Kompensator® Low Voltage

Kompensator self-regulating low voltage heating cable systems are custom manufactured and engineered to suit various applications. Kompensator systems are the only LOW VOLTAGE, external, self-regulating heating cable set supplied job-ready to provide safe, efficient, and reliable freeze protection for various installation parameters. Available in both 12 volt and 24 volt models to optimize efficiency, Kompensator provides dependable freeze protection for both metallic and non-metallic pipes, tubes and hoses. Even if pipes, tubes and or hoses are partially or fully dry the advanced self-regulating properties of the Kompensator will never lead to over or under heating. Designed to be installed directly onto the outside of pipes, tubes and hoses the Kompensator system can protect both small and large diameter fluid systems. Heat-Line recommends to fully insulate Kompensator systems after installation to minimize circuit loads and maximize efficiency. Widely popular in the transportation industry, Kompensator systems are also compatible with off-grid, inverter, and alternator battery generators, making them applicable in a wide variety of industries.

Features

Kompensator is supplied job-ready factory finished to length with a 6 ft. (1.8m) power lead for direct connection. Installation is fast, simple and cost effective as no splicing or electrical work is required. A single trace on small diameter pipes, tubes and hoses is commonly enough when properly insulated.

The Kompensator heating cable is supplied as a job-ready, pre-assembled system that is a safe and reliable solution for all metallic and non-metallic pipe types and materials of many sizes. This includes but is not limited to copper, PEX, polyethylene, ABS, PVC, galvanized, stainless, ductile iron, rubber, vinyl and more. Even in applications where pipes are intended to be dry for short or extended periods of time, Kompensator will never over-heat or melt the pipe due to its advanced self-regulating technology.

In most applications, the Kompensator system is installed in a single run along the pipe, reducing the overall length of heating cable needed by as much as 60%. For larger pipe diameters or where more heat is required, a dual (double) trace system is adequate and if wrapping around valves is required the Kompensator heating cable can safety overlap itself without over heating at the point of contact.

Kompensator employs the unique and advanced performance of self-regulating heating cable technology. Constructed of self-regulating heating cable technology the Kompensator system can effectively increase heat and energy output microscopically to point along its length which are cold and simultaneously reduce heat and energy output to points which are warm. You never have to worry about the Kompensator heating cable overheating causing risk of melting and fire because of the self-regulating heating cable technology.

Kompensator gives you the peace of mind of reliable freeze protection without the risk of traditional heat tapes. It has become an essential product for firefighters, heavy equipment operators, truckers and RV manufactures to provide safe and reliable freeze protection to the vehicles they rely on. When implemented in the heavy equipment industry Kompensator systems are capable of maintaining hydraulic oil and other fluid viscosities in cold temperatures, minimizing stress while maximizing winter performance. The Kompensator system is so versatile that it can be used in a variety of other applications where 12 volt and 24 volt power is available, including small diameter fluid hoses, appliance and comfort heating, condensate freeze protection, oil lines, hydraulic hoses, pumps and compressed air systems.

To further increase the energy efficiency of your Kompensator heating cable system, it is recommended to add thermal insulation and a thermostat. The additional thermal insulation works to reduce heat loss, and the thermostat allows you to duty cycle your Kompensator system based on external pipe temperature. Both accessories combined can increase energy efficiency by as much as 80%.

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Kompensator is ideal for pipe freeze protection in off-grid (solar and wind) applications as well as small diameter hoses, appliance and comfort heating, condensate freeze protection, oil lines, hydraulic hoses, pumps and compressed air systems. When used in the transportation industry, Kompensator systems are capable of maintaining hydraulic oil viscosities in cold temperatures, minimizing stress while maximizing winter performance.

Application examples include but not limited to;

  • Existing Water Supply Lines Subject to Freezing
  • Small Diameter Water Supply Lines
  • Large Diameter Pipes and Hoses
  • Tanker Fluid Delivery Hoses
  • Metallic and Non-Metallic Pipes and Drains
  • Compressed Air Systems
  • Metal and Non-Metal Holding Tanks
  • Values, Shutoffs and other Exposed Fittings
  • Diesel Exhaust Fluid (DEF) Holding Tanks and Lines
  • Hydraulic Oil Lines and Hoses
  • Sewage, Septic and Effluent Pipes

Kompensator can be found providing freeze protection in many of the following places:

  • Commercial Fluid Delivery Trucks
  • Fire Trucks and other Emergency Vehicles
  • Camps and Motorized Recreational Vehicles
  • Mining and Exploration Camps/ Developments
  • Commercial and Industrial
  • Off-Grid Residences, Lake Homes and Cottages
  • Oil and Gas Industry

Kompensator can be customized and provided in a variety of watt densities to suit various installation variables. If you feel you have a special or unique application for Kompensator please contact Heat-Line directly and speak with one of our knowledgeable product specialists.

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Features

  • Compatible with DC and AC voltages
  • Compatible with various methods of power generation including battery alternators
  • Can be installed on all metallic and non-metallic pipes, tanks and vessels
  • Provides reliable freeze protection of all pipe diameters (when properly measured and installed)
  • Easily and quickly installed on most pipes without their removal
  • Can be fully insulated to increase energy efficiency
  • Can be used with a variety of control devices including timers and thermostats
  • Suitable for direct earth burial
  • Suitable for wet location
  • Available in 5 ft. (1.5m) increments, custom lengths are also available

Benefits

  • Manufactured in North America
  • 1 year limited warranty
  • No need for power inverters
  • Continuous ground path
  • Will never melt or burn through the water pipe, even if the pipe is dry
  • Kompensator heating cables can be overlapped with concern of overheating at point of contact
  • Most reliable and energy efficient system on the market
  • Supplied with a 6 ft. (1.8m) power lead as a cord set (CS) to be directly hard wired
  • No other product combines the features and offers the flexibility of Kompensator by Heat-Line
  • Proven performance in extreme cold climates
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Electrical Specifications

  • Self-regulating/conductive polymer heating cable
  • Thermo Plastic Elastomer (TPE) outer jacket
  • 12 V systems – 3W/ft. (9W/m) at 50°F (10°C) maximum length of 40 ft. (12m)
  • 12 V systems – 5W/ft. (15W/m) at 50°F (10°C) maximum length of 30 ft. (9m)
  • 24 V systems – 3W/ft. (9W/m) at 50°F (10°C) maximum length 60 ft. (18m)
  • Lengths up to 25 ft: 6 ft. (1.8 m), 14 AWG SJEOOW supply cord for direct hard wire connection, additional inline fuse protection required
  • Lengths greater than 25 ft: 6 ft. (1.8 m), 12 AWG SJEOOW supply cord for direct hard wire connection, additional inline fuse protection required

Plumbing Specifications

  • Suitable for pipes of all diameters both metallic and non-metallic
  • Nominal heating cable thickness 0.25 in. (6mm) / width 0.50 in.(12.5mm)
  • Direct earth burial and wet location suitable
  • Suitable for exposure temperatures up to 150°F (65°C)
  • Manufactured in North America
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Determine the Length of Kompensator Heating Cable You Need for Pipe Freeze Protection

The Kompensator system is an advanced external low voltage, self-regulating heating cable system factory finished and supplied job-ready to a pre-determined length provided at time of order. Kompensator systems are priced in standard lengths of 5 ft. (1.5m) increments up to a maximum of 60 ft. (18m) depending on the voltage and watt density required. (See Product Specifications)

While most Kompensator systems are manufactured in standard lengths, special lengths of any measurement can also be requested within the maximum lengths allowed for 12 and 24 volt systems. For example, if an 18 ft. (5.5m) system was required, instead of purchasing a 20 ft. (6m) system, a special order could be placed for an exact length of 18 ft. (5.5m).

To freeze protect small diameter pipes of 2 in. (51mm) or less a single trace of Kompensator heating cable is often enough when installed in combination with the proper insulation. In extreme cold applications more insulation and or passes of Kompensator may be required. Increasing your thickness of insulation can also minimize the required amount of Kompensator heating cable and vastly increases your energy efficiency.

In many applications, speaking with a Heat-Line application specialist directly is advised as low voltage Kompensator systems are offered in several voltages and watt densities. A Heat-Line application specialist can help determine the proper amount of heating cable required, the installation process of the heating cable, whether single trace or double trace, and the required thickness of insulation based on the environment and ambient temperatures.

Prior to contacting a Heat-Line application specialist please have the following information available:

  • Pipe Type (Metallic/ Non-metallic)
  • Pipe Diameter
  • Pipe Length
  • Minimum Ambient Temperature
  • Number of valves and or spigots located along the pipe
  • Thickness of Insulation (Heat-Line offers a variety of insulation materials to meet application requirements)

For pipe diameters greater than 2 in. (51mm) and specific questions regarding the required lengths of Kompensator for your parameters please call Heat-Line directly and speak with one of our Heat-Line application specialist.

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Kompensator is a custom order product however in most cases it can be shipped out within 3 days from time of order. Please call for current availability and lead times.  

 

Included in a Kompensator system:

  • Factory finished, low voltage, self-regulating heating cable set in pre-determined length
  • 6 ft. (1.8 m), 14 AWG SJEOOW supply cord on system lengths up to 25ft (7.5m) for direct hard wire connection, additional inline fuse protection is required during installation
  • 6 ft. (1.8 m), 12 AWG SJEOOW supply cord on system lengths greater than 25ft (7.5m) for direct hard wire connection, additional inline fuse protection is required during installation
  • 1 year limited warranty
  • Clear, concise installation and support documentation

 

Kompensaor Accessories: 

PART NUMBER DESCRIPTION
KHL-STAT 12/24V thermostat
INSUL-PAD Elastometric flexible insulation (10 ft long, 6 inch wide, ½ inch thick)
INSUL-TAPE All weather Aluminum foil tape (150 ft)
INSUL-FOIL Aluminum bubble foil insulation (16 in wide, sold by the foot)
INSUL-1.00 Insulation sleeve for 1 inch ID pipe (1 5/8 inch ID, 6 ft long)
INSUL-1.25 Insulation sleeve for 1 1/4 inch ID pipe (1 7/8 inch ID, 6 ft long)
INSUL-2.00 Insulation sleeve for 2 inch ID pipe (2 5/8 inch ID, 6 ft long)
HLP-TAPE Tape for insulation sleeves (100 ft)
PLD-CG Cable guards/protectors (pkg of 4, 6 in each)

 

PART NUMBERS

 

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Q - Is Kompensator safe to use on plastic pipes?

A - The Kompensator system is approved for use on all metallic and non-metallic pipe applications. The advance self-regulating technology employed in the Kompensator product renders it safe on plastic pipes even when dry as it can never overheat and damage the pipes.

 

Q - Can Kompensator be buried?

A - The Kompensator system is manufactured using the same proprietary end seal and power terminations as Heat-Line’s Paladin for Pipe system, making it suitable for both direct burial and wet locations.

 

Q - Do I have to spiral the Kompensator system around the pipe or just run straight along the side of the pipe?

A - Since Kompensator has extraordinary heat transfer properties it can be simply run straight along most the pipes 2’’ ID in diameter or less without the need to pitch or spiral the heater. For pipes greater than 2” in diameter spiralling dual (double) tracing may be necessary.

 

Q - Does Kompensator come with a thermostat?

A - A thermostat is not included with the Kompensator product as they are not required for proper and safe operation; however a thermostat can be purchased as an additional accessory. Depending on system applications, or where automatic operation is preferred, a thermostat can be used to switch the system on and off to help conserve power or to duty cycle the system. When combined with insulation thermostats can substantially increase energy efficiency.

 

Q - What do I do if I have extra Kompensator heating cable?

A - If you have extra heater you can loop the excess back up the pipe or concentrate more heating cable in more exposed sections of the pipe. If needed, it is safe for the heating cable to overlap as it is self-regulating and will not overheat.

 

Q - Does the unit shut off when not required?

A – No. Kompensator self-regulating heating cable systems increase heat output with cold but more importantly, decrease heat output with warmth. As a result, Heat-Line brand products are very energy efficient to operate, but do not completely shut off as they can only idle their output to a minimum amount. To completely shut off the system a switch must be added to the circuit an/or installed with a thermostat.

 

Q - How much power does a Kompensator system consume?

A - All Heat-Line brand systems including Kompensator employ Heat-Line’s advanced self-regulating heating cable technology which operates to deliver energy and heat output to areas of the pipe that are cold and reduces energy and heat output to areas which are warm. While the overall amount of energy consumed depends on multiple factors you can be assured that you are installing the most energy efficient heating cable system available. If you would like to reduce your energy consumption further you can investigate the addition of a thermostat, timer, and or other control device.

 

Q- Is there a maximum length of Kompensator heating cable systems?

A – Yes. The maximum circuit length of Kompensator that is allowed on a 12V, 3W/ft. (9W/m) circuit is 40 ft. (12m), 12V, 5W/ft. (15W/m) circuit is 30 ft. (9m), 24V, 3W/ft. (9W/m) circuit is 60 ft. (18m).

 

Q- What length of Kompensator will I need?

A – The length of Kompensator heating cable that will be required can change from application to application as it depends on the type and size of the pipe, the amount of insulation applied to the pipe after the Kompensator is installed, and the minimum outdoor ambient temperature. In most cases pipe diameters equal to or less than 2in. (51mm) only require a single run of Kompensator for proper protection in climates as cold as -40°F (-40°C) when properly insulated.

 

Q – Can Kompensator be cut to length if too long?

A – No. The Kompensator system manufactured by Heat-Line is a pre-assembled factory terminated advanced self-regulating heating cable system that is not designed to be field terminated and or tailored to length. If you have extra heater you can loop the excess back up the pipe or concentrate more heating cable in more exposed sections of the pipe.

 

Q – My Kompensator system is too short; can I add a small section onto the end? If not, what can be done?

A – No. The Kompensator system manufactured by Heat-Line is a pre-assembled advance self-regulating heating cable system that includes a proprietary end-seal termination and elastomeric heating cable jacket engineered for direct burial and wet locations. As such the Kompensator system cannot be spliced together in the field. If a greater length of the Kompensator is required you may purchase a single continuous product of the proper length, and or relocate a second power source and install an additional Kompensator system to complete the required freeze protection.

 

Q- What type of insulation should I use with the Kompensator system?

A – Heat-Line recommends to use insulation that is best suited to the environment in which it is going to be installed. A common type of insulation employed with Kompensator heating cables is fire resistant water proof pipe foam insulation sleeves. You are also able to implement fiberglass insulation provided it is properly weatherproofed based on the environment.

 

Q – Where do I purchase the Kompensator heating cable system?

A – The Kompensator heating cable system manufactured by Heat-Line is available directly through Heat-Line and or any of our Heat-Line product distributors. For a list of Heat-Line product distributors in Canada and the United States please contact Heat-Line directly on our toll free number at (800) 584-4944.

 

Q – Do I have to use insulation with the Kompensator system?

A – Insulation is highly recommended when using the Kompensator system, especially if the installation is above ground in ambient outdoor air. Insulation helps reduce the overall heat loss and therefore reduce the amount of energy the Kompensator heating cable must consume. It also helps keep the heating cable in consistent contact with the pipe and works as a form of protection to prevent damage to the heating cable.

 

Q - Does a 24-volt system use less power than a 12-volt system?

A – No - Energy efficiency has nothing to do with the designated voltage. We pay and consume energy in watts, not in volts. For instance, a 5W/ft (15W/m) self-regulating 12 volt system would consume more energy at similar temperatures than a 3W/ft (9W/m) self-regulating 24 volt system.

 

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