Tyco Frostex 9800 User's Manual
Contents
1. Important The ground fault unit and plug must be kept dry t is important to include the drip loop to prevent water from getting into the ground fault unit Outlet cover Thermal i insulation 9800 ml Flexfit Cable ties plug or tape Drip loop Figure 1 Typical manufactured housing installation CMSs Figure 2 Typical installation 4B Install the heating cable Single run method Run the heating cable in a straight line approximately a third of the way up from the bottom of the pipe as shown in Figure 3 Frostex 9610 application tape 1 foot spacing lt Ee Figure 3 Single run method Multiple run method When two or more runs are required install the heating cable in the 4 o clock and 8 o clock positions as shown in Figure 4 When three runs are required install the heating cable as shown in Figure 5 12 8 4 8 4 Figure 4 Double runs Figure 5 Triple runs 4C Tape the heating cable and end seal to the pipe e Fasten the heating cable to the pipe at 1 foot 30 cm intervals using two or three thicknesses of 9610 applica tion tape or equivalent e Provide extra heat at valves and spigots by wrapping each with 1 foot 30 cm of additional heating cable overlap ping as required e If you have excess heating cable at the end of your pipe2. 9610 ou un autre ruban quivalent de 1 2 po 1 po 13 mm 25 mm ou des colliers de serrage en plastique e Inspectez le c ble chauffant p riodiquement Si vous d celez la pr sence de tresses bris es ou autres l ments endommag s d branchez le syst me imm diatement et remplacez le c ble chauffant Vous ne devez pas tenter de coller ou de r parer un c ble chauffant endommag Vous devez remplacer les isolants et recouvrements imper m ables endommag s 6 N installez pas le c ble chauffant Frostex proxim it de mati res liquides ou vapeurs inflammables N utilisez que de l isolant tuyau ayant 1 2 po 13 mm d paisseur ou plus ignifuge et r sistant l eau conform ment au Tableau 1 ou 2 General Instructions Observe the safety warnings on page 1 Follow the installation steps pages 2 7 in the exact order given o ensure the plug is properly connected do not assemble at temperatures below 0 F 18 C he Frostex system can be left plugged in all year but you will save energy by unplugging the system when there is no risk of freezing Use a properly grounded 3 prong 120 volt outlet If you are not sure if your outlet is properly grounded call a professional service person n manufactured housing installations use the electrical receptacle on the underside of the home Do not use an extension cord or there may be danger of fire or shock Using an extension cord is not in complian
3. Back wall Indicator post 3A Prepare the cable 3B Insert the cable Cleanly cut off the end of the cable Push back the braid 3 4 2 cm and then twist the end of the braid around the cable to ensure the braid strands are not sticking up Note The clear plastic wrap does not need to be removed 3C Complete the connection Back wall nsert the heating cable all the way into the cable guide until the cable hits the back wall A Be sure no braid wire strands enter cable guide 3D Install the cover Screw down the cable guide alternating between the two screws until the cable guide is flush with the indicator posts and the screws bottom out 0 1 2 om lulu nstall the cover by tightening the screws completely Note The screws will require many turns before the cover starts to close Step 4 Attach the heating cable to the pipe 4A Prepare to install the heating cable Begin the installation at the electrical outlet Leave at least 1 foot 30 cm of extra heating cable so the ground fault unit can be secured to the outside of the thermal insulation as shown in Figures 1 and 2 This will relieve any strain on the heating cable or plug However be careful not to leave heating cable hanging in a loose loop where it could be accidentally snagged and pulled out ake certain you have removed any old heating tapes and insulation
4. 3 4 2 2 3 T 2 3 3 11 4 2 2 3 11 2 2 3 3 3 4 1 2 2 2 2 3 4 2 2 3 i 2 2 3 1 4 2 3 3 A 2 3 3 M 1 3 4 2 2 2 2 1 4 2 2 3 1 2 2 3 3 2 3 3 11 2 3 4 1 2 y 2 2 1 4 2 2 1 2 2 2 a 2 2 3 HE increase insulation thickness 1C Calculate the total length of heating cable required ultiply the number of heating cable runs by your pipe length Add one extra foot 30 cm for each valve in your line Add one extra foot 30 cm for the distance to the power connection For installations in a crock add an additional 2 feet 60 cm of heating cable After cutting the Frostex heating cable to the length you need proceed to Step 2 Example Pipe size and material Lowest ambient temperature 20 F 30 C Pipe length 16 feet 5m Valves 1 ball valve is used 1 inch diameter plastic The water connection is in a crock From Table 2 Plastic Pipe for 20 F 30 C either two or three runs of Frostex heating cable is required depending on pipe insulation thickness Optimal Pipe insulation thickness 3 4 Selecting 3 4 thick insulation requires two runs of Frostex heating cable installed along the entire length of the pipe Table 2 The total length of heating cable equals 32 ft 10 m 2 runs x 16 ft 5 m of pipe 1 ft 0 3 m for one ball valve 1 ft 0 3 m for one power connection 2 ft 0 6 m for installing in a crock Total length 36 ft 11 m Note Do not use more tha
5. or consequential damages and the above disclaimer of implied warranties may not apply The term of any such implied warranty is limited to the term of this two year Limited Warranty Some jurisdictions do not allow limitations on how long an implied warranty lasts so the above limitation may not apply This warranty gives consumers specific legal rights and consumers may also have other rights which vary by jurisdiction
6. Installation Instructions and User Guide Fr ostex j for the Frostex Pipe Freeze Protection System Pipe Freeze Protection System Using the 9800 FlexFit Plug Kit Directives d installation et Guide de l Utilisateur du Syst me Frostex de Protection Anti gel des Tuyaux Utilis avec le Kit Frostex 9800 FlexFit Keep pipes from freezing Protection anti gel des tuyaux ten mie tyco lt Thermal Controls ai Mobile Home ipe Heating Cable Contents Five Important Safety Warnings General Instructions Installation Instructions Periodic Inspections Troubleshooting Limited Warranty Oomannrn 9800 FlexFit plug Reset button Test button Before You Begin Make sure your 9800 FlexFit Plug Kit is complete It should contain 1 9800 FlexFit plug 1 Push on end seal 2 Orange warning labels in English 2 Orange warning labels in French 1 White tape strip 1 Installation instruction Make sure you have sufficient braided Frostex heating cable for the job Do not use earlier versions of Frostex heating cable that have no braid Also make sure you have the following items 2 Phillips Wire cutters 1 2 1 screwdriver 13 mm 25 mm tape N Frostex 9610 application tape is recommended Two 10 25 cm plastic cable ties not included may be used to secure ground fault unit to pipe insulation If you have any questions after reading this guide call this toll free Tyco Thermal Controls number 800 545 6258
7. Save this installation instruction and user guide It con tains important safety warnings and maintenance infor mation Indicator light Table des mati res Cinq avertissements de s curit importants 1 Directives g n rales 10 Directives d installation 10 Inspections p riodiques 16 D pannage 16 Garantie limit e 17 Gel filled end seal Avant de d buter Assurez vous que votre kit 9800 FlexFit contient tout ce qui suit 1 Fiche 9800 FlexFit 1 Obturateur pousser 2 Etiquettes oranges d avertissement en anglais 2 Etiquettes oranges d avertissement en francais 1 Bande de ruban blanc 1 Manuel des directives d installation Assurez vous d avoir suffisamment de c ble chauffant tress Frostex pour effectuer le travail N employez pas les versions ant rieures des c bles chauffants Frostex sans tresses Ayez galement les articles suivants en main Tournevis Un Du ruban Phillips 2 coupe c ble de 13 mm 25 mm 1 2 1po 1 Le ruban de fixation Frostex 9610 est recommand Deux colliers de serrage en plastique de 25 cm 10 po non inclus peuvent tre utilis s pour fixer le disjoncteur diff rentiel l isolant de tuyaux Si vous avez des questions apr s la lecture du pr sent guide contactez le num ro sans frais de Tyco Thermal Controls au 800 545 6258 Conservez ces directives d installation ainsi que le guide de l utilisateur Ils contiennent d importants avertissements de s
8. Warning labels Figure 7 Thermal insulation e Do not leave the heating cable exposed except for the short distance from the pipe to the power connection e Fully insulate and weatherproof all exposed piping Put additional insulation on areas that cannot be heat traced 5B Waterproof the insulation Make sure the thermal insulation is waterproof and stays dry Install a watertight sleeve and a solid cover or a barrier such as polyethylene sheeting around the insulation wherever there is any chance that the insulation might get wet 5C Install the warning label Install the orange warning labels on the insulation with one near the electrical outlet as shown in Figure 7 Additional labels and installation tape are available from Tyco Thermal Controls in the Frostex 9610 kit 6A Plug in the heating cable After installing the heating cable and insulation remove the clear label that covers the test and reset buttons Then plug the 9800 FlexFit plug into a grounded and properly installed outlet Step 6 Start up the system Y e f the Frostex heating cable length is longer than 40 feet and the air temperature is lower than 30 F run water through the pipe before plugging in the unit This will warm up the pipe and help avoid blowing the nonreplace able fuse in the 9800 FlexFit plug e The signal light will go on indicating that the ground fault protection device and the fuse are working properly How
9. between 2 and 20 000 ohms If your reading is within this range you have completed the installation If your reading is not within this range repeat Step 3 Install the 9800 FlexFit plug and retest If your reading is still not within this range or you have questions call Tyco thermal controls for techni cal support at 800 545 6258 Periodic Inspections Each month e Test the 9800 FlexFit plug as described in Step 6B Periodically Each time you plug in the system and at least once a year do the following e Check the entire Frostex system for signs of damage Inspect any exposed portion of the heating cable for evidence of cuts nicks abrasions gnawing by animals and any other physical damage If there is damage immediately replace the damaged heating cable system and thermal insulation Do not attempt to repair any part of the heating cable system e After a thorough inspection start up the system and test the 9800 FlexFit plug and system as described in Steps 6 and 7 Troubleshooting Problem The red button pops out immediately when the plug is plugged in or the button will not reset What to do A strand of braid may have entered the heating cable guide during Step 3B e Unplug the 9800 FlexFit Plug e Remove the cover the reverse of Step 3D e Unscrew the two screws of the heating cable guide the reverse of Step 3C e Using a flat blade screwdriver gently pry the heating cable guide up u
10. ce with national electrical codes Frostex heating cable may be used on metal or plastic pipes and tubing Do not install on garden hoses or in applications with tubing that is flexed frequently Exposure to temperatures above 150 F 65 C will shorten the life of your Frostex heating cable Before installing the heating cable on hot water pipes set the water heater ther mostat below 150 F 65 C low to medium on most ther mostats Remove any old heating tapes and insulation before you install the Frostex heating cable Do not use more than 50 feet 15 meters of Frostex heat ing cable with each 9800 FlexFit plug Longer lengths will blow the nonreplaceable fuse in the plug The homeowner will need to keep these instructions for future reference It contains important safety warnings and maintenance information If you have any difficulty installing the system please contact Tyco Thermal Controls for information at 800 545 6258 or call a professional service person for help Remove the clear label that covers the test and reset buttons after installation Installation Instructions 1A You will need to know the following Step 1 Determine the length of heat ing cable you need Collect the necessary information Type of pipe plastic or metal Length and diameter of pipe Lowest expected air temperature disregard windchill Number of valves and spigots requires additional heating cable If th
11. curit et une notice d entretien Five Important Safety Warnings Follow all five of these instructions to prevent fire or shock 1 Use the correct heating cable e Use only braided versions of Frostex heating cable e Earlier versions of Frostex heating cable with no braid are not compatible 2 Use the right end seal and plug e Seal the heating cable only with the end seal provided do not use electrical tape e Use the 9800 FlexFit plug contained in this kit It has special safety features e Use the 9800 FlexFit Plug Kit only with Frostex heating cable 3 Do not twist wires together or allow them to touch each other e Do not strip the heating cable If wires touch the nonre placeable fuse will blow and the system will not work 4 Keep the entire Frostex system dry This includes the insulation If the system gets wet pipes may freeze e Use the system only on insulated residential pipes carrying water e Do not use the system on buried pipes e Do not use the system to de ice roofs or gutters e Do not install any part of the heating system where it would be under water e Do not use where water is likely to enter the plug 5 The blue plastic heating cable and the metal braid must not be cut or damaged e Before you begin inspect the pipe File and remove any sharp edges Make sure the heating cable crosses only smooth nonabrasive surfaces e Where the system might be damaged by animals o
12. d prof its or other damages or costs of any kind whatsoever whether direct indirect inci dental or consequential Notwithstanding the foregoing Tyco Thermal Controls shall have no liability whatsoever unless a Buyer promptly notifies Tyco Thermal Controls in writing after discovery of an alleged nonconformity and includes a detailed explanation of the alleged nonconformity b Buyer promptly returns the goods to Tyco Thermal Controls postage prepaid at 300 Constitution Drive Menlo Park California 94025 1164 USA and c Tyco Thermal Controls examination of such goods estab lishes to Tyco Thermal Controls satisfac tion that such alleged nonconformities actually exist and occurred in the cause of proper and normal use and were not caused by accident misuse neglect alter ation or improper installation repair or testing or such other cause outside of the responsibility of Tyco Thermal Controls under this Limited Warranty THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER REPRESENTATIONS WAR RANTIES OR CONDITIONS EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITA TION ANY IMPLIED WARRANTY OF MER CHANTABILITY FITNESS FOR A PARTICU LAR PURPOSE OR NONINFRINGEMENT AND OF ANY OTHER OBLIGATION OR LIA BILITY ON THE PART OF TYCO THERMAL CONTROLS WHETHER BY STATUTE CONTRACT STRICT LIABILITY TORT OR OTHERWISE If the goods are a consumer product in buyer s jurisdiction the above exclusion or limitation of incidental
13. double it back along the pipe where the insulation will completely cover it as shown in Figure 6 Using 9610 application tape or equivalent tape the end seal to the pipe as shown in Figures 1 2 and 6 Outlet cover T End seal 9800 i FlexFit d ae plug Drip loop vi Thermal insulation Figure 6 Multiple run installation Important In a crock or standpipe run the Frostex heating cable down and back up the pipe as shown in Figure 6 so that the end seal is well above the ground level and will not be sitting in water 7 RQ Step 5 ON Install the insulation Thermal insulation must be used It protects the Frostex heat ing cable from damage and helps keep the pipes from freezing Before you insulate be sure the Frostex heating cable is undamaged no nicks or cuts and the braid is intact Replace the heating cable if necessary 5A Cover the system with the insulation Cover the pipe heating cable connections valves and spigots with clean dry waterproof fire retardant thermal insulation such as closed cell foam insulation as shown in Figure 7 The insulation must be at least as thick as selected in Table 1 or 2 Secure the 9800 FlexFit plug to the insulation with tape or plastic cable ties being careful not to cover the light or test buttons
14. ere is a crock typically used for manufactured housing applications 1B Determine the amount of Frostex heating cable you will need How to use the tables e Decide on the lowest temperature you can expect in your area down to 40 F 40 C e Measure the diameter of your pipe in inches e Using Table 1 or 2 depending on pipe material determine how many straight runs of Frostex heating cable required to protect the pipe One run is equal to the length of the pipe To minimize the amount of heating cable required select the optimal insulation thickness from Table 1 or Table 2 Cable Length Selection Tables Table 1 Metal Pipe Number of heating cable runs required Metal Pipe Lowest Expected Temperature Insulation Pipe Size 20 F 0 F 20 F 40 F Thickness 10 C 20 C 30 C 40 C 1 2 1 2 1 1 2 2 3 4 1 1 2 2 1 1 2 2 2 11 4 1 2 2 3 11 2 1 2 3 3 3 4 1 2 1 1 1 2 3 4 1 1 2 2 1 1 1 2 2 11 4 1 2 2 2 11 2 1 2 2 3 1 3 4 1 1 1 2 T 1 1 2 2 11 4 1 1 2 2 11 2 1 1 2 2 2 1 2 2 2 11 2 3 4 1 1 1 1 1 1 1 1 1 11 4 1 1 1 1 11 2 1 1 1 2 Pa 1 1 2 2 Table 2 Plastic Pipe Number of heating cable runs required Plastic Pipe Lowest Expected Temperature Insulation Pipe Size 20 F 0 F 20 F 40 F Thickness 10 C 20 C 30 C 40 C 1 2 1 2 2 2
15. ever the light does not confirm that the heating cable is properly connected See Step 7 Test the System 6B Test the plug e Press the white test button The red reset button should pop out from the surface of the plug and the signal light should go out e When the red reset button pops out push it in to restore power and proceed to Step 7 If the red reset button fails to pop out skip to Troubleshooting If the red reset button pops out immediately but cannot be reset skip to Troubleshooting If the signal light does not light skip to Troubleshooting Step 7 Test the system Test the system using one of the two following procedures 7A Test the water temperature After plugging in the system wait about an hour Turn on a water tap on the Frostex protected pipe and test the tempera ture of the water It should feel warm almost immediately because the water heated by the Frostex heating cable will be briefly running through the pipe If the water is warm you have completed the installation If the water is not warm skip to Troubleshooting 7B Test the heating cable s resistance It is possible to test the resistance of Frostex heating cable using a multimeter Follow these steps e Be sure the 9800 FlexFit plug is unplugged e Push in the red reset button on the plug e Connect the two lead wires on the meter to the two flat prongs on the plug The meter reading should be
16. n 50 feet 15 meters of heating cable per plug If the total calculated length exceeds 50 feet 15 meters you will need additional 9800 FlexFit plugs and outlets Longer circuit lengths will blow the nonreplaceable fuse in the 9800 FlexFit plug If you require more than 50 feet per length 15 meters call Tyco Thermal Controls for informa tion on other products Note The end seal can only be used once so do not install it until step 2D Heating Cable Construction Clear plastic wrap Black core bus wires inside Braid Blue jacket 2A Prepare the heating cable 2B Push the braid back Cleanly cut off one end of the heating cable 2C Remove the plastic wrap Push the braid back 1 25 mm from heating cable end 2D Install the end seal Cut and remove the clear plastic wrap Do not cut into the blue jacket 2E Secure the braid Slide the braid up against the end seal and wrap it securely with a 4 10 cm strip of glass fiber or vinyl tape Firmly push the end seal at least 3 4 2 cm onto the heating cable Some gel may ooze out 0 1 lililii 0 10 20 mm hinhin ul in A Step 3 Install the 9800 FlexFit plug Reset button Test button A D A Ground fault E unit SL E A Indicator light Cable guide Ground contact Se
17. ntil the heating cable can be removed e Reinstall the screws completely into the heating cable guide before re attaching e Repeat installation steps 3A 3D ensuring no braid strands enter the heating cable guide during Step 3B e Repeat Step 6 Start up the system Note If the 9800 FlexFit Plug red test button continues to pop out your system is damaged and must be replaced Problem The signal light does not light up What to do Check to be sure the outlet has power If you are not certain how to do this call a professional service person If the outlet has no power correct the problem then follow Step 6 Start up the system If the outlet has power but the signal light still does not light up after you conduct the test described in Step 6B Test the plug the internal nonreplaceable fuse is blown This means the Frostex system is damaged and must be replaced Problem The 9800 FlexFit plug does not trip red button does not pop out What to do Check to be sure the outlet has power If you are not certain how to do this call a professional service person If the outlet has no power correct the problem then follow the instructions in Steps 6 and 7 If the outlet has power but the 9800 FlexFit plug still fails to trip the Frostex system is damaged and must be replaced Problem The heating cable fails to warm up or water is not warm after testing the system What to do The heating cable may n
18. ot be fully inserted into the heating cable guide or the guide may not be screwed down com pletely e Unplug the 9800 FlexFit Plug e Remove the cover the reverse of Step 3D e Unscrew the two screws of the heating cable guide the reverse of Step 3C e Using a flat blade screwdriver gently pry the heating cable guide up until the heating cable can be removed e Reinstall the screws completely into the heating cable guide before re attaching e Repeat installation steps 3A 3D ensuring no braid strands enter the heating cable guide during Step 3B e Repeat Step 6 Start up the system Limited Warranty Tyco Thermal Controls warrants all Frostex self regulating heating cables and compo nents against faulty workmanship and use of defective materials for two 2 years from the date of purchase This warranty can be amended only by a written instru ment signed by a duly authorized officer of Tyco Thermal Controls Buyer s exclusive remedy under this warranty shall be to have Tyco Thermal Controls within a rea sonable time repair such goods or supply replacement goods or credit Buyer s account for such goods and accept their return whichever Tyco Thermal Controls may elect at its sole discretion Tyco Thermal Controls shall in no event be liable for the cost of removal or installation for loss or damage to or loss of use of facili ties or other property loss of revenue loss of use of revenue loss of anticipate
19. r objects protect the complete system with a solid cover such as sheet metal or additional pipe insulation e Do not use any wire or clamps to attach the heating cable to the pipe Instead use the Frostex 9610 applica tion tape or equivalent 1 2 1 13 mm 25 mm tape or plastic cable ties e Inspect the heating cable periodically for damage If you discover broken braid or other damage immediately dis connect the system and replace the heating cable Do not splice or repair a damaged heating cable You must replace any damaged insulation or waterproof covering 6 Do not install Frostex heating cable close to flammable materials liquids or fumes Use only 1 2 13 mm or thicker fire retardant and waterproof pipe insulation in accordance with Table 1 or 2 Cinq avertissements de s curit importants Veuillez suivre les cinq directives suivantes afin de pr venir les risques d incendie ou de choc lectrique 1 Utilisez le c ble chauffant ad quat e Employez uniquement les versions tress es des c bles chauffants Frostex e Les versions ant rieures des c bles chauffants Frostex sans tresses ne sont pas compatibles 2 Utilisez la fiche et obturateur appropri s e Ftanch ifiez le c ble chauffant a l aide de l obturateur fourni seulement n utilisez pas de ruban isolant e Utilisez la fiche 9800 FlexFit incluse dans ce kit elle est dot e de caract ristiques de s curit sp ciales e U
20. tilisez le kit 9800 FlexFit uniquement avec le c ble chauffant Frostex 3 Ne torsadez pas les fils ensemble ni ne leur per mettez de se toucher e Ne d nudez pas le cable chauffant Si des fils se touchent le fusible non rempla able sautera et le sys t me ne fonctionnera plus 4 Gardez le syst me Frostex au sec en entier y compris l isolant Les tuyaux risquent de geler si de l humidit p n tre dans le syst me e Utilisez le syst me uniquement sur des tuyaux r siden tiels et isol s transportant de l eau e N utilisez pas le syst me sur des tuyaux souterrains e N utilisez pas le syst me pour d givrer des toits ou des goutti res e N installez aucun l ment du syst me de chauffage en zones immerg es e N utilisez le syst me pas dans des zones o de l eau ris querait de p n trer dans la fiche 5 Le c ble chauffant en plastique bleu et la tresse m tallique ne doivent pas tre coup s ou endom mag s e Avant de d buter l installation inspectez le tuyau limez et enlevez les rebords ac r s Le c ble ne doit croiser que des surfaces lisses et non abrasives e Si le syst me risque d tre endommag par des animaux ou des objets prot gez le en le recouvrant en entier d un rev tement solide comme une t le ou de l isolant tuyau suppl mentaire e Nutilisez pas de fils ou de griffes pour fixer le c ble chauf fant sur le tuyau Utilisez plut t le ruban de fixation Frostex
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