CLEAR POWER CPPH002 6ft Indoor Water Pipe Heating Cable Instructions

: May 15, 2024
: CLEAR POWER

CLEAR POWER CPPH002 6ft Indoor Water Pipe Heating Cable Instructions

How Heating Systems Work

The Problem
Thermal insulation alone will not prevent water pipes from freezing. For example, a %in/1.91cm pipe having 1in/25mm thick insulation will
freeze solid in only 13 hours when the ambient temperature is at 14°F/-10°C. Frozen water pipes can burst, causing loss of supply, flooding and extensive damage.

The Solution

This Pipe Freeze Protection Cable (pipe heating cable) replaces heat lost through the thermal insulation layer. Replacing the lost heat allows the pipe and water inside the pipe to be kept at a constant temperature. With a built- in bi-metallic thermal cutoff inside the
black cap, the heating cable is operating only when the ambient temperature is 40°F/4°C or less, preventing unnecessary waste in electricity, while keeping pipes protected all winter long. Plus, the indicator light illuminates to show power is being
supplied to the cable even when not heating; this allows you to check the status of the pipe cable at any time, even when it is not cold enough to trigger the thermal cutoff.

Water Pipe Freeze Protection Application

When installed correctly, the heating cable will be applied straight along the pipe with a single layer of fiberglass insulation to protectpipes up to 1.5in/3.8cm in diameter down to -40°F/-40°C.
This Pipe Freeze Protection Cable is approved and qualified for the applications of freeze protection of insulated metallic or plastic general water piping at the generally accepted maintenance temperature of 40°F/4°C.

Warnings:

(This symbol identifies particularly important safety warnings that must be followed. Failure to do so could cause overheating and result in serious fire hazard or electrical shock)
Do not use heating cable on pipes heated above 150°F/65°C (such as steam lines).
Never install heating cable in walls, floors or ceilings.
Never install heating cable on a plastic pipe unless the pipe is filled with water at all times.
Do not use on waste lines, drain lines, fuel lines or hoses.
Do not use pipe-heating cable for roof and gutter deicing applications.

Materials Required

Storage

These Pipe Freeze Protection Cables should be stored in a clean, dry area when not in use. The storage temperature range is 0°F to 140°F (-18°C to 60°C).

Before Installation

If installing on a new construction, the piping, insulation, electrical and instrument groups need to be coordinated before the installatio of any electric heat tracing system. Installation should begin only after the majority of mechanical construction is complete. Make sure
all mechanical testing (i.e. hydrostatic testing/purging) is complete and the system has been cleared.
If the heating cable is stiff (due to ambient temperatures being below 40°F/4°C), first uncoil the cable completely and power it with a 120V outlet until it is warm and pliable, then unplug the cable and begin installation.

Warning:

Improper installation, use and/or maintenance of heating cable can cause fire, electric shock and/or freezing of pipe. Pipe heating cables must be installed in compliance with the National Electrical Code and Canadian Electrical Code. Ground fault
protection (GFCI) is required. If an outlet does not exist close enough to the pipe to plug in the cable, have a licensed electrician install one for you.
For Indoor Use Only.
Do not use with an extension cord.
Do not connect power to the heating cable while it is coiled. Do not install damaged heating cable.
Minimum pipe length is 6ft/1.82m.
Never alter this heating cable in any way. If made shorter, it will overheat. Once cut, the heating cable cannot be repaired.
Do not install the same cable on more than one pipe. Never allow the heating cable to touch, cross or overlap itself at any point.
Disconnect the pipe heating cable from its power source during installation.
While energizing the heating system circuit, regardless of normal operation, installation period or maintenance, always keep the heating section of the heating cable system away from combustible surfaces at least 1in/2.5cm.

Caution:

Do not install the Pipe Freeze Protection Cable when the ambient temperature is colder than the minimum installationtemperature of 32°F/0°C.
These instructions must be saved and made available to the owner and transferred to future owners.
If after reading the following instructions, you still have questions regarding installation or operation of this heating cable, contacttechnical support at info@clearpowerinnovations.com.
Selecting the Proper Heating Cable
Use the following two tables to select the proper heating cable.

Example:

1 (@means you need one CPPHO03
2(® means you need two CPPH00214 + 1(® means you need one CPPH003 + one CPPHO02
This design guide is based on the generally accepted maintenance temperature of 40°F/4°C for freeze protection.
This design guide is also based on ¥ in fiberglass insulation. Closed-cell flexible foam insulation may also be used as long as it israted to withstand temperatures up to 175°F/79.4°C.
The pipe heating cables should be installed beginning with the end opposite the plug. When using 2 pipe heating cables, place onopposite sides of the pipe and do not allow them to cross over or touch. These pipe heating cables do not join together and cannot be changed.

Installation Instructions

Pre-Installation Check

For Commercial Applications, we recommend performing a megohmmeter test with a 500 Vdc megohmmeter to find the electricalinsulation resistance. Perform the test between the heating cable bus wires and the grounding path (heating cable metallic braid).
Minimum resistance should be 20 megohms. Readings below 20 megohms may mean the electrical insulation has been damaged.
Replace the heating cable if readings are below 20 megohms. Once installation is completed, perform this test again to ensure nodamage was sustained during installation. Double check the circuit intended to be used for the heating cable. Make sure the voltage ratings and amperage ratings are highenough to support the heating cable selected.
Walk the pipe system and plan the routing of the heating cable on the pipe. Remove any burrs, rough surfaces, or sharp edges atthe same time. Remove dirt, rust and scale with a wire brush or file. Remove oil and grease film with a suitable solvent leaving nothing flammable behind..
Laying out the Heating Cable Standard lengths: to protect a pipe withstandard length of cable, attach as shownin Fig. 1.

Apply the cable straight along the bottomof horizontal pipe or the “weather side” of vertical pipe.

Non-standard lengths: to protect a pipe – with other than one standard length of Fig.2 heating cable, apply two separate cables on opposite sides of the pipe, starting
from opposite ends (Fig. 2). The overrun should not exceed 4 feet.

Warning: Notto scale

Avoid pulling and jerking the cable and do not install against sharp edges. « Do not kink or crush the cable, including walking on it or running it over with equipment

Attachment

Once the heating cable has been run for the entire section, begin fastening it with application tape or good quality fiberglass tape (fiberglass tape or other tape with a temperature rating higher than 175°F/79.4°C). In order to keep the thermostat and the entire length
of heating cable tightly in contact with the pipe, circumferential bands of tape should be installed at approximately 6in/15¢cm intervals.
The thermostat should be placed on the coldest end of the pipe. Hand-tightened plastic wire ties, which have a temperature rating higher than 175°F/79.4°C may also be used to fasten the cable to pipes. For a plastic pipe system, wrapping the plastic pipe with aluminum foil before installing the heating cable will improve heat transfer and provide more even heat distribution.

Warning:

Substandard adhesive tapes may allow the cable to move at normal cable operating temperatures and could result in overheating,fire, or electrical shock.
Do not use metal attachments such as pipe straps or tie wire to attach the heater cable, as these may damage the heating cable and cause electrical arcing o fire.

Bending, Crossing & Cutting the Heating

Cable The bending radius should be minimum .3in/8mm. Do not bend the heating cable along a flat plane. Sharp bends can damage the heating element.

Warning:

Pipe Freeze Protection cable is not a paralle! circuit cable. It cannot be cut to the desired length. Once cut, the heating cable cannot be repaired. Also, the heating cable should never be overlapped.

Thermal insulation

After installing the Pipe Freeze Protection Fig. 3
Cable, visually inspect the cable to ensure itis properly installed and there are no signs of damage. Use a maximum of 1/2 in fiberglass (including pre- formed fiberglass) insulation over the heating cable and the thermostat to keep the cable working more
efficiently. In order to protect the insulation from moisture and physical damage, and Not to scale to ensure the proper performance of the heating cable, a protective barrier (with an additional waterproof barrier over- wrapped in the opposite direction)
should be installed on the heater-traced system. Apply “Electric Traced” (not included) labels to the insulation weather barrier at intervals of 10ft/3m along the pipe as a warning to maintenance personnel.

Warning: Never use more than %2 in of fiberglass insulation or other non-fire- retardant insulation material with the
Freeze Protection Cable. The overall ‘R’ value of the fiberglass insulation, protective barrier and waterproof barrier should not be greater than 2.0. Over insulation can cause the heating cable to overheat and cause fire hazard or electric shock.

Electrical Requirements

Caution: A ground fault protection device must be used with this heating device.

This cable must be plugged into a 120 volt A/C outlet that:
|s a circuit with an appropriate current (amp/amperage) rating to support the selected heating cable.
The cable should not be more than 80% of the circuit’s total amp rating. (A circuit for a cable drawing 10.00 amps should be ratedat 12.50 amps minimum).
We do not recommend using a circuit rated above 20 amps.
Is protected from weather.
The Indicator Light will illuminate on the male plug to let you know the cable is receiving power. This cord will still conduct electricity even if the indicator light burns out.

Testing

For Commercial Applications, we recommend performing a megohmmeter test with a 500 Vdc megohmmeter to find the electrical insulation resistance. Perform the test between the heating cable bus wires and the grounding path (heating cable metallic braid).
Minimum resistance should be 20 megohms. Readings below 20 megohms may mean the electrical insulation has been damaged.
Replace the heating cable if readings are below 20 megohms. Once installation is completed, perform this test again to ensure no damage was sustained during installation.
Itis the installer’s or electrician’s responsibility to perform visual inspections on the Pipe Freeze Protection Cable at the start of and during installation.
Once power is connected, but before putting the system into operation, retrace the cable to look for possible areas susceptible to cutting, tearing o straining the cable and adjust accordingly. Read back through the manual once finished installing to ensure proper
installation has been completed.

Maintenance

Inspect the cable at the beginning of every heating season and monthly during operation. Check for evidence of cutting, tearing or other signs of wear.
Checks should also be done after any maintenance has been performed.
Check the heating cable to verify that the insulation is not wet. Wet sections of pipe can result in cold spots or frozen sections. If the insulation is damp or wet, it should be replaced.
Turn off or disconnect the power when the heating season ends. Reconnect before the next heating season.
Warning: Disconnect the power connection before inspecting or performing any maintenance.

Limited 2 Year Warranty

The Limited 2 Year Warranty (the “Limited Warranty”), subject to all of the provisions and conditions set forth below, gives you specific legal rights, and you may also have other rights that vary from state to state. This Limited Warranty applies only to Prime Wire
& Cable, Inc., a California corporation (“Prime”).

Limited Warranty

Prime warrants to the original consumer purchaser, and solely for the benefit of such original consumer purchaser (the “Consumer”), that the Prime Pipe Freeze Protection Cable is free of defects in materials and workmanship for up to 2 years after purchase, only if
such Consumer properly installs and uses the Prime Pipe Freeze Protection Cable in accordance with the installation and operating instructions that accompany the cables. Please read the instructions carefully. This warranty does not cover any damages due to accident, misuse, abuse or negligence. Prime will correct defects in its Pipe Freeze Protection Cable by repair or replacement, at its option, if, within thirty (30) days of the discovery of the defect in materials and workmanship, the Pipe Freeze Protection Cable is returned pre-paid, with proof of purchase by the Consumer to: Attention: Quality Assurance Manager, Prime Wire & Cable, Inc., 11701 6th St. Rancho Cucamonga, CA 91765, and if, after analysis and review by Prime’s QC Department, the Pipe Freeze
Protection Cable is deemed covered under the Limited Warranty, as outlined above.

Prime assumes no liability for any incidental or consequential damages, including loss of or damage to property, lost sales or profits or damages resulting from delays or failure to perform under this Limited Warranty.
Defects In Materials Or Workmanship Itis our experience that a product that fails prematurely due to a manufacturing defect in materials or workmanship will generally do so very early in the product’s life cycle, often the first or second time the product is used. When returned for inspection, these products are generally found to still be in like-new condition and show very little signs of use. It is uncommon for a product that was manufactured with a defect to survive under normal use for any extended period of time. Products that are returned for warranty inspection after months or years of continuous reliable service are rarely found to be defective. Most often, a demand for replacement (other than in cases of abuse) is the result of normal wear and tear issues, which are not considered to be a defect in materials or workmanship.