Tubing Bundles

This section will help you select and design a complete tubing bundle system using electric
heat tracing. For steam-traced or untraced tubing bundles, please contact your Tyco Thermal
Controls representative or visit our Web site at www.tycothermal.com.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Approvals and Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tubing Bundle Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Product Selection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Introduction
Achieve a total solution for heat tracing
instrument and small-diameter process
lines with Raychem tubing bundles.

Tyco Thermal Controls provides a total solution for heat tracing instrument and smalldiameter process lines. Raychem brand tubing bundles (RTB) are a pretraced and
preinsulated tubing alternative to field tracing and insulating. RTB systems combine
Raychem electric or steam heat tracing with tubing and insulation for a single bundle that can
be cut to length in the field.
Typical RTB applications include:

H56886

8/07

Impulse lines to flow transmitters, pressure transmitters, level transmitters, and pressure switches

Sample lines to analyzers and chromatographs

Process lines for steam supply, condensate return, water purge, chemical feed, and air
lines

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TUBING BUNDLES

System Overview
An RTB system consists of pretraced and preinsulated tubing bundles. Each tubing bundle
can be configured as single- or dual-tube, as shown below, and can be constructed in various
sizes and materials to meet your small-diameter process needs.
Rugged outer jacket

Heating cable

Single-tube

Dual-tube
Nonhygroscopic
fibrous insulation

Fig. 1 Tubing bundles, single- and dual-tube construction

Raychem tubing bundles simplify design

and significantly reduce installation time.

Raychem tubing bundles (RTB) are pre-engineered to ensure consistent and repeatable performance for maintenance-free operation. Compared to field fabrication, they simplify design
and significantly reduce installation time. The RTBs unique parallel construction allows for a
tight bending radius (down to 8 inch) and eliminates possible tube kinking. Each bundle can
be cut to length in the field and is powered and terminated with simple RTB connection kits.
The insulating material consists of a nonhygroscopic fibrous glass for maximum heat-loss
prevention. Finally, each RTB is encased in a high-performance polyurethane outer jacket that
provides superior UV resistance and installation capability to 40C (40F).
Contact your Tyco Thermal Controls representative for design assistance for the following
applications:

The desired maintain temperature range or process tube size does not appear in Table 3

The ambient temperature range is different than 30C to 38C (20F to 100F)

Supply voltages of 208 Vac and 277 Vac are used

Temperature control is critical

Steam heating is required

Approvals and Certifications

Tyco Thermal Controls heating cables
have agency approvals for use in both
nonhazardous and hazardous locations.

The RTB system uses Raychem brand BTV and XTV heating cables that are approved and
certified for use in nonhazardous and hazardous locations by many agencies, including FM
Approvals, CSA International, PTB, Baseefa (2001) Ltd., DNV, and ABS. For more details,
consult the heating cable data sheets included in the Industrial Heating Product and Design
Guide (H56550) and the Technical Databook for Industrial Heat-Tracing Systems (DOC-389).
Data sheets can be found on the Tyco Thermal Controls Web site, www.tycothermal.com.
Data sheets can be found on the Tyco Thermal Controls Web site, www.tycothermal.com.

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Product Selection

Product Selection
Overview
The product selection process involves three basic steps:

1 Gather the necessary information.

Number of process tubes
Process tube size, wall thickness, and material
Desired maintain temperature range
Heating cable service voltage
Process operating temperature
Maximum exposure temperature
Temperature class for applications in hazardous locations

2 Select the tube type.

3 Select the heating cable.
Before beginning, take a moment to understand the structure underlying tubing bundle catalog numbers. You will refer to this numbering convention throughout the product selection
process. Your goal is to determine the tubing bundle catalog number for the product that
best suits your needs.
A sample application will be followed throughout the product selection process.

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TUBING BUNDLES

Tubing Bundle Catalog Number

RTB comes in a variety of configurations. The following chart outlines the elements that constitute a bundle configuration and the corresponding catalog number. Other configurations
are available on request.
RTB - X - XXX X - XXX - XXX
Heating cable
5B1 = 5BTV1-CT
5B2 = 5BTV2-CT
8B1 = 8BTV1-CT
8B2 = 8BTV2-CT
5X1 = 5XTV1-CT-T3
10X1 = 10XTV1-CT-T3
15X1 = 15XTV1-CT-T2
20X1 = 20XTV1-CT-T2

5X2 =
10X2 =
15X2 =
20X2 =
LTS =
HTS =

5XTV2-CT-T3
10XTV2-CT-T3
15XTV2-CT-T3
20XTV2-CT-T2
Low-temperature steam
High-temperature steam

Process tube wall thickness

030 = 0.030 in
10 = 1.0 mm
032 = 0.032 in
15 = 1.5 mm
035 = 0.035 in
049 = 0.049 in
062 = 0.062 in
Process tube material
S = Seamless 316 SS
W = Welded 316 SS
Process tubing size
1/8 = 1/8 in
1/4 = 1/4 in
3/8 = 3/8 in
1/2 = 1/2 in
3/4 = 3/4 in

M = Monel
C = Copper

P = PFA

6 = 6 mm
8 = 8 mm
10 = 10 mm
12 = 12 mm

Number of process tubes

1 = Single-tube
2 = Dual-tube
Note: Other congurations (in particular heating cable types) are available on request.
Fig. 2 Tubing bundle catalog number elements

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Product Selection

Product Selection Process

Product Selection
1. Gather information
2. Select tube type
3. Select heating cable

Step 1 Gather the necessary information

To select the tubing bundle, gather and record the following information:

Required number of process tubes (one or two)

Required process tube size

Required process wall thickness

Required process material

Desired maintain temperature range (for selection of the heating cable)

Service voltage for the heating cable

Process operating temperature (for selection of the appropriate materials and heating
cable)

Maximum exposure temperature (for selection of the appropriate materials and heating
cable)

Temperature class (T-rating) for applications in hazardous locations (for heating cable
selection)

Example: Information on sample application

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8/07

Number of tubes

Tubing size

1/4 inch

Tube wall thickness

0.035 inch

Tubing material

Stainless steel 316 (seamless)

Maintain temperature

10C (50F)

Service voltage for heating cable

120 V

Process operating temperature

38C (100F)

Maximum exposure temperature

65C (150F)

T-rating

T6

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TUBING BUNDLES

Product Selection
1. Gather information
2. Select tube type

Step 2 Select the tube type

The table that follows lists possible RTB combinations of tube size and wall materials. For
other configurations, contact your Tyco Thermal Controls representative.

3. Select heating cable

Table 1 Raychem Tubing Bundle Options

Tubing size (nominal)
1/8"

1/4"

3/8"

1/2"

6 mm

8 mm 10 mm 12 mm

Tubing wall material and thickness

Stainless steel 316
(seamless)
0.035"

0.049"

1.0 mm

1.5 mm

Stainless steel 316

(welded)
0.035"

Monel 600 (seamless)

0.035"
0.049"

Copper
0.030"

0.032"

0.049"

1.0 mm

PFA Teflon
0.030"

0.060"

1.0 mm

Example: Tube number / size / material selection

Number of tubes

2 (from Step 1)

Tubing size

1/4 inch (from Step 1)

Tubing material

Stainless steel 316 (seamless) (from Step 1)

Tube wall thickness

0.035 inch (from Step 1)

Catalog number

RTB-2-1/4S-035-XXXX

Selection of the heating cable will fill in the one element missing from the catalog number of
your Raychem tubing bundle (RTB).

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Product Selection

Product Selection

Step 3 Select the heating cable

1. Gather information

RTB is available with Raychem brand BTV and XTV heating cables. Use BTV heating cables
for maintain temperatures up to 32C (90F). For higher maintain temperatures or exposure
temperatures above 85C (185F), use XTV heating cables. Use Table 1.2 to identify the cable
family that meets your maximum continuous and intermittent temperatures. For maintain
and exposure temperatures that exceed the maximum for BTV and XTV, contact your Tyco
Thermal Controls representative.

2. Select tube type

3. Select heating cable

For more detailed heating cable information, please refer to Section 1, Self-Regulating Cables
of the Industrial Heating Product and Design Guide (H56550) and the Technical Databook for
Industrial Heat-Tracing Systems (DOC-389).
Table 2 Overview of BTV and XTV Heating Cable Characteristics

Heating cable

Service voltage

Maximum
continuous
exposure
temperature*

BTV1 all types

110/120 Vac

65C

(150F)
(150F)

BTV2 all types

208/277 Vac

65C

5XTV1, 10XTV1

110/120 Vac

121C (250F)

Maximum
intermittent exposure
temperature **

T-rating/
maximum sheath temperature***

85C

(185F)

T6 85C

(185F)

85C

(185F)

T6 85C

(185F)

215C (420F)

T3 200C (392F)

15XTV1, 20XTV1

110/120 Vac

121C (250F)

215C (420F)

T2D 215C (419F)

5XTV2, 10XTV2, 15XTV2

208/277 Vac

121C (250F)

215C (420F)

T3 200C (392F)

20XTV2

208/277 Vac

121C (250F)

215C (420F)

T2C 230C (446F)

* Heating cable power on (= maximum maintain temperature)

** For 1000 hours intermittent (power on or off)

*** Higher maximum sheath temperatures have been approved by other agencies
Note: All heating cables have a fluoropolymer outer jacket (CT)

Example: Heating cable selection

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Process operating temperature

38C (100F) (from Step 1)

Maximum exposure temperature

65C (150F) (from Step 1)

Service voltage for heating cable

120 V (from Step 1)

Appropriate heating cable

BTV1

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TUBING BUNDLES

EXPECTED MAINTAIN TEMPERATURE RANGE

Table 3 provides the minimum and maximum expected maintain temperatures of the tubing
bundle for ambient temperatures ranging from 30C to 38C (20F to 100F).
Go to the column with the tube size you selected and find the heating cable(s) that will maintain the tubing bundle at your minimum temperature requirement or higher. If more than one
heating cable will maintain your applications temperature range, choose the cable with the
lowest maximum temperature. A thermostat should be used if the maximum temperature in
the table exceeds the maximum desired value. Note the heating cable type and the temperature range.
Table 3 Process Tube Maintain Temperatures (MinimumMaximum) for Ambient Range of 20F to 100F (30C to 38C) at 120/240 V
Size

1/4 in or 6 mm
F

(C)

8 mm
F

3/8 in
(C)

10 mm

(C)

1/2 in or 12 mm
(C)

(C)

Single-tube
5BTV1 and 2

66126

(1952)

64125

(1852)

61124

(1651)

60123

(1551)

58122

(1450)

8BTV1 and 2

90136

(3258)

88135

(3157)

85134

(2957)

83134

(2856)

81133

(2756)

5XTV1 and 2

87197

(3192)

82194

(2890)

78190

(2688)

74189

(2387)

70184

(2184)

10XTV1 and 2

145231

(63110)

139226

(60108)

133222

(56105)

128220

(53105)

123214

(51101)

15XTV1 and 2

184250*

(84126)*

177250*

(81123)*

172248

(78120)

170247

(77120)

161240

(71116)

20XTV1 and 2

232250* (111151)*

204250*

(96139)*

224250* (107148)*

217250* (103145)*

215250* (102144)*

Dual-tube
5BTV1 and 2

64125

(1852)

61124

(1651)

58122

(1450)

56121

(1349)

53120

(1249)

8BTV1 and 2

89136

(3258)

86135

(3057)

82133

(2856)

79132

(2656)

76131

(2455)

5XTV1 and 2

85196

(2991)

77190

(2588)

71184

(2285)

66183

(1984)

60176

(1680)

10XTV1 and 2

142228

(61109)

133221

(56105)

125215

(52102)

119213

(48101)

112205

(4496)

15XTV1 and 2

181250*

(83124)*

171247

(77119)

162241

(73116)

160240

(71115)

148230

(64110)

20XTV1 and 2

228250* (109149)*

206250*

(97140)*

203250*

(95139)*

189250*

(87132)*

216250* (102144)*

The temperatures included in Table 5.3 are for approximation. For critical services applications contact your Tyco Thermal Controls Representative.
* Requires overtemperature line-sensing thermostat to ensure operation below maximum continuous exposure temperature.

Example: Heating cable selection

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Number of tubes

2 (from Step 1)

Tubing size

1/4 inch (from Step 1)

Tubing material

Stainless steel 316 (seamless) (from Step 1)

Tube wall thickness

0.035 inch (from Step 1)

Desired maintain temperature

10C (50F) (from Step 1)

Service voltage

120 V (from Step 1)

Selected heating cable type

5BTV1 (from previous page)

Min./max. temperature from table

18C to 51C (64F to 125F) (from previous page)

Catalog number

RTB-2-1/4S-035-5B1
(RTB-2-1/4S-035 is derived from Step 2)

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H56886

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Bill of Materials

Bill of Materials
The creation of a bill of materials involves three basic steps:

1 Determine the total length of tubing bundle and heating cable.

2 Determine the circuit breaker trip rating for bundle.
3 Determine the type and quantity of components and accessories.
Bill of Materials

Step 1 Determine the total length of tubing bundle and heating cable

1. Determine length of
bundle and cable

The length of the heating cable is typically identical to the required length of the tubing bundle. Be sure the length you order includes an additional three feet for each power connection
and end seal.

2. Determine trip rating

3. Select components
and accessories

Bill of Materials

Step 2 Determine circuit breaker trip rating for bundle

1. Determine length of
bundle and cable
2. Determine trip rating
3. Select components
and accessories

Determine the maximum heating cable length permitted on one circuit breaker. Tables 1.8
and 1.9 in Section 1, Self-Regulating Cables of the Industrial Heat-Tracing Product and
Design Guide (H56550) show the maximum heating cable length that may be powered from
different-sized circuit breakers for different start-up temperatures. For designs based on
European approvals, refer to the Technical Databook for Industrial Heat-Tracing Systems
(DOC-389).
If the length of your tubing bundle exceeds the maximum circuit length, either increase the
rating of the circuit breaker or split the bundle into several circuits.

WARNING: Fire hazard

There is a danger of fire from sustained
electrical arcing if the heating cable is damaged or improperly installed. To comply with
Tyco Thermal Controls requirements, certifications, and national electrical codes, and
to protect against the risk of fire, groundfault equipment protection must be used on
each heating cable circuit. Arcing may not
be stopped by conventional circuit breakers.

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8/07

Note: Tyco Thermal Controls and national electrical codes require ground-fault equipment
protection to provide maximum safety and protection from fire.
Example: Circuit breaker trip rating determination
Catalog number

RTB-2-1/4S-035-5B1 (from Product Selection, Step 3)

Heating cable type

5BTV1 (from Product Selection, Step 3)

Tubing bundle length

46 m (150 ft)

Start-up temperature

0C Default

Circuit breaker size

15 A

Maximum circuit length

42 m (140 ft)

Number of circuits

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TUBING BUNDLES

Bill of Materials

Step 3 Determine the type and quantity of the components and accessories

1. Determine length of
bundle and cable
2. Determine trip rating
3. Select components
and accessories

Now that you have determined your circuit-breaker rating and number of circuits, use Table 4
to determine the number of components and accessories required. Raychem BTV and XTV
heating cables must be connected and terminated with appropriate power connection and
end seal kits (see Figure 3 below).

1 C75-100-A

1 JS-100-A
2 E-150

JBS-100
junction box

RTBK-B2A

E-100
end seal

Connection kit

Heating cable

Instrument enclosure Heat-shrinkable boot

or insulation package

Tubing bundle

Heating
cable

Thermal insulation
and cladding, or
insulation package

Fig. 3 Tubing bundle components

WARNING: Fire hazard

To prevent fire or shock, Raychem brand
specified components must be used. Do not
substitute parts or use vinyl electrical tape.

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Table 4 RTB Component and Accessory Quantities Required

Description
Catalog number
Components for heating cables
1 Power connection kits
Single entry power connection
JBS-100
Junction box stand
JS-100
Gland connection
C75-100-A / C25-100
2 End seals*
End seal, above insulation
E-100
End seal, with light
E-100-L
End seal kit (low profile)
E-150
Splice kits (not shown)
S-150, T-100
Tubing bundle accessories
3Heat-shrinkable boots
Boot for single tube
RTB-RTBK-B1A
Boot for single tube with
RTB-RTBK-B2A
electric trace
Boot for dual tubes with
RTB-RTBK-B3A
electric trace
Heat-shrinkable enclosure entry seal (not shown)
RTB-RTBK-CES4
Entry seal for single and dual tubes
from 1/8"3/8" (6mm10 mm) and
1/2" (12 mm) single tubes
Entry seal for 1/2" (12 mm) dual tubes RTB-RTBK-CES5
Other
Jacket patch kit
RTB-TPKJP-1
Silicone sealant
RTB-TPKSK-10

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Quantity
1 per circuit

1 per circuit

As required
1 per connection kit

1 per enclosure entry

As required

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Bill of Materials

System Components
Power Connection Kits for Heating Cable
JBS-100 Power connection for one heating cable in nonhazardous, Zone 1, 2 and Division 2
hazardous locations. Includes cold-applied heating cable core seal. Requires one pipe strap
to be ordered separately.

JBS-100

For North America approvals: JBS-100-A

(H56827)
JBS-100-L-A (with red indicator light)
For IEC approvals:
(DOC-389)

JBS-100-E
JBS-100-EP (with internal earth plate)
JBS-100-L-E (with green indicator light)
JBS-100-L-EP (as above with earth plate)

JS-100-A (H56450)
Junction box stand for one heating cable in nonhazardous and Division 2 hazardous locations. A separate customer-supplied NEMA 4X junction box is required. Includes cold-applied
heating cable core seal. Requires one pipe strap to be ordered separately.
JS-100-A

C75-100-A (North America: H56343)

C25-100 (European: DOC-389)
C75-100-A

A gland kit used to transition heating cables into a junction box in nonhazardous and
hazardous locations. Includes cold-applied heating cable core seal. A terminal block
(3 x 12 AWG) is included. This kit does not include the junction box or the conduit.

End Seal Kits for Heating Cable

E-100 End seal for heating cable in nonhazardous, Zone 1, 2 and Division 2 hazardous loca-

tions. Re-enterable. Includes cold-applied heating cable core seal. Requires one pipe strap to
be ordered separately.
E-100

For North America approvals: E-100-A

(H56829)
E-100-L1-A (with red indicator light, 100-120 V)
E-100-L2-A (with red indicator light, 200-277 V)
For IEC approvals:
(DOC-389)

E-100-E
E-100-L2-E (with green indicator light, 200-277 V)

E-150 (North America: H56835); (European: DOC-389)

Low-profile end seal for heating cable in nonhazardous, Zone 1, 2 and Division 2 hazardous
locations. Includes cold-applied heating cable core seal.
E-150

Splice Kit for Heating Cable

S-150 (North America: H56835); (European: DOC-389)

Splice kit for two heating cables in nonhazardous, Zone 1, 2 and Division 2 hazardous locations. Includes cold-applied heating cable core seal.
S-150

Consult the data sheets in the Technical Data section for more specific information. For
attachment and other accessories for the heating cables, please refer to Section 1,
Self-Regulating Cables of the Industrial Heating Product and Design Guide (H56550)
and the Technical Databook for Industrial Heat-Tracing Systems (DOC-389).

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TUBING BUNDLES

Accessories
Heat-Shrinkable Boots

RTBK-B2A

RTBK-B3A

Used for sealing bundle ends. The boots are designed to provide a weatherproof seal at the
end of the tubing bundles. These boots may be used on all electric-traced bundles. For
steam-traced bundles, use silicone sealant (TPKSK-10).
Use RTBK-B2A for single-tube bundles with electrical heat tracing
Use RTBK-B3A for dual-tube bundles with electrical heat tracing
Important: Although RTB uses a nonhygroscopic thermal insulation, all bundle ends and
jacket penetrations must be sealed to keep the insulation from getting wet.
Heat-Shrinkable Entry Seals

RTBK-CES

May be used to provide a waterproof fitting where the bundle enters an enclosure or penetrates a bulkhead. The thermally stabilized, modified polyolefin entry seal includes an O-ring
assembly that seals at the enclosure, and a heat-shrinkable nose that seals to the bundle.
Table 5 Heat-Shrinkable Sizing Criteria
Tubing size in inches (mm)

Single-tube bundle

Dual-tube bundle

1/4"3/8" (610 mm)

RTBK-CES4

RTBK-CES4

1/2" (12 mm)

RTBK-CES4

RTBK-CES5

Jacket Patch Kits

TPKJP-1

Must be used for sealing around line-sensing thermostat entries. The kit contains thermal
insulation, fiberglass tape to hold the insulation in place, and a black, self-sealing rubber
patch for weatherproofing the bundle.
Silicone Sealant

TPKSK-10

A black silicone RTV sealant used for sealing the ends of the tubing bundle from moisture.
Cure time is approximately 24 hours at 25C (77F). The 10-ounce (280 g) tube will seal
approximately 10 bundle ends. Silicone sealant can be used for either electric or steamtraced bundles.
Electric Traced Label

ETL

Attach the label to the outside of the thermal insulation weather barrier to indicate presence
of electrical heat tracing. Use one label for every 10 feet (3 m) of pipe, alternating on either
side of the pipe.
Controls
RTB can be operated uncontrolled or with temperature controls that you are using for other
heat-tracing applications. Temperature control will be necessary if the maximum value of the
temperature range determined in Step 2 exceeds the maximum maintain temperature for the
heating cable. For more detail, see the Control and Monitoring section in the Industrial
Heating Product and Design Guide (H56550) and the Technical Databook for Industrial
Heat-Tracing Systems (DOC-389)

DigiTrace 920
DigiTrace 910

NGC-30 system

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