Don t return home to 1000 s of water damage! Stop pipes bursting at cold temperatures!

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1 Stop pipes bursting at cold temperatures! Frost Free includes a thermostatic control and self-regulating cable to use minimum energy! Don t return home to 1000 s of water damage! Use a Frost Free system to regulate the temperature of your pipes, keeping them above the point of freezing. This brochure includes information about our Frost Free system as well as complete installation instructions.

2 Why choose Frost Free? Frost Free regulates the temperature of your water pipes to keep them above the point of freezing! Don t return home to 1000 s of water damage! If temperatures drop below zero and water begins to freeze within the pipes in your home the expansion during freezing can cause the pipes to fracture and burst even though your pipes are insulated, frost can still penetrate into the waterpipe (see the pictures on the following page). When the water thaws it will pour out of the pipe until it is noticed and the water is shut off. This will cause visible and hidden damage to the structure of your house as well as damage to your personal posessions and untold disruption. A Frost Free system can prevent this by regulating the temperature of your pipes. It will keep your water pipes above freezing point and ensure that you don t return home to water damaged walls, ceilings, furniture or personal (and often irreplaceable) posessions. The Frost Free Stat detects when the pipe temperature drops to 4 C and switches on the heating cable. When the pipe temerature reaches 8 C, the stat switches the power off. In this way, energy costs are kept to an absolute minimum. 15w Self-regulating heating cable automatically reduces power consumption as temperature increases and it won damage if crossed over itself. Frost Free Stat keeps pipes just above freezing for maximum economy.

3 Real Life Testimonial Testimonial from a victim of frozen pipes My World Ended in 2011! To me this is a horror story of biblical proportions! This is the day that my world was turned upside down, my stomach churned and my heart almost stopped. The bungalow had plenty of insulation sorry, I thought that I had plenty of insulation and we had only been away for a week to visit relatives over the festive season. The boiler had a frost stat; so why should there have been a problem? Continuous really cold weather had penetrated the pipe insulation in the loft and I hadn t switched the water off! The boiler stopped due to the condensate pipe freezing. You can see the result. I very nearly died when I saw the mayhem when we came back. Months of upset - 20,000 from the insurance company and over 2000 from my savings to replace uninsured items you can see what it was like. All this upset for the sake of 118 for a Frost Free kit for the loft, a 84 for a kit for the boiler and a couple of hours for an Electrician. It s done now and I never want to go through that again! In my defence, I didn t know this type of product was available. It s also so easy to install!

4 Basic Facts Frost Free 15w/m Trace Heating Cable (FFTHC) Cable structure: 1. Copper multi-strand wire 2. Conductive (restistive) heating matrix 3. Layer polyolefin insulation, 4. Tinned copper shield 5. Fluorine plastic sheath Standard colours: black, grey. Maximum permissible surface temperature 70C ± 5C. 50m maximum run. Self-Regulating: As the cable heats up, it cleverly reduces its power consumption generally or locally - so if it s crossed over, the cable will automatically compensate for the increase in temperature where it s crossed over - to prevent overheating. Output Watts 20w 15w 10w 5w 0w 0c 10c 20c 30c 40c 50c Degrees Centigrade Thermostatic Control: While the Frost Free Trace Heating Cable can be manually switched on when the weather is cold - the real secret is this clever little device. The Frost Free Stat is situated where it can be easily seen for monitoring and the probe is fixed to the side of the pipe to be protected - under the insulation. The Frost Free Stat will only switch the power on when the temperature falls to 4C and off again at 8C - so power is used only when it s absolutely necessary to keep the pipe above freezing. Termination and Connection Kit: Easy to make connections and terminations - follow the simple instructions for a really proffessional job. Includes push-in connector, glue-lined heat-shrink and rapstraps, sufficient for aprox. 30m of cable. Add 6cm to the actual heated length of cable to allow for end connections.

5 Each Frost Free stat can handle 60m of Frost Free Cable. In this instance 3 runs of Frost Free cable are connected. The probe end from the Frost Free stat should be securely strapped to the side of the cold water pipe away from the cable and again, this should be inside the pipe insulation. The standard probe has a range of -5C to +65C so it will have no problem working when fixed to the side of a cold pipe with Frost Free cable and inside the insulation - it will always be within its parameters and is suitable for normal use. Add 6cm to the length of heating cable required to allow for end connections. Frost Free - is used to protect domestic and commercial pipework from the ravages of frost. The cable is intended to fit inside the pipe lagging and be fixed to the pipe. The self-regulating cable gives a maximum output of 15w/m. Fix the cable to the pipework with the Rapstraps provided at the rate of 3/m - each Rapstrap can be cut and reused. The cable is best situated along the bottom of the pipe where the pipe is suspended, but in many domestic installations, pipe-clips are in the way, so it is much easier to fit the cable along the top of the pipe. The cable can be fixed to the side of inline stoptaps. Frost Free cable is self regulating which means that it automatically reduces its power consumption as the cable heats up. it is always better not to cross over or coil-up the cable but it will not be damaged if this is the case. The cables maximum heat resistance is 75C so thought should be given to protection of hot pipes. If you have a situation where a cold pipe is at risk of freezing but there is also a hot water pipe in the vicinity that may also be damaged, the control probe is on the cold pipe so the heaters are switched on and the hot pipe is still working. The heat from the hot pipe and the cable being switched on can damage the cable. The correct installation here is to use a second Frost Free stat for the hot water pipe and use the optional Frost Free HS Probe (-20C to +100C). This will only allow the heater on the hot pipe to work when the hot water system is not working. If you need further advice please contact Use a connector as required for each run and the connectors can be linked together by a ring main if required. The stat will switch on the Frost Free cable when the temperature drops to 4C and switch off again at 8C such that the pipe temperature is maintained above freezing. In this way the pipes are protected from frost at the absolute minimum cost of electricity. The stat is best situated below the ceiling say, if the pipes are in the loft, where it can be seen by the householder. When using on a boiler condensate pipe, the drain pipe should be insulated including the section that exits through the brickwork. Strap the Frost Free cable to the full length of the bottom of the pipe or spiral-wind the cable around the pipe for larger diameter pipes. The critical area is where the pipe is outside the building, so make sure this is well protected. Use the optional HS Probe and fix the probe end so it is able to pick up the pipe temperature at the end of the condensate pipe outside of the building. Obviously keep it away from the heating cable so it doesn t get a false reading. (Do not use the standard probe for this purpose as it will not activate the heating below -5C). HS Probe Frost Free, Bramley House, Bath Lane, Bramley, Leeds. LS13 3BB. Tel: Fax:

6 Connection & Termination Connection & Termination Instructions Frost Free 15w/metre Trace Heating Cable (THC) is ideally suited for the prevention of domestic and commercial water-pipes from freezing during periods of very cold weather. The cable would normally be strapped to the underside of the water pipe and inside the pipe lagging. It can be crossed over itself without causing problems and can therefore be wound around outdoor taps etc and it is a good idea to read our Basic Installation sheet to determine what length( s) of cable is required. Frost Free THC is available from your dealer cut to any length as required and the following simple electrical connection and end termination will need to be carried out by a qualified electrician. Specified lengths of Frost Free THC can be ordered by your dealer for next-day delivery with the connection/termination already made. Frost Free THC is top of the range self-regulating heating cable and consists of 2 bus-wires with a special heating matrix between them. The bus-wires do not heat up and the heating matrix cleverly changes its resistance as it gets warmer to reduce its power consumption - this is why the cable will not damage if crossed over itself. Standard Pipe Heating Kit Suitable for boiler condensate pipe and general pipe frost protection. Manually activated but can be used in conjunction with Frost-Free Stat. Generally 1-10 metre kits available ex stock or any length made to measure - ask your dealer for prices 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.

7 Connection Instructions 01. You will need simple tools and the blue connector. 02. The cable needs to fit in the smaller female connector. Start by marking a line 8cm from the end. 03. Carefully cut the outer insulation down the middle and remove the sheath to the 8cm mark. 04. This will expose the earth sheath. 05. Cut earth-sheath with scissors. 06. Perpared earth-sheath. 07. Twist (don t pull) the earth sheath into a tail and mark 5cm from the end of the inner core insulation. 08. Carefully remove the inner insulation up to the 5cm line. 08. Carefully remove the inner insulation up to the 5cm line.

8 Connection Instructions 10. Cut down inside of each bus-wire to 5cm mark. 11. Leave the bus wires evenly covered with heating matrix. Remove the centre section of matrix. Expose the ends of the bus-wires for mains connection. 12. Slide on 4cmx5mm dia glue-lined heat-shrink and set with heat gun. 13. Cut earth-tail same length as buswires. Slide earth-sheath over earth tail and set with heat-gun. 14. Slide 10cm x 1.5cm dia. glue-lined heat shrink tube over cable and connect bus-wires (live and neutral) and earth to connector. 15. Slide outer heat-shrink down to connector as far as it will go. Set the heat-shrink - be careful not to burn the connector. 16. Squeeze to waist the heat shrink so that it will fit the cable grip. 17. Fix the outer casing and cable-grip while the heat-shrink tube is still soft Power connection complete! 18. When cool take off the outer casing and check all is OK before refixing. (Note - heat from cable starts approx 1.5cm from connector.) The glue-lined heat shrink tube will shrink to 1/4 of it s original diameter. When the glue lining sets, it will form a perminent and water-tight seal. Now that the centre part of the heating matrix has been removed and each bus-wire insulated, current cannot flow so this section cannot heat up. A really proffessional result!

9 Termination Instructions 01. For the End Termination measure 8cm from the end. 02. Remove outer sheath as before to expose the earth braiding. 03. Pull the earth sheath back and mark a line 4cm from the end. 04. Cut off 4cm making sure the cut is clean and the 2 bus wires are appart. (The bus wires must be in their normal locations well appart.) 05. Use the 5cm x 1cm dia glue-lined heat shrink. Set the heat shrink with heat-gun and squeeze the end together with pliers. Make sure glue squeezes out of the end. 06. It should look like this. 07. Tease the earth-sheath back to the end and bend surplus back on it s self. 08. Now use the 10cm x 1.5cm diameter glue-lined heat-shrink, set with heat-gun and squeeze the end together with pliers. Ensure that glue shows at the end. Job done, the cable is now ready for installation. Please follow the Frost-Free cable installation instructions. Should you have any difficulties, please contact technical help on

10 Cable & Probe Installation Cable Installation Frost Free Trace Heating Cable has an output of 15w/metre run and is used for frost prevention where internal or external pipework is at risk of freezing during cold weather spells. Frost Free Trace Heating Cable may be used on both copper and plastic water pipes up to 75mm diameter depending upon insulation thickness, or may be spirally wound around larger diameter pipes. Heat Loss W/M Pipe Diameter - mm 10mm Insulation 20mm Insulation 30mm Insulation The typical heat loss chart shows the watts/metre of pipe run lost, for a temperature 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. The point is that the Frost Free cable needs to replace the heat loss, which it can easily 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 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 for normal 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. (Don t use plastic cable ties as these have no 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 degrees around the pipe from the cable. (See the Frost Free Stat Instructions for more information). You should ensure that the Frost Free Trace Heating Cable can not slip around 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. Test the installation.

11 Probe & Stat Installation Note: Frost Free Heating Cable has a maximum recommended surface exposure temperature of 65C and can be fixed to normally hot pipes that do not exceed this temperature. The cable will be damaged if it is powered up while the pipe is still carrying heated water. For pipes normally hotter than 65C there is a higher specification but more expensive Frost Free HS cable available that can withstand 100C. Also the Frost Free HS probe should be used for protecting normally hot pipes. (Insulated hot pipes normally 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 where normally hot pipes are left cold for long periods and are consequently at risk during cold weather). Probe Installation The HS Probe should be used in conditions where there is either the possibility of moisture ingress, e.g., outdoors, or where it will be attached to a pipe that has a normal running temperature between 65C and 100C. Always use the HS Probe on outdoor installations and fix the probe end to the pipe with cloth tape. Both the heating cable and the probe end should always be inside the pipe insulation. (The probe cable can be extended with with standard lighting flex to a maximum of 8 metres. Also in this kit is a length of large diameter glue-lined heat-shrink for moisture-proofing the blue cable connector if required - slide the 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. (The standard probe is only suitable for indoor conditions where the pipe is maximum 65C). Stat Installation When the mains power is switched on, the green power light shows on the unit. The middle red active light will show when the system is switched on by the temperature falling to 4 centigrade. The blue error light will show if there is a problem with the probe. Press and hold down the test button for a short while, the system will go active and the red light will be on. (Continued overleaf) 2 metre HS Probe (-10C to 110C)

12 Stat Installation If the button is held down the cable will heat up and can be felt as confirmation that the system is functioning properly. The Frost Free stat is opened as shown, and you will find the simple wiring diagram both on the back of and inside the unit. The Frost Free stat is intended to be located indoors where it is visible and can be periodically 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 is ideal. For boiler condensate pipe protection, the stat will be located by the side of the boiler. There is a probe inside the box with 4 metres of wire connected to it. The wire can be shortened, or lengthened with twin lighting flex as required. The standard probe is used in internal non-hostile environments and has an operating range of 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. Even though the probe is between pipe and insulation, the HS probe is waterproof and will not be affected if moisture gets under the insulation when outdoors. The end of the probe should be fixed to the pipe, minimum 90 degrees and ideally 180 degrees around the circumference of the pipe from the Frost Free THC. Ensure that the probe wire is not run along the heating cable and we would recommend that the probe connection wire is taken through the insulation adjacent to where the probe end is connected to the pipe. Consideration should be given to the location of the probe and it should be connected to the water pipe where it is likely to be the coldest locale. For example, a water pipe fixed to the rafters is going to get colder than water pipes running along the ceiling joists under glass fibre insulation so fix the probe to the pipe fixed to the rafters. Other Frost Free protected pipes in the locale that are slaving off this probe will be thus protected. Do not leave the Frost Free Trace Heating Cable or the probe end exposed to the atmosphere - the water pipe run should always be insulated. The power supply to the system should be connected by a qualified electrician an be on an RCD protected circuit via a suitably fused twin pole isolator switch.