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PDS QUALITY
On first impression, various manufacturers of screw plug immersion
heaters appear to be all alike; but when you take a closer look at screw plug
immersion heaters, it becomes evident that considerable differences exist.
The following information will help to explain the differences in construction
of Chromalox screw plug immersion heaters compared to other manufacturers.
It will also describe Chromaloxs third party listing program, quality testing,
and delivery capabilities.
Before buying a screw plug heater, you should ask the manufacturer
questions to insure you are getting a quality heater that will last in your
application. Below, you will find a list of some of these important questions.
wire sized?
2 What grade of
threads to industry
standards?
10 Do you provide a standard
magnesium oxide is
being used?
thermowell?
11 Is the terminal housing
rotatable?
attached to your
resistance wire?
element diameter?
grounding lug?
13 Are your heaters UL listed
5 Do you passivate
when required?
sealant as a standard?
8 How are your elements
http://www.chromalox.com
Basic Construction
Rotatable Terminal
Housing
Hex
Hex Threads
Thermowell
Elements
Elements Internal
Construction
Metallic
Sheath
Resistance Wire
-Computer Designed for
correct gauge wire
Compacted
Solid Cold
Magnesium Oxide Pin Junction
Insulation
Element Diameter
Chromalox standard 0.475 Diameter
,
,
0.475
Chromalox connects the resistance wire to the cold pin with a weld. This provides a
solid electrical connection that better withstands thermal cycling. Some manufacturers press or braze the cold pin onto the resistance wire, making failure due to
thermal cycling more common. Ask the heater manufacturer how they make
their cold pin connections. Chromalox uses only high purity magnesium oxide
insulation to insure good dielectric resistance between the resistance wire and the
metal sheath. In addition, Chromalox uses a rolling method to reduce the diameter
and compact the MgO refractory. Other manufacturers often use lower grades of
MgO, and swage versus rolling down the element diameters, causing inferior
dielectric properties which can lead to a less reliable heater. By utilizing high
grade materials and having controlled manufacturing processes, good thermal
conductivity is achieved and a longer life heating element is produced. Ask the
heater manufacturer how they compact element refractory.
Although Chromalox makes elements that range from 0.315 to 0.475 in
diameter, our standard 2 and 2-1/2 NPT screw plug immersion heater
elements are 0.475 in diameter. Other manufacturers have standardized on
0.430 diameter elements to reduce costs. For an equivalent immersion length,
the 0.475 diameter heating element provides 10% more surface area versus a
0.430 diameter element. The greater the surface area, the lower the heater
watt density and lower its operating temperature. Lower operating temperatures result in longer heater life. Ask the heater manufacturer what
diameter elements they supply as standard.
Chromalox
www.chromalox.com
http://www.chromalox.com
Elements U-Bends
Air gaps
in Mgo
Electrical
short
to sheath
Most screw plug immersion heater elements are bent in a U-bend configuration. When bending a heating element on a tight radius, air gaps can occur in
the magnesium oxide insulation within the element bend. Air gaps can permit a
dielectric (insulation) breakdown to occur, and cause an electrical short to the
metal sheath of the heater.
Chromalox represses U-bends to recompact the MgO and remove any air gaps,
which ensures dielectric integrity. Many manufacturers do not repress bends to
save time and money. Ask the heater manufacturer if they repress
U-bends when necessary.
Epoxy
200F continuous exposure
Good moisture barrier
Heating element refractory can absorb moisture from the air, and if enough
moisture is absorbed, high leakage current could occur during start-up.
Chromalox screw plug immersion heaters contain heating element terminal
sealant as a standard feature. A terminal sealant inhibits moisture from being
absorbed by the heating element refractory.
There are several optional types of terminal sealants to suit the particular
application. Ask the heater manufacturer about terminal sealants before
making a purchase decision.
Hermetic
Up to1000F sheath temperature
The only true seal
Welded Stainless/
Steel Elements
Minimizes corrosion
at element attachment
Chromalox stainless steel, INCOLOY and carbon steel elements are welded to
stainless and carbon steel screw plugs. A welded element provides superior
corrosion protection and element attachment. Some manufacturers braze
elements to the screw plug without concern for the heaters intended application. In heating a corrosive fluid, braze material is susceptible to being chemically attacked by the fluid. A welded-in element prevents corrosive fluid
leakage into the terminal housing which can lead to heater failure. Ask the
heater manufacturer how they secure their elements to the screw plug.
Chromalox
www.chromalox.com
http://www.chromalox.com
Chromalox heater design provides a screw plug hex and threads that are user
friendly. Wide hex and generous threaded lengths allow standard tools to be
used and allows a secure fit.
Other manufacturers often provide a narrow hex, making the hex difficult to
grip, potentially damaging the screw plug threads, or short thread lengths that
may not provide a tight seal. Chromalox screw plug immersion heaters are easy
to install no special tools are required. Ask the heater manufacturer if
their Hex and Threads meet industry standards.
Chromalox stainless steel and steel screw plugs come with a standard solid hex
and threads. Others use stamped, cast or hollow plugs and threads that can fail
under higher pressures.
Thermowells
Standard to accept
sensing bulbs
Rotatable Terminal
Housing
IT DOES
THE
TWIST
Unique with
360 Degree
Rotation Feature
The NEMA 1 terminal enclosure of the Chromalox screw plug heater is fully
rotatable. This patented feature allows 360 rotation of the terminal enclosure
(270 rotation for heaters with thermostat). Thus, you are able to rotate the
enclosure (housing) to face the electrical conduit connection after the heater
has been properly installed.
During installation, it is preferred that the conduit for the wiring be in a down
position. This prevents any moisture that may accumulate on the conduit from
running down into the terminal enclosure of the heater and cause potential
heater failure. No other heater manufacturer offers this feature.
Chromalox
www.chromalox.com
http://www.chromalox.com
Electrical Grounding
National
Electrical Code
Requirement
Chromalox
Standard
Ground lugs
not provided
by all suppliers
UL
Chromalox has the most extensive third party listing in the industry. We provide
more heaters with Underwriters Laboratory listing and/or Canadian Standards
Association Certification than all other heater manufacturers combined.
This assures the heater is built to stringent standards and allows you to receive
quick electrical inspector approval. Ask the heater manufacturer about UL
Listing and CSA Certification.
Canadian Standards
Association (CSA)
Quality Testing
100% Hydrostatic
Pressure Test for
Weld Leaks
100% Resistance Check
for Element Wattage
Insulation Resistance
Check for Moisture
20 Megohms or greater
Dielectric Hi-pot Check
Chromalox
www.chromalox.com
http://www.chromalox.com
In Summary
Over 80 years of experience
Highest quality heater
construction
Extensive UL/CSA
Listings/Certifications
Comprehensive testing
prior to delivery
Fast delivery and
customer service
Benefit
Welded Elements
Rotatable Enclosure
Third Party Listing (for a list, ask your Representative Insures Highest Quality and Strict Manufacturing
for bulletin PD314)
Procedures
Comprehensive Quality Assurance Testing
Greater Reliability
Product Availability
Large Stock & Assembly Stock Offering
Responsive Production Facilitye
Lower Lead Times for Assembly Stock and Special Order Products
Highly Technical and Experienced Sales Force
Support and Assistance When You Need It Most
PD315-1
PDS QUALITY
Chromalox
www.chromalox.com
OCT 98
99-006
1.000+.031
-.062
1.000+.031
-.062
.328
+.000
-.187
NOTES:
"B".125
"C".750
.248+.000
-.187
.437 REF
.875 REF (TYP)
FIG I
PART NUMBER
FIG II
VOLTS
WATTS
156-563153-
120
208
240
277
480
600
600
600
600
600
-006
SG-1077
120
208
240
277
480
750
750
750
750
750
SG-1107
120
208
240
277
480
1000
1000
1000
1000
1000
SG-1103
120
208
240
277
480
1000
1000
1000
1000
1000
SG-1127
120
208
240
277
480
1250
1250
1250
1250
1250
7.750
2.125
117
457385
SG-1123
120
208
240
277
480
1250
1250
1250
1250
1250
7.750
2.125
117
459401
455363
SG-1157
120
208
240
277
480
1500
1500
1500
1500
1500
SG-1153
120
208
240
277
480
1500
1500
1500
1500
1500
SG-1207
120
208
240
277
480
2000
2000
2000
2000
2000
SG-1203
120
208
240
277
480
2000
2000
2000
2000
2000
7.750
2.125
SG-2257
120
208
240
277
480
2500
2500
2500
2500
2500
7.437
2.125
SG-1253
120
208
240
277
480
2500
2500
2500
2500
2500
9.500
2.125
SG-1303
120
208
240
277
480
3000
3000
3000
3000
3000
10.687
2.125
SG-1353
208
240
277
480
3500
3500
3500
3500
12.687
2.125
187
SG-2357
208
240
277
480
3500
3500
3500
3500
9.937
2.125
II
130
-008
CATALOG NUMBER
-011
-013
-016
-018
-021
-023
-027
-028
-031
-033
-036
-037
-038
Material:
Metric
0.80
0.25
0.13
Reference:
DWO-054585, 156-048666-000
English
.030
.010
.005
General Tolerances:
x.x
x.xx
x.xxx
Angles: 2
Wattage: +5-10%
-041
-043
-046
-047
-048
"
PCN NUMBER
REMARKS
459575
7.750
2.125
70
459567
457406
7.750
2.125
94
459161
458118
7.750
2.125
94
458100
459129
459073
7.750
7.750
2.125
2.125
141
452613
141
455347
459268
455355
455056
10.687
2.125
185
457414
459428
455320
194
459436
452867
2-26-09
11-19-08
3-20-06
DATE
PMO
PMO
RKC
BY
FMS
RY
FMS
CVM
RB
APVD.
452656
RER
459444
455312
REVISIONS
452630
DESCRIPTION
133
12
II
REV.
187
455400
459410
455339
452621
13
129
6-23-09
-071
W/
14
Date:
9-25-97
-066
-067
Emerson Heating Products
Revision:
15
Sheet:
1 Of 2
Drawing No.:
156-563153-000
-062
-063
FIGURE
15
Date:
6-16-88
Title:
Size:
-056
-057
-058
"C"
Checked by:
RM
Date:
9-10-96
Drawn by:
RKC
Approved by:
S.SPRINGER
Critical to Quality
(x.xx=Cpk requirements)
-053
"B"
1.000+.031
-.062
.328
+.000
.-187
NOTES:
7
"B".125
"B".312
"C".750
.248+.000
-.187
.187 REF (TYP)
.437 REF
.875 REF (TYP)
FIG II
FIG I
PART NUMBER
156-563153-075
-078
-079
-083
-086
-087
-091
-095
-098
-099
-103
Material:
Metric
0.80
0.25
0.13
Reference:
DWO-054585, 156-048666-000
English
.030
.010
.005
General Tolerances:
x.x
x.xx
x.xxx
Angles: 2
Wattage: +5-10%
-106
-107
-111
"B"
"C"
11.750
2.125
4.187
2.125
2.125
FIGURE
SG-2457
208
240
277
480
4500
4500
4500
4500
11.750
2.125
II
137
SG-1453
208
240
277
480
4500
4500
4500
4500
13.687
2.125
221
SG-2453
208
240
277
480
4500
4500
4500
4500
7.937
2.125
II
221
SG-2507
208
240
277
480
5000
5000
5000
5000
13.437
2.125
II
130
SG-2503
208
240
277
480
5000
5000
5000
5000
9.937
4.187
4.187
2.125
2.125
II
212
212
206
206
SG-2557
208
240
277
480
5500
5500
5500
5500
15.125
2.125
4.187
2.125
2.125
II
132
136
132
132
SG-2553
208
240
277
480
5500
5500
5500
5500
9.937
2.125
4.187
2.125
2.125
II
204
233
204
204
SG-2607
208
240
277
480
6000
6000
6000
6000
15.125
2.125
II
137
SG-2603
208
240
277
480
6000
6000
6000
6000
11.750
4.187
4.187
2.125
2.125
II
203
203
198
198
SG-2307
120
208
240
277
480
3000
3000
3000
3000
3000
9.000
2.125
2.125
4.187
2.125
2.125
II
142
142
146
142
142
SG-1173
120
208
240
277
480
1750
1750
1750
1750
1750
SG-1163L
120
208
240
277
480
1650
1650
1650
1650
1650
7.750
2.125
156
SG-1383
120
208
240
277
480
3800
3800
3800
3800
3800
13.687
2.125
187
452672
459460
452859
459225
452681
459284
455398
459170
457502
452760
15
-123
-128
452648
412072
7.750
2.125
164
459237
6-23-09
2-26-09
11-19-08
3-21-06
DATE
RER
PMO
PMO
RKC
BY
FMS
RY
FMS
CVM
RB
APVD.
-135
459250
455371
459230
REVISIONS
196
DESCRIPTION
12
2.125
459452
455380
REV.
13.687
452664
4000
4000
4000
4000
REMARKS
SG-1403
208
240
277
480
132
135
132
132
PCN NUMBER
13
4000
4000
4000
4000
"
14
SG-2407
208
240
277
480
II
W/
Date:
12-15-94
-114
-115
-120
Title:
15
Revision:
Drawing No.:
156-563153-000
Sheet:
2 Of 2
WATTS
Date:
1-5-92
Checked by:
ADA
Date:
12.20-94
Size:
C
Critical to Regulatory Requirements
(x.xx=Cpk requirements)
VOLTS
Drawn by:
RKC
Approved by:
L.KEEFOVER}
Critical to Quality
(x.xx=Cpk requirements)
CATALOG NUMBER