tubular and finned tubular elements - Indeeco

C50-4tubular andfinned tubularelementselectric heating and controls

Table Of ContentsConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Physical & Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Watt Density & Sheath Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5Terminals, Insulators & Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Limited Warranty

ConstructionIntroductionINDEECO designs and manufactures commercial andindustrial electric heating and control systems that setthe industry standard for excellence. The company’sheating solutions reflect more than 70 years of innovation,product quality and efficient service.Our product offering ranges from the tubular heatingelements described in this catalog to the most sophisticated,custom designed system. INDEECO’s attentionto detail and rigorous testing give worldwide customerspremium products that they receive quickly and at a fairmarket price.ConstructionStandard ConstructionTwo-Pass ConstructionFor applications requiring both terminations at the sameend, either a U-bent or a two-pass element may be used.Two-pass elements, as shown in the cutaway view, have aU-bent coil inside the sheath and two leads or terminals atone end. The opposite end is sealed by welding or silversoldering. These elements are available in straight lengths,either finned or unfinned. They can be permanently mountedwith a variety of factory-furnished mounting methods (seepage 12). By contrast, standard elements in straight lengthsmust have a flexible electrical connection at one end to allowfor thermal expansion.Finned ConstructionThe cutaway view of a typical INDEECO tubular elementshows its basic construction. A coil of the highest graderesistancewire (80% nickel, 20% chromium) is preciselycentered in a heavy gauge metal tube while the tube is filledwith granular magnesium oxide powder. Terminal pins arewelded or silver soldered to the resistance coil at each endto provide an unheated length near the terminals and tosecure the coil in the magnesium oxide. Through rolling, thediameter of this assembly is reduced and the magnesiumoxide compacted, insuring rapid heat transfer from the coilto the sheath, as well as high dielectric strength.After compaction, the element is processed in one of threeways:1. Straight length elements are sealed and appropriate terminalsapplied.2. Formed elements are annealed and bent before they aresealed and terminated.3. Finned elements are wound with a helical fin before theyare sealed and terminated.Standard Construction: A corrugated 304 stainless steel finis helically wound on a .475" diameter 304 stainless steelelement. To insure a permanent bond, each end of the finis tack-welded to the element sheath. The entire assemblythen goes through a computer controlled atmosphere furnace.This process prepares the element to be bent into a varietyof configurations. Standard fin density is five fins per inch,while eight fins per inch can be furnished when specified.Special Materials: .475" diameter elements can be furnishedwith monel fins and/or sheath. There are a varietyof other exotic materials available that are useful for uniqueapplications. Contact your local sales representative orINDEECO for the appropriate material for your application.www.indeeco.com800-243-81621

Construction/Quality ControlConstruction TechniquesINDEECO construction techniques are designed to insurehigh quality and long life.• Rolling – All standard diameter elements listed in thiscatalog are compacted through multi-stage rolls. Thisprocess insures uniform compaction of the magnesiumoxide, a truly round cross section and a consistent diameter.This is critical if the element is being inserted into amachined hole.• Terminal Construction – A threaded 10-32 stainless steelterminal is welded onto the cold pin for the standardconstruction. This technique allows the use of a relativelysmall diameter pin since it is not carrying the elementcurrent at its most critical point: connection to field wiring.The smaller pin also results in greater electrical clearancesbetween the pin and the sheath, which is critical at highervoltages.Stainless steel nuts and washers are furnished for fieldwiring. This hardware fits up to an integral shoulder withtwo flat sides on the terminal. Using an end wrench on theflats will prevent the terminal from rotating when connectingfield wiring.The terminal insulator and seal must be suitable for thetemperature, voltage and atmospheric conditions of theapplication. INDEECO offers a wide variety of terminals,insulators and seals to meet virtually any combination offield conditions (see pages 6 and 7).• Recompaction – In the process of bending, hairline crackscan develop in the compacted magnesium oxide. Thesecracks, in turn, can lead to overheating and coil failure,especially at high temperatures or high watt densities.To prevent such failures, we recompress most bends witha center-to-center diameter of 2" or less, eliminating cracksin the magnesium oxide.Quality ControlFrom raw materials through the finished product, INDEECOmaintains the highest standards in the industry through aseries of Quality Control/Assurance checks.• Magnesium Oxide – INDEECO uses only 96% pure MgO,the highest grade available for electric heating elements.Each batch is checked against two ASTM Standards:ASTM D3347 determines tap density to assure a high insulationdensity. ASTM D2755 is used for sieve analysis.Samples are sifted through ten progressively coarsersieves to assure a high concentration of larger grains,which have better thermal conductivity and dielectricstrength. As a result, INDEECO elements have extremelyhigh MgO density.• Certification to Special Standards – Elements can becertified to Military Standards such as MIL-H-22577Cand MIL-H-22594A, and special customer specificationsregarding tolerances, hydrostatic testing, etc. Pleaseconsult the factory for details.UL and CSA RecognitionMost of the elements described in this catalog are Recognizedby the Underwriters Laboratories under UL Standard 1030.Our File No. is E78533. In addition, epoxy-sealed elementsfor refrigeration defrost are Recognized under File No.SA3254. Such recognition makes it simpler for manufacturersto incorporate INDEECO elements into equipment that isUL Listed. Tubular and finned tubular elements are also CSAapproved under Report No. LR 11895-39. Please consult thefactory for details.2www.indeeco.com800-243-8162

Physical & Electrical SpecificationsPhysical & Electrical SpecificationsTable IDescriptionSheath Materials (1) (Max Sheath Temp)Copper (seamless) (350° F)Steel (750° F)304 SS (1400° F)316 SS (1400° F)Inconel 625 (1800° F)Incoloy 800 (1600° F)Incoloy 800 (seamless) (1600° F)321 SS (seamless) (1400° F)Monel 400 (1000° F)Sheath DiametersMinimumMaximumNominal Wall Thickness (2)Sheath LengthsMinimumMaximumSheath Length TolerancesCold EndsMinimumMaximumMaximum Current DrawMaximum VoltageWattage ToleranceUnfinned Tubular ElementsStandardTwo-PassFinned Tubular ElementsStandardTwo-Pass.312" .475" .475" .475" .475"CustomN/AStockCustomN/AStockN/AN/AN/AStockStockStockStockStockStockCustomCustomStockStockStockStockStockN/AStockN/AN/AStockN/AStockStockStockN/AN/AN/AN/AStockN/AStockStockStockN/AN/AN/AN/AStock.309".469".469".469".469".317".477".477".477".477".030" .035" .035" .035" .035"11"256"(1) Stock – Material in stock.Custom – Material is either stocked in small quantity or must be special ordered for each job.(2) Other wall thicknesses available.11"256"11"96"11"256"11"96"1% of overall sheath length with a minimum of 1/8" and a maximum of 1"1-1/2" 1-1/2" 1-1/2"1-1/2"1-1/2"24"28"16"28"16"40 40 30 40 30277 600 277 600 277+5/-10% +5/-10% +5/-10% +5/-10% +5/-10%www.indeeco.com800-243-81623

Watt Density & Sheath SelectionWatt Density & Sheath SelectionWatt density and sheath material are the two most criticalfactors affecting element life. Watt density (watts persquare inch of heater surface area) determines heateroperating temperature for a given set of conditions. Thesheath material must be suitable for the corrosive conditionsand the extreme temperatures of the application.Watt density is calculated as follows:Element WattageWatt Density =3.14 x Element Diameter x Heated LengthElement diameter and heated length are expressed in inches.Heating Air and Other Gases – Charts A through C givemaximum sheath temperatures for a range of watt densitiesand velocities. This data is based upon air at atmosphericpressure and a 75° F inlet air temperature. For higher inlettemperatures, the sheath temperature will increase accordingly.Contaminants in the air, while normally not affectingthe sheath temperature, may require a more highly corrosion-resistantsheath and/or fin material. For heatingcompressed air and other gases, consult the factory or yourlocal INDEECO representative for watt density and sheathrecommendations.Chart BChart AChart C4www.indeeco.com800-243-8162

Watt Density & Sheath SelectionHeating Liquids – Recommended watt densities and sheathmaterials for heating several common fluids are listed inTable II.Heating Metals – Table III gives recommended watt densitiesand sheath selection for elements that are clamped orinserted. Allowable watt densities will vary with such factorsas element fit in a machined opening and metal thickness.This information should be used only as a guide. INDEECOcannot be responsible for heater failures due to corrosion orexcessive temperatures in the application.Watt Density & Sheath MaterialsTable IIMaximum FluidMaterial Sheath Material W/Sq. In.Temperature °FAsphaltCaustic Soda (50%)Dowtherm AEthylene GlycolFuel Oil, #5 & #6Lube Oil, SAE 10-30Lube Oil, SAE 40-50OakitesTherminol 66Water-PotableWater-Deionized300180100200300500200200250160210500600650100212100212Steel304 SSSteelSteelSteelSteelSteelSteelSteelSteelSteelSteelSteelSteelCopperIncoloy304 SS304 SSFor a comprehensive list of sheath materials compatible with fluids under a variety of conditions, refer to INDEECO Immersion Heater Catalog C70.5-91555-6040-5020-353-530-405-1215-205-1230-4025-3020-2510-157550-757550-75Table IIIApplicationMaximum MetalTemperature °FRecommended Watt DensityW/Sq. In.RecommendedSheath MaterialClamped to Flat Metal SurfaceInserted into Machined Groovesor Holes200200400200200400600600800203020253525202515Steel304 SS304 SSSteel304 SS304 SS304 SSIncoloyIncoloywww.indeeco.com800-243-81625

Terminals, Insulators & SealsTerminals, Insulators & SealsExcept as noted, various terminations, insulators and seals can be combined as required to fit the application.Table IVTerminalsDescriptionUse1. Threaded Terminal(Standard)10-32 stainless steel stud with9/16" threaded lengthFor lead attachment in the field.40 amp, 600V rating2. Threaded Terminal(Short)10-32 stainless steel stud with5/16" threaded lengthFor installations with tight clearance.3. Threaded Terminal(Long)4. Quick Connect Terminal10-32 stainless steel stud with7/8" threaded lengthStandard quick connect configurationFor multiple leads and heavy bus bars.For connection to matching female terminalon field furnished lead. 30 amp, 600V rating5. Weld NutTab is welded to terminal pin andfurnished with 10-32 terminal screwWhere it is more convenient to usethis terminal orientation.6. Insulated LeadsL1-1/4"1-3/4"Element Dia..312".475"7. Silicone Insulated Leads8. Type TGGT LeadsStandard copper conductors insulated with5/64" or 1/16", 90° C neopreneStranded nickel-clad copper leads with1/32" silicone rubber insulationand glass braidStranded nickel-clad copper leads withTeflon – Glass – Glass – Teflon,4-layer insulationUsed primarily with epoxy waterproof seal(see No. 14) for defrost applications. Rated480V at the following amperages:18 gauge – 10 amps max16 gauge – 15 amps max12 gauge – 30 amps maxFor higher temperature applicationsrequiring a 200° C insulation.Rated 600V at the following amperages:14 gauge – 20 amps12 gauge – 30 ampsFor applications requiring 250° C insulation.Rated 600V at the following amperages:14 gauge – 20 amps12 gauge – 30 amps6www.indeeco.com800-243-8162

Terminals, Insulators & SealsTable IV (continued)TerminalsDescriptionUse9. Ceramic Terminal Block10-32 female terminal tabs spot-welded toterminal pins running through ceramic blockFor .475" diameter two-pass elements wheretemperature exceeds insulation limit or forconvenience in attaching field furnished leads.Rated 30 amps at 277V10. Grounding StrapTo ground long straight single-pass finnedtubular elements, eliminating arcing dueto secondary currentsRecommended for straight single-passfinned tubular elements over 6' long.Note: Terminations Nos. 1 through 8 are available on standard single-pass elements. Two-pass elements available with Nos. 9 and 15 only.Terminal InsulatorsUse11. Silicone Rubber(Standard)12. MicaGeneral applications where terminal temperatures do not exceed 400° F.1/4" thick insulation furnished up to 250V; 1/2" thick up to 600V.(Standard insulator unless otherwise specified)Applications where terminal temperatures do not exceed 1000° F.1/4" thick insulation furnished up to 250V; 1/2" thick up to 600V.Note: Terminal insulators are used in conjunction with Terminals Nos. 1 through 5 on standard elements.13. Epoxy Barrier14. Epoxy SealL Element Dia.1-1/4" .312"1-3/4" .475"Terminal Seals15. Epoxy Barrier (for two-pass construction)16. Hermetic SealDescriptionEpoxy resin is mostly absorbed by themagnesium oxide insulation, but athick film forms a barrier against moistureEpoxy resin fills a metallic adapter enclosingthe connection between lead wireand element terminal pinEpoxy resin is mostly absorbed by themagnesium oxide insulation, but athick film forms a barrier against moistureCeramic to metal hermetic seal is solderedto the element sheath and terminal pin.1/4"-28 threaded terminalUseFor applications where low to moderatehumidity may be present in the terminal area.For use at 200° F maximum.Primarily defrost applications and otherswhere water may drip on the terminal end.UL Recognized under File SA3254. Suitablefor a maximum adapter temperature of 200° F.For applications where low to moderatehumidity may be present in the terminal area.For use at 200° F maximum.Absolute seal up to 1000° F.www.indeeco.com800-243-81627

BendingBendingStandard single-pass tubular elements may be bent in aninfinite variety of configurations. Utilizing the most up-todatecomputer numerical control (CNC) bending equipmentand techniques, INDEECO is able to produce an element tofit virtually any application.Table VBends that are less than 2" center-to-center are normallyrepressed on unfinned elements to recompact the magnesiumoxide insulation, eliminating hairline cracks that maydevelop during bending.Figures A through T show some of the configurations frequentlyspecified. For configurations not shown, submit a drawing orsketch of your requirements. Any of these are availableeither finned or unfinned.SheathDiameter(Inches).312.475Unfinned.475FinnedSheath MaterialsCopper & Incoloy 800304 SSCopper, Steel & Incoloy 800304 & 316 SSInconel 600 & Monel 400Steel304 SSMonel 400Minimum Bending (1) (Inches)InsideRadius3/81/41/21/43/8(1) Contact factory for requirements below minimum bending dimensions shown.Center-To-CenterDimensions7/811-1/411-1/2222Center-To-Center Dimensions (Inches)Available For Repressing Dies For 180° Bends5/8, 11/16, 3/4, 1, 1-1/2, 2, 2-3/8, 2-1/21, 1-1/16, 1-1/8, 1-1/4, 1-3/8, 1-1/2,1-5/8, 1-3/4, 1-7/8, 2, 2-1/4, 2-1/2Not repressed. Bending dies are availablein 1/8 increments from 2 through 3-1/2.Figure AFigure CFigure B8www.indeeco.com800-243-8162

BendingFigure DFigure GFigure HFigure EFigure FFigure Iwww.indeeco.com800-243-81629

BendingFigure JFigure MFigure KFigure NFigure LFigure O10www.indeeco.com800-243-8162

BendingFigure RFigure PFigure SFigure TFigure QNote: Unheated section must not end in bend.www.indeeco.com800-243-816211

Mounting AccessoriesMounting AccessoriesTwo types are available: Threaded Fittings and Mounting Plates.Threaded FittingsThreaded fittings are furnished with nuts and optional fibergaskets, washers and lockwashers. They are designed forimmersion applications. Fittings are silver soldered, welded ormechanically pressed (staked) to the sheath. Welding requiressheath and fitting material compatibility. Standard elementsrequire two fittings, one for each terminal end. Two-pass elementsrequire only one fitting.Dimensional details shown in Table VITable VIFitting Part No.MaterialA(Inches)B(Thread Size)C(Inches)D(Inches)EHex Nut (Inches)(Inches) F G10071391007219100714210072151007127100722510072281007279100684610000581007249BrassBrassBrassSteelBrassBrassStainlessStainless***Steel**SteelSteel0.3120.3120.3120.3120.4750.4750.4750.4750.4750.4750.4751/2 - 209/16 - 185/8 - 183/4 - 165/8 - 183/4 - 163/4 - 163/4 - 165/8 - 183/4 - 163/4 - 167/81/21/21-1/169/167/87/83/81/21/21-1/165/161/85/161/45/161/41/43/161/81/83/163/41111*1*7/8*11*7/8*13/47/87/817/817/87/87/8115/165/161/83/161/81/81/81/81/83/163/16* These fittings have a hex flange instead of a round flange.** This fitting is copper plated steel, normally furnished on finned tubular elements with palnut type locknuts standard. Gaskets are not furnished unless specified.*** This fitting is nickel plated steel, with palnut type locknuts standard.Mounting PlatesMounting plates provide a simple, convenient means of holdingelements in place in an airstream and other applications wherethe element is not immersed in a liquid. Stainless steel platesare mechanically pressed (staked) or tack welded to stainlesssheathed elements; copper-plated steel plates are brazed tosteel sheathed elements.The mounting plates shown to the right are for .475"diameter elements. Consult factory for .312" diameters.Type IITable VIIType IHeating ElementMounting PlateConfiguration Type Material2-1/2" C-C U-Bent2-1/2" C-C U-BentStraight or Two-PassStraight or Two-PassIIIIIISteelStainlessSteelStainless12

Limited WarrantyIndustrial Engineering and Equipment Company (INDEECO)products are warranted against defects in workmanship,material, design, labeling and packaging. No other warranty,expressed or implied, written or oral, applies. No personother than an officer or the general manager of INDEECO isauthorized to give any other warranty or assume any liability.Warranty Period: This warranty is effective for eighteenmonths from the date of shipment of the product fromINDEECO’s factory, or for twelve months from the date theproduct is first placed in service, whichever period lapsesfirst.Conditions of Warranty: INDEECO products must be installed,operated and maintained in accordance with INDEECO’sinstructions. INDEECO is not liable for damage or unsatisfactoryperformance of the product resulting from accident,negligence, alteration, unauthorized repair, improper applicationor installation of the product, improper specificationsor corrosion. INDEECO IS NOT LIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGES. Claims against carriers fordamage in transit must be filed by the purchaser with thecarrier.Remedy: The part or product in question should be returned,freight prepaid, to:INDEECO425 Hanley Industrial CourtSt. Louis, Missouri 63144Attention: Return Goods ManagerIf after receipt of the product and the claim, INDEECO findsto its reasonable satisfaction that the product is defective inworkmanship, material, design, labeling or packaging, theproduct will be repaired or replaced or the purchase pricerefunded at INDEECO’s option. There will be no charge to thepurchaser for parts or labor. Removal and reinstallation ofthe product, and shipment of the product to INDEECO forrepair or inspection shall be at the purchaser’s risk andexpense.THE REPAIR, REPLACEMENT OR REFUND PROVIDED FOR INTHIS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THEPURCHASER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANYOTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDINGANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICHEXTEND BEYOND THE TERMS OF THIS LIMITEDWARRANTY.

INDUSTRIAL ENGINEERING & EQUIPMENT CO.425 HANLEY INDUSTRIAL COURTST. LOUIS, MO 63144314-644-4300Fax: 314-644-5332www.indeeco.comFOR YOUR NEAREST INDEECO REPRESENTATIVE CALL:800-243-816250-1100-82-45M702-06