components · standard component heaters in many shapes, sizes and wattages. chromalox is the...

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1-800-443-2640www.chromalox.com

Component Heaters include thebasic types of heating elements:

• Tubular Elements

• Thin Blade Heaters

• Strip Heaters

• Ring & Disc Heaters

• Band & Nozzle Heaters

• Cartridge Heaters

• Flexible Heaters

• Specialty Heaters

• Cast-in Heaters

ComponentsOverview

Component heaters may be used bythemselves to solve many heating problems.They may also be incorporated into morecomplex heating systems, providing acomplete thermal solution for your heatingrequirements.

Chromalox carries the widest selection ofstandard component heaters in many shapes,sizes and wattages. Chromalox is the “FirstChoice for Thermal Solutions”.

Applications

With component heaters, most often theshape and size will be the determining factorin most heater applications. Brief descriptionsof each heater type follow, with selectionguidelines that lead to a detailed descriptionon individual product pages.

Tubular heating elements perform exceptionalheat transfer by conduction, convection orradiation to heat liquids, air, gases andsurfaces. In most heater assemblies, tubularelement design configurations vary — round,triangular, flat press and formed bends aremade to customer requirements Custom builtfrom 0.200" to 0.475" diameters, a multitudeof sheath materials with temperatures to1600°F, watt densities to fit many applicationsand up to 600 volts. Over 20 optionalterminations and many stocked accessories.

Thin blade heater elements provide moresurface area than standard tubular elements tooffer greater wattage or lower watt densities.Select from many sheath materials with wattdensities to 75 W/in2 and temperature as highas 1200°F. Heating elements can be as long as120" and are capable of being formed intomany configurations for heating via immer-sion, direct surface contact or convection.Three wire construction within the elementprovides uniform heating. Available in singleor 3-phase current terminations with a 120 to240 volt range.

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1-800-443-2640 www.chromalox.com

ComponentsApplication GuidelinesApplications (cont’d.)

Strip/Ring/Disc heating elements are ruggedand easy to install for heat transfer byconduction or convection to heat liquids, air,gases and surfaces with temperatures to1500°F and watt densities to 35 W/in2.Common applications include dying, melting,baking and curing. Strip heater sizes rangefrom 0.5" wide to 2.5" and lengths to 72" long.Heaters bolt or clamp to many surfaces.Nested ring heaters can provide concentratedheat in small areas. Select from many sheathmaterials, termination styles, operatingtemperatures, sizes, voltages, wattage ratingsand mounting devices.

Band heaters grip tightly to cylindricalsurfaces to supply uniform heat transfer,critical to the heater life. Chromalox bandheaters are flexible and come in one or two-piece construction for easy installation and

removal. Accommodate diameters as small as15/16" and as large as 20" and capable ofreaching temperatures of 1600°F. Stainlesssteel braids and conduit protect terminationsand resist contamination. Completelycustomize your heater by specifying exactphysical dimensions, material, electric ratingsand terminations.

Cartridge heaters are high efficiency heatingelements. Diameters of cartridge heaters rangefrom 0.25" to 1.25". Watt densities from 25W/in2 to 200 W/in2 and sheath temperatures to1600°F. Optional end seals resist contaminantsand moisture from entering inside the heateras operating temperatures increase.Chromalox provides a variety of sizes, wattageratings, voltages and protective features tomeet many challenging applications.

Flexible heaters are very versatile and providesolutions to a vast number of low-to-medium

temperature applications. Heaters aremanufactured with rugged light-weightmaterials providing chemical and moistureresistance with operating temperatures to390°F. Wire elements are durable and woundprecisely within the structure for optimalperformance. A variety of electrical, shape andcontour fittings to meet many specifications.

Cast-in heaters are custom designed forcontour and multi-plane, clamp-on applica-tions. Many sizes and contours are available toaccommodate machined and cast contactsurfaces that require close tolerances. Holes,cutouts or slots to accommodate thermo-couples or machine obstructions providedwhen required. From as short as 2.5" and aslong as 30", cast-in heaters provide operatingtemperatures to 1200°F with watt densities to40W/in2. Select from aluminum alloys, bronzealloys and iron cast materials.

Tubular Heaters — Section Outline Tubular Heaters — Selection Guidelines

Application-Modifications A-4Factory Bending A-8Terminals A-10Customer Bending A-12

Section Page

Round INCOLOY® 0.475 TRI A-130.475 TRID A-140.475 TRIW A-140.430 TRI A-150.375 TRI A-160.315 TRI A-170.260 TRI A-190.246 TRI A-200.200 TSSM A-21

Stainless Steel 0.475 TRSS A-220.475 TRSSH A-230.475 TRSSN A-23

Steel 0.475 TRS A-240.475 TRSCD A-240.475 TRSC A-250.315 TRS A-27

Copper 0.475 TRC A-280.475 TRCC A-280.315 TRC A-30

Heart Shaped INCOLOY® 0.5 TI A-310.375 TI A-330.375 RTU A-350.375 UTU A-370.375 UTU-LT A-400.375 URPT A-410.375 LMS A-42

Steel 0.5 TS A-430.375 TS A-44

Flat Pressed INCOLOY® 0.375, 0.4375 ATS A-460.375, 0.4375 ATU A-46

Round/Single End INCOLOY® 0.475 STRI A-470.315 STRI A-48

Steel 0.475 STRS A-490.315 STRS A-50

Copper 0.475 STRC A-510.315 STRC A-52

Hopper Heater INCOLOY® FSRM A-53Thin Blade Stainless Steel CTB A-54

DiameterType Sheath (In.) Model Page

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Cartridge Heaters — Section OutlineStrip, Ring & Disc Heaters — Section Outline

Cartridge Heaters — Selection Guidelines

ComponentsSelection Guidelines

Strip, Ring & Disc Heaters — Selection Guidelines

Application Guidelines A-90Selection Guidelines A-91Installation Recommendations A-92Modifications A-93Thermocouple Leadwire A-95

Band & Nozzle Heaters — Selection Guidelines

Application & Features A-55Selection & Installation A-56Modifications A-57Accessories A-58

Section Page Section Page

Strip 1-1/2 OT A-61S & SE A-62ST A-63PT A-63TH A-64STTH A-64

Strip 3/4 SN A-652-1/2 WS A-651 SNH A-661 NH A-663/4 NS A-673/4 NSL A-671/2 NSA A-681-1/8 SSNHM A-681-11/16 SSE A-691-11/16 SSEM A-69

Explosion-Proof AEPS A-70AECH A-71

Ring A A-72HSN A-73HSW A-73RHSW A-73

Disc HSP A-74

SizeType (In.) Model Page

One-Piece Band 1-1/2 DB A-752-1/2 DBW A-76

Two-Piece Band 1-1/2 HB A-772 HBT A-78

One-Piece/Mica Ins. MB-1 A-79Two-Piece/Mica Ins. MB-2 A-81Ceramic Band CB A-82One-Piece Nozzle HBA A-88

HBZ A-89

SizeType (In.) Model Page

INCOLOY® 1/4 - 3/4 CIR A-96Stainless Steel 15/16, 1-1/4 C-DE A-101

C-LD A-101Brass 15/16 - 1-19/64 C-HD A-102Screw Base SCB A-103Sleeve Adapter Accessory A-103Heavy Duty CTRH A-104Stud Heater CBH A-105

SizeType/Sheath (In.) Model Page

Section Page

Overview A-106Technical & Applications A-107Selection Guidelines A-109Ordering Guidelines A-116

Flexible Heaters — Section Outline

Flexible Heaters — Selection Guidelines

Slicone Rubber General Purpose SL-N A-111Drum Heater SL-D A-112Enclosure & Air SL-B A-113

KAPTONTM Foil/Polymide KH A-114Fiberglas® Woven General Purpose W & SLW A-115Heavy Duty Woven Drum Heaters PHD A-117

with Thermostat PHDT A-117Thermal Insulation Drum IBG A-118

Type Description Model Page

Specialty Heaters — Selection Guidelines

Soft Metal Melting Pot P A-119Heavy Duty Hot Plate ROPH A-120Open Coil Oven Elements OV & OVS A-121Cast-in Heaters A-122

Type Model Page

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Transferring Heat to Metal

In Moving Air — Compressionfittings, factory mounted fittings orbrackets will mount a tubular elementin a duct or air heating chamber.

Tubular HeatersApplication Guidelines

• Up to 172" Lengths (Std.)

• 75 - 10,000 Watts (Std.)

• 120, 240 and 480 Volt (Std.)

• 3 - 53 W/In2 (Std.)

• Max. Sheath Temp.

• Copper — 350 °F

• Steel — 750°F

• Stainless Steel — 1200 °F

• INCOLOY® — 1600°F

Applications

Extremely Versatile Heat Source — Highlyadaptable, the tubular element, in its manyforms and as a component of Chromaloxpackaged heaters and systems, has vastlyincreased the scale of electric heatingapplications. The heaters' mechanical andelectrical flexibility are important to processengineers and product designers alike, asheating requirements can be matchedaccurately by proper selection from a greatvariety of element lengths, sheaths, diametersand watt densities.

Product Uniformity — Electric tubular heatingelements provide a method of applying theexact amount of heat required at a specificarea. When used with appropriate temperaturecontrol, product repeatability is assured.

Increased Production — Adding heat to aprocess often leads to increased production.For example, drying time may be reduced byheating the air or the product being dried.Chemical and cleaning processes are oftenmore efficient when heated and a moreconsistent finished product results.

Less Down Time — Chromalox quality tubularelements with properly applied watt densityand sheath material will provide long life, lessdown time and little or no maintenance.

Construction

Chromalox tubular elements are used forpractically the entire range of electricresistance heating applications.

A metal sheath material is selected. The propersize resistance wire for the heating element iscarefully selected and verified by computercalculations to ensure the longest service lifepossible. The high quality resistor wire iscarefully tested and inspected to meet rigidspecifications prior to being coiled. Theresistance wire is then welded to a terminalpin to assure positive connection. The wire iscentered in a metal sheath and insulated withhigh quality magnesium oxide which is highlycompacted around it and acts as an electricalinsulator. This material readily conducts theheat from the coiled resistor to the metalsheath and puts the heat where it is required,which results in maximum heater life.

The highly compacted magnesium oxide holdsthe terminal pin securely allowing maximumtorque of eight inch pounds when tighteningterminal hardware

In Liquids — Tubular elements listed may bemounted through the side wall of a tank withcompression fittings or by factory mountedfittings.

Typical Installations

In Free Air — For applications like ovens anddrying cabinets, tubular elements arecompact, rugged heat sources. Their formabil-ity permits fitting around other oven compo-nents and work protrusions, concentratingheat at any point.

In Free Air

In Moving Air

In Transferring Heat to Metal Parts - Dies,Molds, Platens — The available diameters,lengths, ratings, watt densities, cross-sections, and maximum temperatures providethe solution for a given job.

In Liquids

MetalSheath Compacted

Magnesium OxideTerminal Pin

Cold Length

Helically Coiled Resistor Wire

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SolidsMolds, Platens, Up to 1400 Clamp-On INCOLOY® Up to 300 30Dies, Pipes, Up to 500 20Tanks Up to 800 15

Up to 1000 10Up to 1200 7Up to 1400 2.5

LiquidsWater, Clean Up to 250 Immersion Copper 250 Up to 802

Up to 550 Immersion INCOLOY® 550 40Water Solutions, Up to 200 Immersion 304SS 200 50Mild Corrosion1, Up to 200 Immersion INCOLOY® 200 50Corrosive1

OilLow Viscosity Up to 180 Immersion Steel Up to 180 23Med. Viscosity 15High Viscosity 6.5

Air & GasesMoving, 9'/sec Up to 1500 In Ducts INCOLOY® 500 40Velocity 800 32

1000 251200 151500 2

Still Up to 1500 Ovens INCOLOY® 700 301000 201200 101500 2

Temperature Work AllowableProduct To Desired Suggested Sheath Temperature Watt DensityBe Heated (°F) Application Material (°F) (W/In2)

1. See Corrosion Guide in Technical section. 2. VDE - 50 W/In2 max.

Tubular Heating Application Guidelines

Tubular HeatersApplicationGuidelines (cont’d.)Liquid Heating

Direct Immersion — Water and watersolutions can generally be heated to anydesired temperature. If liquid is underpressure, temperatures should not exceed themaximum sheath temperature of the elementminus 100°F.

Note — Heated section of element must beimmersed at all times when energized. Longercold ends can be provided, if required.

Threaded fittings are available for mountingthrough tank walls.

Oil Heating

Steel sheath elements can be used for heatingoils, heat transfer oils and other solutions notcorrosive to steel sheath.

Air & Gas Heating

Use watt densities compatible with worktemperatures. Refer to Technical section ofthis catalog. Heaters mounted horizontallymust be supported to avoid sagging at hightemperatures.

Proper spacing of supports may vary withapplication temperature, element diameter andsheath material. Generally 12 to 18" spacing ofsupports is adequate.

Where air flowing over elements permits useof higher watt densities, make sure air flow isevenly distributed.

Allow approximately 1/8" per foot of elementlength for expansion and contraction ofelements (i.e., 24" long element could expand1/4" when energized).

Clamp-On Heating

Use watt densities compatible with worktemperatures. Refer to Application Guide forTubular Heating of Solids, Liquids, Air & Gasor use curve G-175S in Technical section.Heaters should be clamped tightly for goodheat transfer but should be allowed to expandas they heat up. Heaters clamped too tightlywill bow away from the heated surface whichresults in poor heating efficiency and possibleheater failure. It is generally best to tighten themiddle clamp first to hold the element. Otherclamps should be tightened enough to hold,but back off 1/2 turn to allow for expansionand contraction.

Heaters should be spaced on approximatelytwo inch centers minimum.

Heaters are commonly installed by clampinginto machined grooves for better heat transfer.

Note — Depth of groove should never exceedelement diameter to assure positive clamping.

Grooves should be machined to the followingtolerences:

WARNING — When insulation is used overelements, an air space must be providedbetween the elements and insulation.Insulation should never be in direct contactwith heated section of elements.

Application Engineering

Is available from direct sales and engineeringrepresentatives. The largest, most experiencedorganization of field engineers in the countryis ready to help solve any heating problem.Contact your Local Chromalox Sales office.

Clamp-On Heating

0.5 12.70.475 12.070.43 10.920.375 9.530.315 80.26 6.60.246 6.250.2 5.08

Inches (±0.005) Millimeter

Metric Diameter Equivalents

Copper 350Steel 750MONEL® 900Stainless Steel 1200INCOLOY® 1600INCONEL® 1600

Max. AllowableSheath Material Sheath Temp. (°F)

Max. Sheath Temperatures

To assure maximum life, tubular elementsshould not be operated beyond the tempera-tures in this tabulation:

ElementDia. Less

0.0080.010

0.0030.015

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Tubular HeatersDesign & InstallationGuidelinesDesign Considerations

Sheath Material — For resisting corrosioninherent in the process or environment and forwithstanding the sheath temperature required— Standard sheath materials are INCOLOY®,steel, copper and stainless steel (type 304).Other types of stainless steel, MONEL®,titanium and INCONEL® are available.

Job Requirements — The calculation of totalheat requirements for an application isoutlined in Technical section. For assistance,contact your Local Chromalox field salesengineer who will be glad to contribute hisjudgement, experience and knowledge insolving your heating problem.

After the specific heater size and rating hasbeen tentatively selected, the watt densitymust be checked against the curves inTechnical section.

If the heater selected has a watt density higherthan stipulated by the curve, consider thesealternatives:

1. Use more heaters of a lower watt densityto obtain the required kW capacity.

2. Reduce the kW capacity needed byreducing heat losses and/or allowing fora longer heat-up time.

Watt Densities — The watt density of theelement, or watts per square inch of elementheated area, should be low for heating asphalt,molasses and other thick substances with lowheat transferability. It can be higher for heatingair, metals, liquids and other heat-conductingmaterials. See curves in Technical section fordetermining allowable watt densities.

When high operating temperatures areneeded, watt density must be limited in ordernot to exceed the maximum sheath tempera-ture. Watt density is given in the specificationsfor each tubular heater.

In general, a viscous material with low thermalconductivity requires a low watt density.Higher watt densities can be used with thinnerliquids and with materials of high thermalconductivity. Premature loss of the elementdue to excessive temperature may result if thematerial’s heat-take-away ability is low. Also,the material may be charred, carbonized or itschemical makeup altered by overheating.

Terminal Selection — Stocked tubulars areshipped with standard terminals, see TerminalOptions in this section. Many other terminalsand terminal end seals are available made toorder.

CAUTION — Protect terminals from possiblecontamination from surrounding atmospheressuch as oil fumes, chemical vapors from otherprocesses, moisture, weather, etc. MgOinsulation is hygroscopic.

Vacuums — Tubular heaters operate at highertemperatures in a vacuum because there is noair to take away the heat. Therefore, wattdensities are recommended to be 20 to 30%lower. It is recommended terminals of theelement be kept outside of the vacuum.

Code Compliance — Chromalox manufac-tures the highest quality heaters and controlsand, where applicable, in compliance withsuch codes as the Canadian StandardsAssociation (CSA), Underwriters LaboratoriesInc. (UL) and Verification of Devices forEurope Testing and Certification Institute(VDE).

Installation Guidelines

Wiring — Must be in accordance with TheNational Electrical Code (NEC). It is importantto use the correct wire gauge to carry theamperage required. A wire not large enoughcan overheat, become brittle and break. Theambient temperature must also be consideredin choosing the correct type of wire andinsulation. Make sure wiring to terminals istight. Keep terminals away from heat, ifpossible. (For higher temperatures, contactyour Local Chromalox Sales office.)

Mounting Methods — Elements can besupplied with threaded fittings for mountingthru walls of tanks, ovens, etc. Compressionthreaded fittings are also available for easyfield installation. Rings, clips, brackets andwashers can also be attached to elements formounting purposes.

Copper 1 1 3/8 21/64 3-3/8 1-1/2 1±1/16 #10-32Steel or INCOLOY® 1 1 3/8 21/64 3-3/8 1-1/2 1±1/16 #10-32Copper, Steel or INCOLOY® 1 1 1/2 15/32 3-7/16 2-1/2 13/16±1/16 #8-32

TerminalSheath Material A B C D E F G Size

Dimension (In.)

1. See complete heater dimensions in table on product pages.

Easy Bending — To put heat whereit is needed, tubular elements can be bent to fitmost requirements. See following pages forcustomer bending and factory bending details.Bending should be done around a smoothround object such as a piece of pipe. Forminimum bending radii, see BendingGuidelines.

Triangular Cross-Section

These unique cross-sectioned elements arespecially designed for high element surfacetemperature applications, and whereverextreme rigidity is required.

Triangulation — A patented extra step byChromalox to increase insulation density andmaximize heat transfer and operating life. Thismethod of compaction increases uniformity ofresistance wire spacing to help eliminate hotand cold spots. It also increases the rigidity ofthe element, which is an advantage in someapplications.

The terminal ends of these elements are re-rounded to facilitate the use of threadedfittings or other mounting methods.

The heart shaped cross-section is recom-mended for certain heavy duty applications. Ithas added structural strength, achievedthrough die pressing, which resists deform-ation or sagging when installed in the flow ofhigh velocity air or thick oils and compounds,or in high surface temperature air heating.

E

Heated LengthB

CD

F

E

F

G G

TerminalSize

Insulation

A

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Tubular HeatersModificationsWorld Leader in the Manufacture of ElectricHeating Elements — Chromalox offers themost complete line of tubular heatersavailable. Standard diameters are:

Cross-SectionViews

Round

Triangular(heart shape)

Flat Pressed

0.20.2460.2600.3150.3750.430.475

3/8”1/2”

3/8”7/16”

}}

}Other diameters available are 0.440, 0.496,0.625" round, also 0.553 and 0.660" round insingle-end terminal construction only.

Round Cross Section — Highly adaptablewhere elements must be bent — particularly ifbending is performed in the field.

Triangular Cross Section — Patented processproduces elements with the closest possibledimensional control.

Triangulated Cross Section — Flat pressed.Patented process provides large contact areafor clamp-on applications. This means moreefficient heat transfer, fewer elements sincehigher element ratings may be employed.

Voltage or Wattage — Heaters can be madefor operation on any voltage and rated at anywattage suitable for the application withinpractical limits. For voltages higher than 480V,specify high voltage terminal construction.See Component section Tubular Heater (0.475or 1/2" diameter only).

Special Wattage Distribution — Heaters canbe made with higher wattages toward the endof the heated section to help offset losses incertain applications. Check with your LocalChromalox Sales office for additionalinformation.

Tubing — Standard industrial grade wallthickness:

In addition, titanium and other 300series stainless steel sheaths areavailable upon request. For applica-tions requiring other materials,contact your Local Chromalox Salesoffice.

Cold Section — Longer cold ends can besupplied, as required, up to 20 inches. Forlonger cold ends, contact your LocalChromalox Sales office.

Factory Bending — Tighter bends can bemade at the factory.

Tubular heaters can be formed to manydifferent shapes to suit your application. Thisis done by specially designed bending toolsand repressing dies for bending on manydifferent radii.

Additional Features — Many additionalfeatures are available for the difficult jobswhich require custom designed elementsemploying Chromalox's vast engineeringexperience.

Repressed Bends — Tubulars can be bent totighter radii at the factory. Bends are thenrepressed to ensure restoration of insulationfor long life. Customer bending on larger radiidoes not require repressing. (See FactoryBending Guidelines in this section).

Sheath Length — Heaters can be made inunspliced lengths up to 51 feet.

This eliminates the need for a spliced jointwhich is always a possible weak point thatmight cause premature heater failure.

Terminal Construction — Many choices tosuit your application. Tubular elementsgenerally have a terminal for electricalconnection at each end. Single endconstruction has both terminals at the sameend.

UL and CSA — Chromalox tubular heaters canbe furnished as UL Recognized and CSACertified components with the addition of aterminal end seal. Terminal end seals can beadded to stock elements and shipped in oneweek. (UL File E 65554, Guide UBJY2, CSAFile 40859). Use “end seal/moisture barrier” inplace of end seal.

VDE — Chromalox tubular heaters can befurnished as VDE Certified. Contact your LocalChromalox Sales office.

Wide Choice of Sheath Materials — Availableto meet a wide variety of applications.Standard sheath materials are: INCOLOY®,steel, type 304 and 316 stainlesssteel, copper, INCONEL® and MONEL®.

0.246 Brass 13/32 7/32 3/8 - 24 15/32 7/80.315 Brass 15/32 5/16 7/16 - 28 13/16 7/83/8 Brass 17/32 5/16 1/2 - 28 13/16 7/81/2-0.475 Brass 21/32 5/16 5/8 - 24 13/16 10.246 Steel 13/32 7/32 3/8 - 24 15/32 7/80.315 Steel 15/32 5/16 7/16 - 28 13/16 7/83/8 Steel 17/32 5/16 1/2 - 28 13/16 7/81/2-0.475 Steel 21/32 5/16 5/8 - 24 13/16 10.246 Stainless Steel 13/32 7/32 3/8 - 24 15/32 7/80.315 Stainless Steel 15/32 5/16 7/16 - 28 13/16 7/83/8 Stainless Steel 17/32 5/16 1/2 - 28 13/16 7/81/2-0.475 Stainless Steel 21/32 5/16 5/8 - 24 13/16 1

Max. WallElement Fitting Mtg. Hole Thickness Thrd. Size

Dia. (In.) Material Dia. (In.) (In.) F A B

Dimensions (In.)

Nickel PlatedSteel Washer

B

Gasket WasherA

Threaded Fittings

Welded orBrazed Ring

0.2 100.246 400.375 400.315 400.43 400.475 513/8 17±1/8"1/2 17±1/8"

Element Dia. Max. Heater (In.) Length (Ft. ± 1%)

Note — Single-end elements have amaximum sheath length of 10 feet.

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Tubular HeatersFactory BendingGuidelines

OAL = 2L2 + 1.14R1 - 1.29" Dia. + 2L1 + 1.14R2

L1

L2

AB1

B2

Dia.R1

R2

R1

Dia.

R2

A

L

BC

H

R1

OAL = 2H - 0.86R2 - 2.86" Dia. + 2A + 1.14R1

OAL = 2L + 1.14R - 0.43" Dia.

Dia.

B

AR

L

Dia.

A

L

R

OAL = 2L - 0.86R - 1.43" Dia. + A

Figure 1 Figure 2

Figure 3 Figure 4

Minimum Bends for Tubular Heaters

To Order — Specify model, PCN, volts, watts, special features, if required, and quantity.

Specify for Factory Formed Tubulars:A. Figure number.B. A, B1,2, C, D, E, H, J, K, L1,2 and R1,2,3 dimension as required.C. N - number of turns, Dia. - Element Diameter- aid < - angle as required.D. Material for threaded fittings.E. Special terminal type.F. Position of crown (flat side) of element (TC, TI, TS only).G. Submit sketch with special details.

Notes —1. These are general guidelines only. Special dimensions and configurations

are possible. Contact your Local Chromalox Sales office.2. A dimension can be less if no fittings are required.3. C dimension may need to be greater if special fittings are used.4. E dimension is a minimum when R dimension is less than customer

minimum bending radius.5. Heart Shaped cross-section only.

1/2" INCOLOY® 5 3/4 1-3/8 1 1-1/2 5 8Steel & Copper 1/2 1-3/8 1 1-1/2 8 60.475" INCOLOY® 3/4 1-3/8 1 1-1/2 3 8Steel & Copper 1/2 1-3/8 1 1-1/2 3 60.430" INCOLOY® 7/16 1-3/8 1 1 3 8Steel & Copper 7/16 1-3/8 1 1 3 63/8" INCOLOY® 5 9/16 1-3/16 1 1-1/2 3-3/4 5Steel & Copper 3/8 1-3/16 1 1-1/2 6 30.375" INCOLOY® 3/8 1-3/16 1 1 2-5/8 5Steel & Copper 3/8 1-3/16 1 1 2-5/8 30.315" INCOLOY® 9/16 1-3/16 1 1-1/2 2 5Steel & Copper 5/16 1-3/16 1 1-1/2 2 30.260" INCOLOY® 1/4 1-1/8 1 1-7/8 5Steel & Copper 1/4 1-1/8 1 1 1-7/8 30.245" INCOLOY® 3/8 1-1/16 1 1-3/16 1-1/2 5Steel & Copper 1/4 1-1/16 1 1-3/16 1-1/2 30.200" INCOLOY® 1/4 1/4 1 3/4 1-1/4 5

Element Dia. Inside& Sheath R1,2,3 A B1,2 C Inside D E

Dimensions (In.)1

∆

∆

Note — OAL represents overall length.

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B

OAL = 2L2 + 2H + 2I + 2L3(X-1) - 0.86R3 - 0.86R4 - 4.86Dia.+ 1.14R1(X) + 1.14R2(X-1) - (2X-1)0.43Dia.

OAL = 2L2 + 2H - A - 2.28R1 - 0.86R2 - 3.29Dia.

Dia.

L2

R1

B1

L1

R2

H

A

C

B2

Figure 16

Figure 5

OAL = (D + Dia.)3.14 + 1.14R + 2C + 3.71Dia. - A

L

A

C

Dia.

D

R

Figure 11

OAL = (D + Dia.)3.14 + 1.14R + 2H + 3.28Dia. - A

D

Dia. C

A

R

H

Figure 12

Tubular HeatersFactory BendingGuidelines (cont’d.)

OAL = 2H + 0.86R3 - 0.86R4 - 6.15Dia.+ 2I + 2L1 + 2.28R1 + 1.14R2

L1

R1

R2B

R1

Dia.

AR3

R4C

H

L2

I

Figure 7

OAL = 0.0175(<.)(2D/2 + Dia.) + 1.14R + 0.43Dia.

Dia.R A

<.

D

Figure 8

K

J

C

D

Dia.

OAL = [(D + Dia.)(3.14)(Number of 360°’s)] + 2C

Figure 13

L1

L2

R1

B1C A

R2

Dia.

H

Figure 15

B2

I

OAL = 2H + 2L2 + 2L1 - A - 1.72R1 - 0.86R2 - 6.29Dia.

OAL = 2L + 3.42R - 1.29Dia. + 2E

Dia.EL

A

B

R

J

Figure 9

R2

R1 A

B2

B1

L1

L2

OAL = 2L1 + 2.28R2 - 1.29Dia. + 2L2 + 1.14R1

Figure 10

K

J

View A View B

Dia. Dia.D

D

AA

Figure 14

OAL = [(D + Dia.)(3.14)(No. 360°’s)] + (D/2) + K + C

OAL = 2H + 0.86R3 - 3.72Dia. + 2L1 + 2L2 + 2.28R1 + 1.14R2

Dia.

BR3 C

H

L2L1

R1

B2

R2B1

R1

A

Figure 6

R1

R1 H

R2

B2

R2

R3Dia.

L1

X = No.OutsideHairpins

L2

L3

R4

A

B1

R1

C

C

A-10

Components


28 0.246 2400.25 2400.26 240

Welded on threaded pin (#8-32), nutand washer

34 0.2 240

Leadwire with sleeving, #6 ConnectorSTRI/ 0.315 240

STRS/ 0.475 480STRC

Single-end tubular termination, 10"leadwire

30 All 240

Ark-LesR Connector

30R All 240

Right-angle Ark-LesR Connector

37 0.315 2400.375 2400.43 4800.475 480

Extra mechanical strength# 8-32 thread

1/4Sheath Dia.

Per Tab

3/4

Standard Terminals

3 0.315 4800.375 4800.43 4800.475 480

Welded on threaded pin (#10-32), nutand washer

4 0.43 4800.475 4800.5 480

Threaded terminal pin (#8-32), nutand washer

8 0.246 2400.25 2400.26 2400.315 2400.375 4800.43 4800.475 480

Terminal connector - 5/16" long, #10-32machine screw

Alternate Terminals

23 0.43 6000.475 6000.5 600


24 0.43 6000.475 6000.5 600


25 0.246 2400.25 2400.26 2400.315 2400.375 4800.43 4800.475 480

5/16" Long #10-32 Bolt with nut

SheathDia. Max.

Type Description (In.) Volts

SheathDia. Max.


3/4

Tubular HeatersTerminal Options

Sheath Dia. Per Tab

1

1/4Stacked Mica

Sheath Dia. Per Tab

1/4"

Sheath Dia. Per Tab

1/4

Sheath Dia. Per Tab1

1/4 Stacked Mica

1/2

3/8

Stacked Mica

10

Sheath Dia.Per Tab 1-1/2

3/8

13/16

6

1/4

13/16

3/4

Stacked Mica

3/4

11/32

Sheath Dia.Per Tab

1/4

1-1/8

1/2Sheath Dia. Per Tab

Stacked Mica

9/16

1/4Sheath Dia. Per Tab

1/2

1/23/8

15/32 3/4

3/4 1

0.315, 0.375 0.43, 0.475

Standard, Alternate and Moisture Resistant Terminals

A-11

Components

Tubu

lar


Alternate Terminals (cont’d.)

38 0.315 4800.375 4800.43 4800.475 480

Leadwire type terminal

47-L 0.315 4800.375 4800.43 4800.475 480

105°C leadwire, silicone sleeving

47-M 0.315 4800.375 4800.43 4800.475 480

200°C leadwire, silicone sleeving

39/40 0.43 4800.475 4800.5 480

Epoxy, 194°F max. temp., (type 39)RTV, 350°F max. temp., (type 40)

42 0.475 480

Silicone rubber boot potted with RTVsealant, 0.475" dia. single-end only

Moisture Resistant Terminals Note: Type 26 is the only Hermetic Seal, all others are Barriers.

13 0.246 2400.25 2400.26 2400.315 3000.375 4800.43 4800.475 4800.5 550

EPDM rubber vulcanized to sheathand leadwire

26 0.315 2400.375 4800.43 4800.475 4800.5 480

Hermetic seal, 1000°F max.element temp.

39/40 0.315 4800.375 4800.43 480

Epoxy, 194°F max. temp., (type 39)RTV, 350°F max. temp., (type 40)

2

0.375" Dia. and Larger

Sheath Dia. Per Tab

Sheath Dia. Per Tab

2-1/8

SiliconeRubber Boot

141/2

16 Gauge Lead Wire

1-7/8

3/4

1-7/8

0.43" Dia.and Larger

0.315" Dia. and Smaller

1-3/4

15/32

0.375" Dia.and Smaller

#10-32

1/4-28

Sheath Dia. Per Tab

1-5/8

A

Dia. (In.) A

0.315 3/80.375 1/2

0.43, 0.475 9/16

48 0.246 2400.25 2400.26 2400.315 2400.375 4800.43 4800.475 480

Narrow profile terminal connector,5/16" Long #10-32 or #8-32machine screw.

49/50 0.43 4800.475 4800.5 480

Silicone bushing/ceramic disc seal,epoxy/RTV/silicone resin can be placedunder bushing (type 49, #8-32 thread/type 50, #10-32 thread)

53 0.315 4800.375 4800.43 4800.475 480

Air set cement, >700°F temp.

SheathDia. Max.


SheathDia. Max.


Tubular HeatersTerminal Options (cont’d.)

1-3/412

1/2

1-3/412

1/2

Sheath Dia. Per Tab

1/47/8

5/16

Silicone Bushing

13/32

Ceramic Spacer 7/8

7/16

1-1/8

Sheath Dia. Per Tab

Ceramic Bushing

#10-32

1

SheathDia. Per Tab

Ceramic Bushing

1/4 13/32 #10-32

#8-32Ceramic BushingSheath Dia.

Per Tab

13/161/4 1/45/16

Standard, Alternate and Moisture Resistant Terminals

A-12

Components


Flange - Support0.315" Element

Flange - Support0.475" Element

4-1/2"3-3/8"

4-1/2"3-3/8"

3/4"

1-7/16"1-15/16"31/32"

3/4"

1-1/2"1-15/16"31/32"

Disc Clip-Anchor

Elements are on1" Dia. Bolt Circle

1-1/2" O.D.

5/32"

7/16"

Tubular HeatersCustomer Bending &Accessories

Compression Fittings

Field Installed Compression Fittings — For0.475, 0.315 and 0.246" diameter elements.Available in both brass and steel, these fittingshave been tested to 600 psi hydrostaticpressures and may be used in tank walls forliquid immersion as well as in air ducts and avariety of other applications.

Compression fittings do not require brazingand can be field mounted in minutes. Theymay be positioned anywhere along the coldsection of the heating element. Do not positionover heated section. Cannot be installed overterminal Type #26 (Hermetic Seal.)

Brackets, Discs & Clips

Brackets, Discs and Clips — Various types ofbrackets and clips can be fastened to theheaters to facilitate installation. The followingare typical.

For other brackets to meet your installationrequirements, contact your Local ChromaloxSales office.

Compression Fittings for 0.475, 0.315 and 0.246"Diameter Elements for Installation in the Field.

Washer

Hex Nut

Tank Wall

GasketFitting

Thread F Thread GFerrule

CompressionNut

Customer Bending

Simple element configurations can be madeeasily in the field from stocked tubulars listedin this catalog. If copper or stainless sheathsare selected, specify “To be fully annealedfor bending.” Elements can be bent aroundany round, smooth surface of the rightdiameter.

Three precuations should be observed toprevent damage to the element:

1. Radius of the round object, around whichthe element is bent, should be no smallerthan the minimum radius for the element,as shown in the table below.

2. Sharp edges of tools should not bepermitted to gouge the element sheathwhile bending.

3. End of cold section of the element shouldnot fall within the bend nor come within 1/4"

of either side of the bend. To locate end ofcold section, see dimensions for the elementon its catalog page and determine as follows:Example — To locate end of cold sectionof TRI-1645 tubular element, refer tothe individual product page.Sheath length: 16"Less heated length: 9-1/8"Total cold length: 6-7/8"Cold length of each end(6-7/8" ÷ 2) = 3-7/16"

Terminal end bending can be done with pipesection of slightly larger diameter than sheath.A minimum 1" straight section should be leftat the end. Note — To protect sheath, coppersheet can be bolted to vise jaws and end ofpipe can be filed to remove sharp edge.

Before bending, it is best to lay out anddimension the configuration. Also, it is best tostart bending from the center of the heater andwork toward the terminal ends.

Terminal End BendingEnd of Heated Section Must Not Be Within These Two Points

1/4R

1/4

Leave 1" Min.Straight Sectionat Terminal End

Brass 0.246 13/32 7/32 1-7/16 3/8-24 1/2-24 144151Brass 0.315 15/32 5/16 1-1/2 7/16-28 1/2-24 144143Brass 0.475 21/32 5/16 2 5/8-24 3/4-24 144135Steel 0.246 13/32 7/32 1-3/4 3/8-24 1/2-24 143474Steel 0.315 15/32 5/16 1-3/4 7/16-28 1/2-24 143466Steel 0.475 21/32 5/16 2-1/8 5/8-24 3/4-24 143458

AssembledElem. Mtg. Hole Max. Wall Overall

Material1 Dia. Dia. Thickness Length F G PCN

To Order— Specify PCN, material, element diameter and quantity. Available in pairs only.

1. Available only in brass and steel at this time.

Thread SizeDimensions (In.)

1. For radii smaller than shown, special processing is required to achieve good lifequalities. Contact your Local Chromalox Sales office.

Copper 90 3-1/2 1-1/2 1-1/2 2-5/16 1-5/16 1-1/16 15/16 3/4180 3-1/2 1-1/2 1-1/2 2-5/16 1-5/16 1-1/16 15/16 3/4

Steel 90 2-1/2 1-1/2 1-1/2 1-7/8 1-5/16 1-1/16 15/16 3/4180 2-1/2 1-1/2 1-1/2 1-7/8 1-5/16 1-1/16 15/16 3/4

Alloy 90 2-1/2 1-1/2 1-1/2 1-7/8 1-5/16 1-1/16 15/16 3/4 5/8180 2-1/2 1-1/2 1-1/2 1-7/8 1-5/16 1-1/16 15/16 3/4 5/8

Degree Customer Bending — Min. Inside Radius (In.)Sheath of

Material Bend 1/2" 0.475" 0.430" 3/8" 0.375" 0.315" 0.26" 0.246" 0.2"Not Std.Mat.in thisDia.

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