc.8. Refer to the manufacturer’s “Freezer Floor <strong>Frost</strong> <strong>Heave</strong> Protection<strong>Design</strong> <strong>Guide</strong>” for design details, insulation requirements,maximum circuit lengths and accessory information.Part 3 . . . System Performance1. Heating cable layout should be based on (select preferreddesign method):a. Manufacturer’s frost heave protection design guide.b. Section 6.5, <strong>Frost</strong> <strong>Heave</strong> Prevention, of the IEEE Standard515.1-1995, Recommended Practice for the Testing,<strong>Design</strong>, Installation, and Maintenance of ElectricalResistance Heat Tracing for Commercial Applications.2. System performance shall be based on temperatures belowthe insulation barrier of 40°F (4°C) during freezer operation.Part 4 . . . Manufacturer1. The manufacturer shall demonstrate experience manufacturingand designing freezer floor frost heave protectionsystems with self-regulating heating cables. This experiencemay be documented with a list of ____ projects utilizing atleast 500 feet (152 m) of self-regulating heating cable.2. Manufacturer’s Quality Assurance Program shall be certifiedto the ISO 9001 Standard.Part 5 . . . Installation1. Heating cable shall be installed in a minimum 3/4" conduitwithin the base layer of the substrate, approximately 2"(5 cm) below the insulation barrier.2. Installer shall follow manufacturer’s installation instructionsand design guide for proper installation and layout methods.Deviations from these instructions could result in performancecharacteristics other than intended.3. Power connections and end terminations shall be located inNEMA 4 junction boxes. Heating cable located betweenjunction boxes and substrate shall be encased in conduit.4. All installations and terminations must be made to conformto the NEC and any other applicable national or local coderequirements.5. Locate the RTD sensors as indicated on the system drawings.6. Circuit breakers supplying power to the heat tracing mustbe equipped with a minimum of 30 mA ground-fault equipmentprotection (5 mA GFCI should not be used as nuisancetripping may result).7. The electrician (see Division 16–Electrical) shall connectsystem to power.Part 6 . . . Testing1. Heating cable shall be tested with a 2,500 Vdc megohmeter(megger) between the heating cable bus wires and the heatingcable’s metallic braid. While a 2,500 Vdc megger test isrecommended, the minimum acceptable level for testing is1,000 Vdc. This test should be performed a minimum ofthree times:a. Prior to installation while the cable is still on reel(s).b. After installation of heating cable and completion ofpower connection and end terminations.c. Upon completion of concrete cap pour.2. The minimum acceptable level for the megger readings is20 megohms, regardless of the circuit length.3. Results of the megger readings should be recorded andsubmitted to the construction manager.8
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