Frostfree Brochure

8/10/2019 Frostfree Brochure

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Dont return home to1000s of water damage!

Stop pipes bursting atcold temperatures!

Frost Free includes a thermostatic control andself-regulating cable to use minimum energy!

Use a Frost Free system to regulate the temperature ofyour pipes, keeping them above the point of freezing.

is brochure includes information about our Frost Free system

as well as complete installation instructions.


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Frost Free regulates the temperatureof your water pipes to keep themabove the point of freezing!Dont return home to 1000s of water damage!

Why chooseFrost Free?

15w Self-regulating heating cableautomatically reduces power consumption astemperature increases and it won damage ifcrossed over itself.

Frost Free Stat keeps pipes just abovefreezing for maximum economy.

If temperatures drop below zeroand water beginsto freeze within the pipes in your home theexpansion during freezing can cause the pipesto fracture and bursteven though your pipesare insulated, frost can still penetrate into thewaterpipe (see the pictures on the followingpage).

When the water thaws it willpour out of the

pipe until it is noticed and the water is shut off.Tis will cause visible and hidden damageto thestructure of your house as well as damage to your

personal posessionsand untold disruption.

A Frost Free system can prevent thisby regulatingthe temperature of your pipes. It will keep yourwater pipes above freezing point and ensurethat you dont return home to water damaged

walls, ceilings, furniture or personal (and oftenirreplaceable) posessions.

Te Frost Free Stat detects when the pipetemperature drops to 4C and switches on theheating cable. When the pipe temerature reaches8C, the stat switches the power off. In this way,energy costs are kept to an absolute minimum.


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Testimonial from a victim offrozen pipesMy World Ended in 2011!

Real Lifeestimonial

o me this is a horror story of biblical proportions!

Tis is the day that my world was turned upsidedown, my stomach churned and my heart almoststopped.

Te bungalow had plenty of insulation sorry, Ithought that I had plenty of insulation and wehad only been away for a week to visit relativesover the festive season. Te boiler had a frost stat;so why should there have been a problem?

Continuous really cold weather had penetrated thepipe insulation in the loft and I hadnt switched thewater off! Te boiler stopped due to the condensatepipe freezing.

You can see the result. I very nearly died when Isaw the mayhem when we came back.

Months of upset - 20,000 from the insurance

company and over 2000 from my savings toreplace uninsured items you can see what it waslike.

All this upset for the sake of 118 for a Frost Freekit for the loft, a 84 for a kit for the boiler and acouple of hours for an Electrician. Its done nowand I never want to go through that again!

In my defence, I didnt know this type ofproduct was available.

Its also so easy to install!


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Frost Free 15w/m race Heating Cable (FFHC) Cable structure:

1. Copper multi-strand wire2. Conductive (restistive) heating matrix3. Layer polyolefin insulation,4. inned copper shield5. Fluorine plastic sheathStandard colours: black, grey. Maximum permissible surface temperature 70C 5C.50m maximum run.

Self-Regulating:

As the cable heats up, it cleverly reduces its powerconsumption generally or locally - so if its crossedover, the cable will automatically compensate for theincrease in temperature where its crossed over - to

prevent overheating.

Termostatic Control:

While the Frost Free race Heating Cable can be manuallyswitched on when the weather is cold - the real secret is thisclever little device. Te Frost Free Stat is situated where it canbe easily seen for monitoring and the probe is fixed to the side

of the pipe to be protected - under the insulation. Te FrostFree Stat will only switch the power on when the temperaturefalls to 4C and off again at 8C - so power is used only when itsabsolutely necessary to keep the pipe above freezing.

ermination and Connection Kit:

Easy to make connections and terminations- follow the simpleinstructions for a really proffessional job.Includes push-in connector, glue-lined heat-shrink and rapstraps, sufficient foraprox. 30m of cable. Add 6cm to the actual heated length of cable to allow for endconnections.

5 4 3 2 1

BasicFacts

20w

15w

10w

OutputWatts

Degrees Centigrade

5w

0w

0c 10c 20c 30c 40c 50c


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HS Probe

Each Frost Free statcan handle 60m ofFrost Free Cable.

Add 6cm to the length of heating cablerequired to allow for end connections.

Te probe end from the Frost Free stat shouldbe securely strapped to the side of the cold waterpipe away from the cable and again, this should beinside the pipe insulation. Te standard probe hasa range of -5C to +65C so it will have no problemworking when fixed to the side of a cold pipe withFrost Free cable and inside the insulation - it willalways be within its parameters and is suitable fornormal use.

Frost Free - is used to protect domestic and commercial pipeworkfrom the ravages of frost. Te cable is intended to fit inside thepipe lagging and be fixed to the pipe. Te self-regulating cablegives a maximum output of 15w/m. Fix the cable to the pipeworkwith the Rapstraps provided at the rate of 3/m - each Rapstrapcan be cut and reused. Te cable is best situated along the bottomof the pipe where the pipe is suspended, but in many domesticinstallations, pipe-clips are in the way, so it is much easier to fit thecable along the top of the pipe. Te cable can be fixed to the side ofinline stoptaps.

Frost Free cable is self regulating which means that it

automatically reduces its power consumption as the cable heatsup. it is always better not to cross over or coil-up the cable but itwill not be damaged if this is the case. Te cables maximum heatresistance is 75C so thought should be given to protection of hotpipes. If you have a situation where a cold pipe is at risk of freezingbut there is also a hot water pipe in the vicinity that may also bedamaged, the control probe is on the cold pipe so the heaters areswitched on and the hot pipe is still working. Te heat from thehot pipe and the cable being switched on can damage the cable.Te correct installation here is to use a second Frost Free stat forthe hot water pipe and use the optional Frost Free HS Probe (-20Cto +100C). Tis will only allow the heater on the hot pipe to workwhen the hot water system isnot working.

If you need further adviceplease contact 0113 2577 588.

In this instance 3 runsof Frost Free cable areconnected.

Use a connector as required for eachrun and the connectors can be linkedtogether by a ring main if required.

Te stat will switch on the Frost Free cable when thetemperature drops to 4C and switch off again at 8C such thatthe pipe temperature is maintained above freezing. In this waythe pipes are protected from frost at the absolute minimum

cost of electricity. Te stat is best situated below the ceilingsay, if the pipes are in the loft, where it can be seen by thehouseholder.

When using on a boiler condensate pipe, the drain pipe should be insulatedincluding the section that exits through the brickwork. Strap the Frost Freecable to the full length of the bottom of the pipe or spiral-wind the cablearound the pipe for larger diameter pipes. Te critical area is where the pipeis outside the building, so make sure this is well protected. Use the optionalHS Probe and fix the probe end so it is able to pick up the pipe temperatureat the end of the condensate pipe outside of the building. Obviously keep itaway from the heating cable so it doesnt get a false reading. (Do not use thestandard probe for this purpose as it will not activate the heating below -5C).

Frost Free, Bramley House, Bath Lane, Bramley, Leeds. LS13 3BB.el: 0113 2577 588. Fax: 0113 236 2399.


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Connection & TerminationInstructionsFrost Free 15w/metre race Heating Cable (HC) is ideally suited for theprevention of domestic and commercial water-pipes from freezing duringperiods of very cold weather.

Te cable would normally be strapped to the underside of the water pipe andinside the pipe lagging. It can be crossed over itself without causing problemsand can therefore be wound around outdoor taps etc and it is a good idea to readour Basic Installation sheet to determine what length(s) of cable is required.

Frost Free HC is available from your dealer cut to any length as required andthe following simple electrical connection and end termination will need to becarried out by a qualified electrician. Specified lengths of Frost Free HC can beordered by your dealer for next-day delivery with the connection/termination

already made.

Frost Free HC is top of the range self-regulating heating cable and consists of2 bus-wires with a special heating matrix between them. Te bus-wires do notheat up and the heating matrix cleverly changes its resistance as it gets warmerto reduce its power consumption - this is why the cable will not damage ifcrossed over itself.

Standard Pipe Heating KitSuitable for boiler condensate pipe and general pipe frost protection. Manuallyactivated but can be used in conjunction with Frost-Free Stat. Generally 1 - 10metre kits available ex stock or any length made to measure - ask your dealer forprices and delivery. Order before 2pm for overnight Carrier (6.50 extra)

Pack Contents:- 15w/m Self Regulating Heating Cable.- 2m connection cable.

- Push in connector attached.- Rapstraps.- Full Instructions.

Connection &Termination


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01. You will need simple tools and the

blue connector.

03. Carefully cut the outer insulation

down the middle and remove thesheath to the 8cm mark.

02. Te cable needs to fit in the smaller

female connector. Start by marking aline 8cm from the end.

04. Tis will expose the earth sheath. 06. Perpared earth-sheath.05. Cut earth-sheath with scissors.

07. wist (dont pull) the earth sheathinto a tail and mark 5cm from the endof the inner core insulation.

08. Carefully remove the innerinsulation up to the 5cm line.

08. Carefully remove the innerinsulation up to the 5cm line.

ConnectionInstructions


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10. Cut down inside of each bus-wire to

5cm mark.

12. Slide on 4cmx5mm dia glue-lined

heat-shrink and set with heat gun.

11. Leave the bus wires evenly covered

with heating matrix. Remove the centresection of matrix. Expose the ends ofthe bus-wires for mains connection.

13. Cut earth-tail same length as bus-wires. Slide earth-sheath over earth tailand set with heat-gun.

15. Slide outer heat-shrink down toconnector as far as it will go. Set theheat-shrink - be careful not to burn theconnector.

14. Slide 10cm x 1.5cm dia. glue-linedheat shrink tube over cable and connectbus-wires (live and neutral) and earthto connector.

16. Squeeze to waist the heat shrink sothat it will fit the cable grip.

18. When cool take off the outer casingand check all is OK before refixing.(Note - heat from cable starts approx1.5cm from connector.)

17. Fix the outer casing and cable-gripwhile the heat-shrink tube is still softPower connection complete!

ConnectionInstructions

Te glue-lined heat shrink tube willshrink to 1/4 of its original diameter.When the glue lining sets, it will form

a perminent and water-tight seal.Now that the centre part of theheating matrix has been removed

and each bus-wire insulated, currentcannot flow so this section cannot heatup. A really proffessional result!


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01. For the End ermination measure

8cm from the end.

03. Pull the earth sheath back and mark

a line 4cm from the end.

02. Remove outer sheath as before to

expose the earth braiding.

04. Cut off 4cm making sure the cut isclean and the 2 bus wires are appart.(Te bus wires must be in their normallocations well appart.)

06. It should look like this.05. Use the 5cm x 1cm dia glue-lined heatshrink. Set the heat shrink with heat-gunand squeeze the end together with pliers.Make sure glue squeezes out of the end.

07. ease the earth-sheath back to theend and bend surplus back on its self.

08. Now use the 10cm x 1.5cm diameterglue-lined heat-shrink, set with heat-gunand squeeze the end together with pliers.Ensure that glue shows at the end.

TerminationInstructions

Job done, the cable is now readyfor installation.

Please follow the Frost-Free cableinstallation instructions.

Should you have any difficulties,please contact technical help on0113 2577 588.


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Cable & ProbeInstallation

Cable InstallationFrost Free race Heating Cable has an output of 15w/metrerun and is used for frost prevention where internal or externalpipework is at risk of freezing during cold weather spells.

Frost Free race Heating Cable may beused on both copper and plastic waterpipes up to 75mm diameter dependingupon insulation thickness, or may bespirally wound around larger diameterpipes.

Te typical heat loss chart shows the watts/metre of pipe run lost, for atemperature differential of 20C: -for example, at -20c the heat loss on a 22mm pipe with 10mm insulation will be

less than 10w/m to maintain a temperature of 0C.Te point is that the Frost Free cable needs to replace the heat loss, which it caneasily do.

1. Remove existing insulation if any.2. Measure the length of pipe to be protected and add 6cm to allow for connection and termination.3. 3. Do not exceed 50 meter single runs. Lengths of cable for multiple pipe runs adding

up to 60 metres can slave off 1 Frost Free Stat. e 15w/m cable at 0.065amps/m fornormal running has a momentary start-up load of 0.24amps/m.

Please size fuse, contactor and RCD accordingly to prevent tripping.4. Use a Frost Free connection and termination kit to prepare the cable for connection.5. Fix the cable to the underside of the pipe where possible and use the Rapstraps

provided or cloth tape to secure to the pipe. (Dont use plastic cable ties as these haveno give in them and may damage the cable).

6. Fix the probe to the pipe with cloth tape at least 90 degrees and ideally 180 degreesaround the pipe from the cable. (See the Frost Free Stat Instructions for moreinformation). You should ensure that the Frost Free race Heating Cable can not sliparound the pipe and touch the probe.

7. Insulate the pipe and ensure that the pipe, Frost Free cable and probe end are completely covered and not left exposed to the atmosphere.8. Make the necessary connections to the frost free stat and test. (See the Frost Free Stat

Instructions for more information).9. est the installation.

15

10

HeatLossW/M

Pipe Diameter - mm

10mm Insulation

20mm Insulation

30mm Insulation5

15 22 28 35 42 54


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Note: Frost Free Heating Cable has a maximum recommended surface exposuretemperature of 65C and can be fixed to normally hot pipes that do not exceed thistemperature. Te cable will be damaged if it is powered up while the pipe is still carryingheated water. For pipes normally hotter than 65C there is a higher specification butmore expensive Frost Free HS cable available that can withstand 100C. Also the FrostFree HS probe should be used for protecting normally hot pipes. (Insulated hot pipesnormally will not require protecting as they should be protected by the boiler frost-stat,but there are instances where buildings are left unattended during winter periods wherenormally hot pipes are left cold for long periods and are consequently at risk during cold

weather).

Probe InstallationTe HS Probe should be used in conditions where there is either the possibilityof moisture ingress, e.g., outdoors, or where it will be attached to a pipe that hasa normal running temperature between 65C and 100C.Always use the HS Probe on outdoor installations andfix the probe end to the pipe with cloth tape. Boththe heating cable and the probe end should alwaysbe inside the pipe insulation. (Te probe cable canbe extended with with standard lighting flex to amaximum of 8 metres.

Also in this kit is a length of large diameter glue-linedheat-shrink for moisture-proofing the blue cable connector if required - slidethe heat-shrink over the blue connector and set the material with a heat gun.You will need to sweeze together the ends of the heat-shrink with pliers - to seal

arround the various cable configurations - ensure the glue shows at the ends.

(Te standard probe is only suitable for indoor conditions where the pipe is maximum65C).

Stat InstallationWhen the mains power is switched on, the green power light showson the unit. Te middle red active light will show when the system

is switched on by the temperature falling to 4 centigrade. Te blueerror light will show if there is a problem with the probe. Pressand hold down the test button for a short while, the system will goactive and the red light will be on. (Continued overleaf)

2 metre HS Probe(-10C to 110C)

Probe & StatInstallation


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If the button is held down the cable will heat up and can be feltas confirmation that the system is functioning properly.

Te Frost Free stat is opened as shown, and you will find thesimple wiring diagram both on the back of and inside the unit.

Te Frost Free stat is intended to be located indoors where it is visible and can beperiodically monitored by the householder or user of the building. For example,

if the water pipes are in the attic, then just below the ceiling on the landing isideal. For boiler condensate pipe protection, the stat will be located by the side ofthe boiler.

Tere is a probe inside the box with 4 metres of wire connected to it. Te wirecan be shortened, or lengthened with twin lighting flex as required. Te standardprobe is used in internal non-hostile environments and has an operating rangeof 5C to 65C.

You should use the optional HS Probe (-10C to 100C) when attached to a hot

water pipe or for a boiler condensate pipe where the probe end is outdoors. Eventhough the probe is between pipe and insulation, the HS probe is waterproof andwill not be affected if moisture gets under the insulation when outdoors.

Te end of the probe should be fixed to the pipe, minimum 90 degrees andideally 180 degrees around the circumference of the pipe from the Frost FreeHC. Ensure that the probe wire is not run along the heating cable and we wouldrecommend that the probe connection wire is taken through the insulationadjacent to where the probe end is connected to the pipe.

Consideration should be given to the location of the probe and it should beconnected to the water pipe where it is likely to be the coldest locale. Forexample, a water pipe fixed to the rafters is going to get colder than water pipesrunning along the ceiling joists under glass fibre insulation so fix the probe tothe pipe fixed to the rafters. Other Frost Free protected pipes in the locale thatare slaving off this probe will be thus protected.

Do not leave the Frost Free race Heating Cable or the probe end exposed to theatmosphere - the water pipe run should always be insulated.

Te power supply to the system should be connected by a qualified electrician anbe on an RCD protected circuit via a suitably fused twin pole isolator switch.

StatInstallation

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Frostfree Brochure