EN 62395-1:2006

SLOVENSKI SIST EN 62395-1:2007

STANDARD
januar 2007
Industrijski in komercialni sistemi električnih uporovnih grelnih trakov - 1.
del: Splošne in preskusne zahteve (IEC 62395-1:2006)
(istoveten EN 62395-1:2006)
Electrical resistance trace heating systems for industrial and commercial
applications - Part 1: General and testing requirements (IEC 62395-1:2006)
ICS 25.180.10 Referenčna številka
©  Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno

EUROPEAN STANDARD
EN 62395-1
NORME EUROPÉENNE
September 2006
EUROPÄISCHE NORM
ICS 25.180.10
English version
Electrical resistance trace heating systems
for industrial and commercial applications
Part 1: General and testing requirements
(IEC 62395-1:2006)
Systèmes de traçage par résistance Elektrische Begleitheizungen
électrique pour applications industrielles Trace-Widerstandsheizungen
et commerciales für industrielle und gewerbliche Zwecke
Partie 1: Exigences générales et d'essai Teil 1: Allgemeine Anforderungen
(CEI 62395-1:2006) und Prüfanforderungen
(IEC 62395-1:2006)
This European Standard was approved by CENELEC on 2006-09-01. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, the Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2006 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 62395-1:2006 E
Foreword
The text of document 27/533/FDIS, future edition 1 of IEC 62395-1, prepared by IEC TC 27, Industrial
electroheating equipment, was submitted to the IEC-CENELEC parallel vote and was approved by
CENELEC as EN 62395-1 on 2006-09-01.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2007-06-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2009-09-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 62395-1:2006 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following note has to be added for the standard indicated:
IEC 62086-1 NOTE  Harmonized as EN 62086-1:2005 (not modified).
__________
- 3 - EN 62395-1:2006
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications

The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

NOTE  When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD
applies.
Publication Year Title EN/HD Year

IEC 60050-841 2004 International Electrotechnical Vocabulary - -
(IEV)
Part 841: Industrial electroheat

1) 2)
IEC 60068-2-9 - Environmental testing EN 60068-2-9 1999
Part 2: Tests - Guidance for solar radiation
testing
IEC 60519-1 2003 Safety in electroheat installations EN 60519-1 2003
Part 1: General requirements
IEC 60519-10 2005 Safety in electroheat installations - -
Part 10: Particular requirements for electrical
resistance trace heating systems for industrial
and commercial applications
1)
Undated reference.
2)
Valid edition at date of issue.

NORME CEI
INTERNATIONALE
IEC
62395-1
INTERNATIONAL
Première édition
STANDARD
First edition
2006-08
Systèmes de traçage par résistance électrique
pour applications industrielles et commerciales –
Partie 1:
Exigences générales et d’essai

Electrical resistance trace heating systems for
industrial and commercial applications –
Part 1:
General and testing requirements
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Aucune partie de cette publication ne peut être reproduite ni No part of this publication may be reproduced or utilized in any
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électronique ou mécanique, y compris la photocopie et les photocopying and microfilm, without permission in writing from
microfilms, sans l'accord écrit de l'éditeur. the publisher.
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Telephone: +41 22 919 02 11 Telefax: +41 22 919 03 00 E-mail: inmail@iec.ch Web: www.iec.ch
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Pour prix, voir catalogue en vigueur
For price, see current catalogue

62395-1  IEC:2006 – 3 –
CONTENTS
FOREWORD.5
INTRODUCTION.9

1 Scope and object.11
2 Normative references .13
3 Terms and definitions .13
4 General requirements .23
4.1 General .23
4.2 Metallic braids or sheaths.23
4.3 Electrical circuit protection requirements for branch circuits .23
4.4 Control and temperature requirements .25
5 Testing .25
5.1 Type tests – General .25
5.2 Type tests .25
5.3 Type tests – Additional tests for outdoor exposed area installations without
thermal insulation .51
5.4 Type tests – Additional tests for installations with embedded trace heater.55
5.5 Type tests – Additional tests for installations with trace heater inside conduit
or piping.55
5.6 Routine tests .57
6 Marking .57
6.1 General .57
6.2 Product markings .57
6.3 Markings for field-assembled components .59
7 Installation instructions.59

Bibliography.61

Figure 1 – Flammability test.31
Figure 2 – Impact test .33
Figure 3 – Cold bend test.37
Figure 4 – Moisture resistance test .39
Figure 5 – Verification of rated output .43
Figure 6 – Verification of sheath temperature using system approach .47
Figure 7 – Maximum sheath temperature using the product classification approach .49
Figure 8 – Abrasion test.55

Table 1 – Test voltages for the dielectric test.27

62395-1  IEC:2006 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTRICAL RESISTANCE TRACE HEATING SYSTEMS
FOR INDUSTRIAL AND COMMERCIAL APPLICATIONS –

Part 1: General and testing requirements

FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with an IEC Publication.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62395-1 has been prepared by IEC technical committee 27:
Industrial electroheating equipment.
The text of this standard is based on the following documents:
FDIS Report on voting
27/533/FDIS 27/547/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

62395-1  IEC:2006 – 7 –
A list of all parts of IEC 62395, under the general title Electrical resistance trace heating
systems for industrial and commercial applications, can be found on the IEC website.
The committee has decided that the contents of this publication will remain unchanged until
the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in
the data related to the specific publication. At this date, the publication will be
• reconfirmed;
• withdrawn;
• replaced by a revised edition, or
• amended.
62395-1  IEC:2006 – 9 –
INTRODUCTION
IEC 62395-1 provides the essential requirements and testing appropriate to electrical
resistance trace heating equipment used in industrial and commercial applications. While
some of this work already exists in national or international standards, this standard has
collated much of this existing work and added considerably to it.
IEC/TS 62395-2 provides detailed recommendations for the system design, installation and
maintenance of electric trace heating systems in industrial and commercial applications.
It is the objective of IEC 62395 that, when in normal use, electrical trace heating systems
should operate safely under their defined conditions of use, by
a) employing heaters of the appropriate construction and meeting the test criteria detailed in
Part 1. The construction should include a metallic sheath, braid, screen or equivalent
electrically conductive covering;
b) operating at safe temperatures when designed, installed, and maintained in accordance
with Part 2;
c) having at least the minimum levels of overcurrent and ground fault protection
recommended in Part 2.
Some tests of Part 1 differ from similar tests developed by TC 20 and are to be reviewed in
the future. These and other tests are almost identical to the tests given in IEC 62086-1:2001
and are duplicated in Part 1 for completeness (see notes in the text).
—————————
Permission to reproduce the text of several tests from IEC 62086-1:2001 that are not specific to explosive gas
atmospheres has been granted by TC 31.

62395-1  IEC:2006 – 11 –
ELECTRICAL RESISTANCE TRACE HEATING SYSTEMS
FOR INDUSTRIAL AND COMMERCIAL APPLICATIONS –

Part 1: General and testing requirements

1 Scope and object
This part of IEC 62395 specifies requirements for electrical resistance trace heating systems
and includes general test requirements.
This standard pertains to trace heating systems that may comprise either factory-fabricated or
field-assembled (work-site) units, and which may be series heater cables, parallel heater
cables, heater pads or heater panels that have been assembled and/or terminated in
accordance with the manufacturer’s instructions for connection to voltage supplies up to and
including 450-750 V.
This standard also includes requirements for termination assemblies and control methods
used with trace heating systems.
This standard does not include or provide for any applications in potentially explosive
atmospheres.
This standard does not cover induction, impedance or skin effect heating.
Trace heating systems can be grouped into different types of applications and the different
conditions found during and after installation necessitate different requirements for testing.
Trace heating systems are usually certified for a specific type of installation or application.
Typical applications for the different types of installation include, but are not limited to:
a) installations of trace heating for surface heating on pipes, vessels and associated
equipment – applications include:
– freeze protection and temperature maintenance;
– hot water lines;
– oil and chemical lines;
– sprinkler system mains and supply piping;
b) outdoor exposed area installations of trace heating – applications include:
– roof de-icing;
– gutter and down-spout de-icing;
– catch basins and drains;
– rail heating ;
c) installation with embedded trace heating – applications include:
– snow melting;
– frost heave protection;
– floor warming;
—————————
Further evaluation may be required to address application specific conditions such as fluctuations in impressed
voltage and voltage spikes.
62395-1  IEC:2006 – 13 –
– energy storage systems;
– door frames;
d) installations with trace heating inside conduit or piping – applications include:
– snow melting – in conduit;
– frost heave protection – in conduit;
– floor warming – in conduit;
– energy storage systems – in conduit;
– internal trace heating for freeze protection of potable water lines;
– enclosed drains and culverts.
2 Normative references
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any amendments) applies.
IEC 60050-841:2004, International Electrotechnical Vocabulary (IEV) – Part 841: Industrial
electroheat
IEC 60068-2-9, Environmental testing – Part 2: Tests – Guidance for solar radiation testing
IEC 60519-1:2003, Safety in electroheat installations – Part 1: General requirements
IEC 60519-10:2005, Safety in electroheat installations – Part 10: Particular requirements for
electrical resistance trace heating systems for industrial and commercial applications
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-841 and in
IEC 60519-10, some of which are repeated here, as well as the following, apply.
3.1
ambient temperature
average temperature of air or another medium in the vicinity of the equipment
NOTE Where electrical trace heaters are enclosed in thermal insulation, the ambient temperature is the
temperature exterior to such thermal insulation.
[IEV 826-10-03, modified]
3.2
branch circuit
that portion of the wiring installation between the overcurrent device protecting the circuit and
the trace heater(s)
3.3 connections (terminations)
3.3.1
cold lead (for trace heater)
electrically insulated conductor or conductors used to connect a trace heater to the branch
circuit and designed so that it does not produce significant heat

62395-1  IEC:2006 – 15 –
3.3.2
end termination
termination, which may be heat producing, applied to a trace heater at the end opposite that
where the power is supplied
3.3.3
integral components
factory-fabricated or field-assembled electrical terminations and connections, such as heat
shrink terminations, moulded end seals or splices, which conform to the general shape of the
trace heater and are exposed to the same environments as the trace heater
3.3.4
power termination
termination applied to the end of a trace heater at which the power is supplied
3.3.5
tee
electrical connection of trace heaters, in series or in parallel, to accommodate a branch in the
circuit and resembling the shape of a capital T
3.4
dead leg
segment of process piping segregated from the normal flow pattern for the purpose of
providing a heat-loss reference
3.5
design loading
minimum power that will meet the design requirements, in the worst conditions, after voltage
and resistance tolerances and appropriate safety factors have been considered
3.6
factory-fabricated unit or set
trace heater unit or set, including the necessary terminations and connections, assembled by
the manufacturer
3.7
field-assembled unit or set
trace heaters supplied in bulk with terminating components to be assembled at the work site
3.8
heat loss
energy flow from a pipe, vessel or equipment to its surroundings
3.9
heat sink
part that conducts and dissipates heat away from a workpiece
NOTE Typical heat sinks are pipe shoes, pipe supports and items of large mass such as valve actuators or pump
bodies.
3.10
heat transfer aids
thermally conductive materials, such as metallic foils or heat transfer compounds used to
increase the heat-transfer efficiency from trace heaters to the workpiece

62395-1  IEC:2006 – 17 –
3.11
heater pad
trace heater comprising series or parallel connected elements having sufficient flexibility to
conform to the shape of the surface to be heated
3.12
heater panel
non-flexible trace heater comprising series or parallel connected elements fabricated to
conform to the general shape of the surface to be heated
3.13
high limit temperature
maximum allowable temperature of the system, including piping, fluid and trace heating
system
3.14
maximum ambient temperature
highest ambient temperature at which the trace heater is operable and should perform
according to specified requirements
3.15
maximum withstand temperature
maximum operating or exposure temperature that does not adversely affect the thermal
stability of the trace heater and its component parts
3.16
metallic covering
metallic sheath, braid, screen or equivalent electrically conductive covering used to provide
an electrical path to operate an electrical protection device and may also provide additional
physical protection for a trace heater
3.17
minimum ambient temperature
lowest ambient temperature specified at which the trace heater is operable and performs
according to specified requirements
NOTE Heat-loss calculations in IEC/TS 62395-2 are based on the minimum ambient temperature.
3.18
operating voltage
actual voltage applied to the trace heater when in service
3.19
overjacket
continuous layer of material applied outside the metallic sheath, screen or armouring to
protect against corrosion
3.20
parallel trace heater(s)
heating elements electrically connected in parallel, with the heating element either continuous
or in discrete units or zones, such that the watt density per unit length is not significantly
changed with any change in circuit length
3.21
power density (linear or surface)
power output in watts per linear metre for trace heater cables and cable units, and in watts
per square metre for trace heater pads and panels and trace heater pad and panel units

62395-1  IEC:2006 – 19 –
3.22
rated output
total power or power per unit length or unit surface area of the trace heater, at rated voltage,
temperature, length or area which is normally expressed in watts, watts per metre or watts per
square metre
3.23
rated voltage
voltage to which operating and performance characteristics of trace heaters are referred
3.24
routine test
test to which each individual device is subjected during or after manufacture to ascertain
whether it complies with certain criteria
[IEV 151-16-17]
3.25
series trace heater(s)
heating elements electrically connected in series with a single current path and with a specific
resistance at a given temperature for a given length
3.26
sheath
uniform and continuous metallic or non-metallic outer covering enclosing the trace heater,
used to provide protection for the cable against influence from the surroundings (corrosion,
moisture, etc.)
NOTE See overjacket (3.19).
3.27
sheath temperature
temperature of the outermost continuous covering that may be exposed to the surrounding
atmosphere
3.28
stabilized design
concept where the temperature of the trace heater will, by design and use, stabilize below the
limiting temperature, under the most unfavourable conditions, without the need for a
protective system to limit the temperature
3.29
start-up current
current of a trace heater immediately upon energizing
3.30
system documentation
information typically provided by the supplier to allow satisfactory understanding, installation
and safe use of the trace heating system
3.31
temperature controller
device or combination of devices incorporating a means of sensing temperature and of
controlling the power supplied to the trace heater

62395-1  IEC:2006 – 21 –
3.32
temperature sensor
temperature sensing element
device designed to respond to temperature providing an electrical signal or mechanical
operation
3.33
thermal insulation
material having air- or gas-filled pockets, void spaces, or heat-reflecting surfaces that, when
properly applied, retard the transfer of heat
3.34
trace heater
device designed for the purpose of producing heat on the principle of electrical resistance and
typically composed of one or more metallic conductors or an electrically conductive material,
suitably electrically insulated
NOTE This may typically be in the form of a trace heater cable, tape, heater panel or heater pad.
3.35
trace heater cable
cable constructed with one or more discrete or continuous electrically insulated heating
elements
3.36
trace heater unit
trace heater set
series trace heater cable, parallel trace heater cable, heater pad or heater panel suitably
terminated in conformity with the manufacturer’s instructions
3.37
trace heating
utilization of electric trace heater cables, pads, panels and support components, used to raise
or maintain temperatures
3.38
type test
conformity test made on one or more items representative of the production
[IEV 151-16-16]
3.39
weather barrier
material that, when installed on the outer surface of thermal insulation, protects the thermal
insulation from water or other liquids, from physical damage caused by sleet, wind or
mechanical abuse, and deterioration caused by solar radiation or atmospheric contamination
3.40
workpiece
object to which a trace heater is applied

62395-1  IEC:2006 – 23 –
4 General requirements
4.1 General
Electrical resistance trace heating system within the scope of this standard shall be designed
and constructed so as to ensure electrical, thermal and mechanical durability and reliable
performance such that, in normal use, it poses no danger to the user or the surroundings.
Trace heaters may be supplied with additional mechanical protection to meet the
requirements of this standard if they are supplied as an integral assembly (prefabricated), and
that contain the following statement in the instructions: “This mechanical covering shall not be
removed and the trace heaters shall not be operated without the mechanical covering in
place.“.
All parts of a trace heating unit intended for use in contact with potable water shall be
constructed of materials that meet the relevant toxicity requirement.
The manufacturer shall declare the maximum withstand temperature in degrees Celsius. The
materials used in the trace heater shall withstand a temperature 20 K greater than its
maximum withstand temperature, when tested in accordance with 5.2.10.
4.2 Metallic braids or sheaths
Trace heaters shall be provided with an evenly distributed electrically conductive metallic
sheath, braid, screen or other equivalent electrically conductive covering. This sheath, braid,
screen or conductive material shall cover at least 70 % of the surface and shall enable
protection device(s) to operate as intended.
4.3 Electrical circuit protection requirements for branch circuits
The minimum requirements for trace heating systems are:
a) a means of isolating all line conductors from the supply;
b) over-current protection provided for each branch circuit;
c) ground fault equipment protection for each branch circuit.
The trace heater device branch circuit protection shall be capable of interrupting ground
faults, as well as short-circuit faults. A ground-fault equipment protective device or a
controller with ground-fault interruption capability shall be used. A nominal 30 mA trip rating is
recommended except where capacitive leakage may lead to nuisance tripping, in which case
devices having a trip current not greater than 300 mA may be used. These devices are
intended for use in conjunction with circuit overcurrent protection. Where conditions of
maintenance and supervision ensure that only qualified persons will service the installed
systems and continued circuit operation is necessary for the safe operation of the equipment
or processes, ground-fault detection without interruption is acceptable if alarmed in a manner
assuring an acknowledged response.

62395-1  IEC:2006 – 25 –
4.4 Control and temperature requirements
4.4.1 General
A trace heating system shall be designed so that under all conditions that may reasonably be
foreseen, the surface temperature of the trace heater does not exceed the maximum
withstand temperature of the heater or the workpiece. This shall be achieved either by a
stabilized design, in accordance with 4.4.2, or by the use of temperature control devices to
limit the maximum equipment temperature.
4.4.2 Stabilized design
Stabilized design applications, in which the maximum surface temperature of the trace heater
is determined without thermostatic control, shall employ either the systems approach
specified in 5.2.11.2 or the product classification approach specified in 5.2.11.3.
5 Testing
5.1 Type tests – General
All trace heaters shall meet the requirements of the type tests given in 5.2. Trace heaters
intended for applications described in Clause 1, items b), c) and d) shall also meet the
requirements of 5.3, 5.4 and 5.5, respectively.
Samples of trace heaters at least 3 m in length, unless otherwise specified, shall be selected
for testing.
Connections and end terminations may be identified as integral components of a trace heater
or may be identified separately. Integral components, whether intended to be factory
fabricated or field assembled, shall be subjected to the same type test as the trace heater.
System components, other than those identified as integral, shall be evaluated in accordance
with standards relevant to their construction and use.
Tests shall be conducted at a room temperature between 10 ºC and 40 ºC unless otherwise
specified.
Separate samples shall be used for each test unless otherwise specified. These shall be
prepared in accordance with the manufacturer's recommendations.
5.2 Type tests
5.2.1 Dielectric test
The dielectric test shall be performed on trace heaters in accordance with Table 1.

62395-1  IEC:2006 – 27 –
Table 1 – Test voltages for the dielectric test
Rated voltage Test voltage
U V a.c. (r.m.s.)
< 30 V a.c. (r.m.s.) 500
< 60 V d.c. 500
2U + 1 000
> 30 V a.c. (r.m.s.)
> 60 V d.c.
2U + 1 000
For single conductor series cables the voltage shall be applied between the conductor and the
metallic sheath, braid, screen or equivalent electrically conductive covering.
For a multi-conductor series cable the voltage shall be applied between the conductors
connected together and the metallic sheath, braid, screen or equivalent electrically conductive
covering, and also between each conductor in turn with the remaining conductor(s) connected
together.
For parallel cables the voltage shall be applied between the conductors connected together
and the metallic sheath, braid, screen or equivalent electrically conductive covering.
The rate of rise shall be neither less than 100 V/s nor more than 200 V/s and maintained for
1 min at the specified test voltage without dielectric breakdown. The test voltage waveform
shall be essentially sinusoidal, with a frequency of 45 Hz to 65 Hz.
When determining U, the correct use of phase-to-phase or phase-to-neutral voltage levels
shall be considered.
5.2.2 Electrical insulation resistance test
The electrical insulation resistance shall be measured on the test sample(s) prepared in
accordance with 5.1 after the dielectric test specified in 5.2.1.
For single conductor series cables the resistance of the electrical insulation shall be
measured between the conductor and the metallic sheath, braid, screen or equivalent
electrically conductive covering.
For a multi-conductor series cable where the conductors are electrically insulated from each
other, the resistance of the insulation shall be measured between the conductors connected
together and the metallic sheath, braid, screen or equivalent electrically conductive covering,
and also between each conductor in turn with the remaining conductor(s) connected together.
For parallel cables the resistance shall be measured between the conductors connected
together and the metallic sheath, braid, screen or equivalent electrically conductive covering.
The insulation resistance shall be measured by means of a d.c. voltage of 1 000 V for mineral
insulated heaters and 2 500 V for other constructions. The measured value shall be not less
than 50 MΩ.
62395-1  IEC:2006 – 29 –
5.2.3 Flammability test
NOTE This test differs from a similar test developed by TC 20 and should be reviewed. This test is almost
identical to a test given in IEC 62086-1 and is duplicated here for completeness.
A flammability test shall be performed on trace heaters (i.e. not total assemblies). The test
shall be made in a room free from draughts. The sample trace heater at least 450 mm in
length shall be supported in a vertical position. For heater panels, heater pads and any other
trace heaters with a width greater than 80 mm, the sample width need only be 80 mm.
A gummed unbleached paper indicator shall be wrapped once around the sample so that it
projects 20 mm from the sample. The paper indicator shall be positioned 250 mm above the
point at which the inner blue cone of the flame contacts the sample. A layer of dry, pure
surgical cotton not more than 6 mm in depth shall be placed underneath the sample so that
the distance from the cotton to the point of the flame application is 250 mm.
The height of the natural gas flame of the burner shall be adjusted to 130 mm with an inner
blue cone 40 mm high, as shown in Figure 1a. The burner shall be tilted to an angle of 20º
from the vertical and the flame applied to the cable so that the tip of the inner blue cone of the
flame touches the specimen at the point approximately 150 mm above its lower end. The
flame shall be brought up to the trace heater in such a manner that the vertical plane
containing the major axis of the burner tube is at right angles to the plane of the cable being
tested as shown in Figure 1b. The flame shall be applied for 15 s, then removed for 15 s, until
five such applications have been made.
The test results shall be considered satisfactory if the trace heater does not support
combustion for more than 1 min after the fifth application of the flame, does not burn more
than 25 % of the extended unbleached paper and does not ignite the cotton with falling,
burning particles.
62395-1  IEC:2006 – 31 –
20°
IEC 1660/06 IEC 1661/06
Dimensions in mm
Figure 1a – Height of natural gas flames Figure 1b – Vertical plane at right angles to sample under test
Key
1 Burner 4 Test sample
2 Support 5 Dry pure surgical cotton
3 Unbleached paper flag
Figure 1 – Flammability test
5.2.4 Impact test
NOTE 1 This test differs from a similar test developed by TC 20 and should be reviewed. This test is almost
identical to a test given in IEC 62086-1 and is duplicated here for completeness.
NOTE 2 Electric trace heaters are, in the majority of applications, covered by thermal insulation and therefore
afforded some mechanical protection. In some applications, however, trace heaters may be installed under
conditions where they will not always be mechanically protected by thermal insulation; for example, during
installation before the thermal insulation is applied or where the trace heater exits from the thermal insulation into
a junction box.
A sample approximately 200 mm in length is placed on a rigid flat steel plate and positioned
underneath an intermediate piece of hardened steel in the shape of a horizontal cylinder with
a diameter of 25 mm. This cylinder is required to have a length of 25 mm with smoothly
rounded edges to a radius of approximately 5 mm when used to test heater pads and heater
panels (see Figure 2). For the test, the cylinder is laid horizontally on the sample and, in the
case of a trace heater cable, its axis is placed across the sample. A trace heater cable having
a non-circular cross-section shall be so positioned that the impact is applied along the minor
axis (that is to say the trace heater cable is positioned flat on the steel plate).
62395-1  IEC:2006 – 33 –
Other than in tests on electrical trace heaters intended for use in applications with low risk of
mechanical damage, a hammer with a mass of 1 kg shall be allowed to fall once onto the
horizontal cylinder from a height of 700 mm (impact load of 7 J).
For trace heaters intended for use in applications with low risk of mechanical damage, the
height may be reduced to 400 mm (impact load of 4 J). Electrical resistance trace heaters
submitted to such a test shall be examined by the certifying body (test house) to verify that
the manufacturer’s installation instructions adequately caution the user regarding the use of a
trace heater with reduced mechanical capability.
Conformity is verified by testing the electrical insulation in accordance with 5.2.1 and 5.2.2
while the steel cylinder and hammer are still in place on the sample.

4 IEC 1662/06
Key
1 Hammer with mass of 1 kg 4 Cylinder with 25 mm overall length and 5 mm radius
rounding when used to test heater pads and heater panels
2 Cylinder with diameter of 25 mm
3 Minor axis of non-circular trace heater cable 5 Height of fall of hammer: 700 mm or 400 mm
Figure 2 – Impact test
5.2.5 Deformation test
NOTE 1 This test differs from a similar test developed by TC 20 and should be reviewed. This test is almost
identical to a test given in IEC 62086-1 and is duplicated here for completeness.
A sample is placed on a rigid flat steel plate. A crushing force of 1 500 N is then applied for
30 s, without shock, by means of a 6 mm diameter steel rod with hemispherical ends and a
total length of 25 mm. For the test, the rod is laid flat on the sample and in the case of a trace
heater cable it is placed across a specimen at right angles. In the case of a panel or pad, it is
necessary to ensure that the cylinder rests across an active element.

62395-1  IEC:2006 – 35 –
For trace heaters intended for use in applications with low risk of mechanical damage, the
crushing force may be reduced to 800 N. Electrical resistance trace heaters submitted to such
a test shall be examined by the certifying body (test house) to verify that the manufacturer’s
installation instructions adequately caution the user regarding the use of a trace heater with
reduced mechanical capability.
Conformity is verified by testing the electrical insulation in accordance with 5.2.1 and 5.2.2
while the horizontal steel rod is still in place on the sample and the load applied.
NOTE 2 Trace heater cable samples need only be approximately 200 mm in length.
5.2.6 Cold bend test
This test applies only to trace heaters that have a stated minimum bending radius less than
300 mm.
The apparatus used for the cold bend test is shown in Figure 3, with the radius of the metal
mandrel as shown, or with the radius equal to the manufacturer's stated minimum bend
radius. A sample of trace heater, without integral terminations or connections, shall be fixed in
the apparatus as shown. The apparatus and sample shall be placed in a refrigerated
compartment and maintained at the manufacturer’s minimum recommended installation
temperature for a period not less than 4 h. At the end of this period, and with the sample
maintained at the minimum recommended installation temperature, the sample shall be bent
through 90º around one of the mandrels, then bent through 180º in the opposite direction over
the second mandrel and then straightened to its original position. All the bending operations
shall be carried out in the same plane. This cycle of operations shall be performed three times
and the rate of bend shall not be faster than 5 s per cycle.
Conformity is verified by testing the electrical insulation in accordance with 5.2.1 and 5.2.2.
NOTE The system documentation provided by the manufacturer should state the minimum installation
temperature and the minimum bending radius.

62395-1  IEC:2006 – 37 –
d
6d 6d
IEC 1663/06
Key
1 Sample trace heater 3 Metal mandrel
2 Metal base d Trace heater cable diameter or thickness for primary bending plane
Figure 3 – Cold bend test
5.2.7 Water resistance test
A sample of trace heater cable at least 3 m in length, or a sample of heater panel or heater
pad, including integral terminations, shall be immersed under at least 50 mm of tap water at
10 ºC to 25 ºC for a period of 336 h (14 days). After this period, the sample shall be tested
using the dielectric voltage test, 5.2.1, and shall withstand this for 1 min without dielectric
breakdown. The same sample shall then be tested using the electrical insulation resistance
test, 5.2.2, and the measured value shall not be less than 50 MΩ.
For samples supplied with overjackets, a section of the overjacket shall be removed prior to
testing.
Terminations and connections for systems intended strictly for use in dry locations are not
subject to this test.
5.2.8 Moisture resistance test
NOTE This test is almost identical to a test given in IEC 62086-1 and is duplicated here for completeness.

62395-1  IEC
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