INSTALLATION INSTRUCTIONS FOR MICA HEATERS

Before Installation:

  1. Unpackage the mica heater(s) and inspect for any shipping damage.  DO NOT OPERATE DAMAGED EQUIPMENT.
  2. Verify marking the wattage and volt rating and compare to your Mica-heater-installation.

Installation Instructions:

  1.  Mica heaters should be installed on smooth clean cylinders or flat surfaces.
  2.  When putting mica band heaters on a barrel or nozzle, to avoid damage or premature failure, do not open up the heater for installation unless it is designed to be a one-time expandable band heater or hinged band heater.
  3.  Make sure the mica heater is seated snugly, and the clamping band is tightened as much as possible.

Optimizing Heater Performance:

  1. Use the correct mica band heater diameter on the application to ensure a proper fit.
  2.  Retighten the mica heater clamps after the heater has been energized and cooled.
  3.  Avoid using excessive torque when tightening the post terminals. Use a wrench to hold the bottom nut while loosening/tightening the top nut.
  4. Do not allow contaminants such as dirt, oil, and plastics to collect on the mica heaters.  These materials can carbonize and cause electrical shorts.
  5.  The maximum sheath temperature of a standard mica heater is 900 degrees Fahrenheit.

Backer Marathon Starflex Band Heaters

STARFLEX COMMON HEATER BAND DESIGNS--Custom Diameters & Wattages Available Upon Request

WIDTH (IN)VOLTAGESWATTSDIAMETER (IN)PART NUMBER
0.75120/2406006.25SF060-007A
 1.5240/4808754SF040-015A
 1.5240/4807804.25 SF042-015A
 1.5240/4806005.25 SF052-015A
 1.5240/4809006.5 SF065-015A
 1.5240/48013007 SF070-015A
 1.5240/48013758.5 SF085-015A
 1.5240/48016759 SF090-015A
 1.5240/480212513.94 SF139-015A
 1.5240/480220019 SF190-015A
 1.5240/4802350 20.00 SF200-015A
 1.5240/4803600 22.50SF225-015A
 1.5240/4803000 24.50SF245-015A
2.5120/2403503.5SF035-025A
2.5240/4809004SF040-025A
2.5240/48012004.5SF045-025A
2.5240/4808006SF060-025A
2.5240/48013006.75SF067-025A
2.5240/48013006.88SF068-025A
2.5240/48011407.5SF075-025A
2.5240/48024259SF090-025A
2.5240/48015009.88SF097-025A
2.5240/480237510.25SF102-025A
2.5240/480212511SF110-025A
2.5240/480305011.44SF114-025A
2.5240/480337012.19SF121-025A
2.5240/480145012.5SF125-025A
2.5240/480160012.63SF126-025A
2.5240/480237512.63SF126-025B
2.5240/480300012.63SF126-025C
2.5240/480 357513SF130-025A
2.5240/480 327513.19SF131-025A
2.5240/480 300014SF140-025A
2.5240/480 272514.94SF149-025A
2.5240/480 372514.94SF149-025B
2.5240/480 230015.19SF151-025A
3240/480 200010SF100-030A
3240/480 325011.5SF115-030A
3240/480 353515SF150-030A
3240/480 540019SF190-030A

Chromalox Screw Plug Immersion Heaters Water Guide

Chromalox Screw Plug Immersion Heaters Water Guide

Clean or Process Water 1 YES ARMTS
Clean Water 1-1/4 NO MT-1
Clean Water 2 NO EMT-3
Clean Water 2 YES ARMT-2
Clean Water 2 NO MT-2
Clean Water 2 NO CH-SD
Clean Water 2-1/2 YES ARMT-3
Clean Water 2-1/2 NO MT-3
Process Water  2 YES ARMTS-2
Process Water  2 NO MTS-2
Process Water  2 YES AREMTS-3
Process Water  2 NO EMTS-3
Process Water  2-1/2 YES ARMTS-3
Process Water  2-1/2 NO MTS-3

Chromalox Flange Immersion Heaters Guide

Chromalox Flange Heaters Guide

Application Type Flange Sizes Available Sheath Material Flange Material Heater Model
Clean Water 3, 5, 6, 8, 10, 12, & 14 Copper Steel TM
Process Water 3, 5, 6, & 8 St. Steel Steel TMS
Solution Water 3, 5, 6, & 8 Incoloy Steel TMI
Mildy Corrosive Solution 3, 5, 6, & 8 St. Steel Steel TMS
Corrosive Solution & Gas 3, 5, 6, 8, 10, 12, & 14 Incoloy Steel TMI
Severely Corrosive Solution 3, 5, & 6 Incoloy  St. Steel TMIS
Clean Water 14 Copper Steel ARMT-3
Clean Water 2-1/2 NO MT-3
Process Water  2 YES ARMTS-2
Process Water  2 NO MTS-2
Process Water  2 YES AREMTS-3
Process Water  2 NO EMTS-3
Process Water  2-1/2 YES ARMTS-3
Process Water  2-1/2 NO MTS-3

Call Jobco for help with finding a Chromalox heater for your application by dialing 479-424-1300.

Important Usage Information about the Urn Heater

Operation

Urn Heater Ran WITHOUT water

Urn Heater Ran WITHOUT water

Disconnect all electrical power BEFORE installing or servicing the buffet table element or resetting the manual reset button for the thermal cutout safety device.  Failure to do so could result in personal injury or property damage.  The heater must be installed by a qualified person in accordance with the National Electrical Code, NFPA 70.

Do not operate at voltages that exceed the stamped/engraved voltage on the actual heater.  Using higher voltages will dramatically shorten the heater life.

Mount heater in the tank so the tubular heated section above the mounting plate is TOTALLY IMMERSED in the tank by the liquid specified by the equipment manufacturer. The heated section of the heater must ALWAYS be totally immersed in the tank liquid BEFORE the heater is energized.

The thermal cutout on your urn heater provides burn-out protection when the heater is accidentally run dry, and the thermal cutout will need to be replaced after it cuts the heat power off a few times. If users repeatedly run the tank with no water, the thermal cutout will only shut the heater off two to four times, and then it may no longer function properly and the heater will burn out. Replacement thermal cutouts are available to help prevent premature heater burnout.

The thermal cutout is a safety device ONLY and should NOT be used as a control for monitoring low liquid and no liquid levels in the tank.  PARTIAL IMMERSION of the heating elements while energized can dramatically shorten the heater element life.

It is the responsibility of the purchaser and/or equipment manufacturer to select the heater sheath material based upon their experience with the liquid solution’s chemical composition and corrosiveness, the materials entering or making contact with the liquid solution, and the equipment controls maintained on the liquid solution process. Urn immersion heaters are typically used as a source of heat for steam tables, coffee urns, kettles, sterilizers, percolators, humidifiers and other water heating application.

Maintenance

Urn heater tubular elements should be checked regularly for visible signs of calcium or scale build-up or signs of corrosion and should be cleaned, if necessary, using a wire brush or stainless steel wool.  Build-up or corrosion can act as insulation and will shorten the heater life.

The liquid tank should be checked regularly for sediment around the heater.  Sediment build-up left in the tank can act as an insulator and will reduce the electrical heater life.

Check for loose terminal connections and clean terminal ends to remove any contamination.

If corrosion is noted in the terminal enclosure, please check the terminal box gasket and replace, if necessary.  The conduit should also be examined to fix any conditions that are allowing corrosion to enter into the terminal housing.

Cartridge Heater Lead Wires

Lead Wire Type Temperature Rating Comments Products
Duraflex 1022° F/ 550° C Excellent all around wire. Flexible, easy to strip. Not waterproof. Standard on all cartridge heaters, band heaters, strip heaters. Optional on silicone rubber heaters.
TGGT 482° F/ 250° C Durable, not waterproof. Optional on all heater products
Teflon 482° F/ 250° C Easy to pull through conduit, abrasion resistant, waterproof. Smaller OD than other wire types. Standard on silicone rubber heaters. Optional on all others.
Silicone Rubber 302° F/ 150° C Very flexible, water proof. Nicks easily. Optional on all heaters. Forms excellent moisture seal when used with RTV potting.
Braided Silicone Rubber 392° F/ 200° C Very flexible, waterproof. More abrasion resistant than plain silcone, but less so than other types. Standard on nozzle heaters, optional on all others.
HPN Cord 194° F/ 90° C Inexpensive, compact two conductor cord. Sometimes called lamp cord. Optional on all heater products.
SJO Cord 194° F/ 90° C Available in 2 or 3 conductor. More rugged than HPN cord. Also available with molded plug. Optional on all heater products.

Types of Cartridge Heater Terminations

swaged in leadsSwaged in Leads

Swaged in leads are ideal for applications where there is a lot of movement or the leads must be bent sharp upon exiting the heater. Standard lead wire type is Duraflex wire, rated to 550 deg C. Other lead wire types are available.


crimped on leads

Crimped or Welded on Leads

Crimped on leads are generally used where the temperature at the end of the heater exceeds the maximum rated temperature of the lead wire. Since the connection between the leads and power pins is made outside the heater, the unheated length at the lead end of the heater is kept to a minimum. Crimped on leads are not recommended for applications where the leads must be bent sharply near the heater, or in applications where the leads will be subject to a lot of flexing. For flexing applications, a welded on connection would be better. The high temperature connectors are covered by 1- 1/2″ of 2500 volt silicone rubber coated fiberglass sleeving.


post terminalsPost Terminals

Also called screw terminals or stud terminals are used in applications where easy lead replacement is desirable. They work great with ring terminals or fork terminals. Post terminals are only available on 1/2″ diameter heaters and larger. Terminals are #6-32, other sizes are available.


right angle leadsRight Angle Leads

Right Angle Leads are ideal for applications where space is limited. leads are covered with silicon impregnated fiberglass sleeve where they exit the heater.

 


swaged in braid

Stainless Steel Braid

Provides excellent abrasion protection while allowing the leads to be bent in a tight radius. Because the braid is swaged in, it is extremely resistant to pulling out of the heater.


right angle braidRight Angle Stainless Steel Braid

Right angle stainless steel braid offers the same advantages as swaged in stainless steel braid, but allows use in tight spaces. When ordering, please specify the overall length.


swaged in conduitStainless Steel Flexible Conduit

Also known as armor or hose, Stainless Steel Flexible Conduit provides maximum lead protection from abrasion, but can not be bent quite as sharply as stainless steel braid. Conduit is swaged into the heater for maximum durability.


gala-convoluted-conduitConvoluted Conduit

Unlike standard conduit, convoluted conduit is sealed and provides complete water resistance at any temperature, while forming a positive seal against contamination entering the heater. It is available on standard 5/8″ and 3/4″ diameter cartridge heaters. In most cases, Convoluted Conduit is brazed directly to the heater. Convoluted Conduit is best used in applications where moisture or contamination is an issue. Located to the left, see close-up cross-section of convoluted conduit.


StrainReliefStrain Relief

This is used for applications that require the leads to flex repetitively