Immersion Heaters Haz Area UK+USA

IMMERSION HEATERS
HAZ AREA
00 - 02 - 0414
IMMERSION HEATERS HAZ AREA
Hazardous Area Screw Plug Heaters
Our experience on designing, engineering, manufacturing Immersion Heaters, allows us to help you for all your heater needs standard or
special execution.
We also have a number of standard designs from which your special needs can be made up from stock components. As if that is not
enough, we custom build as well.
All our heaters are made of the fnest quality materials, precision engineered to exacting standards to give long life performance and low
maintenance costs.
We design and manufacture under our own quality system. We will collaborate with you to obtain optimum performance designing
together heater and control. In fact, with the increasing importance of control in electric process heating, the heater is fast becoming only
as good as the system that controls it. So in summary, standard or special, Ex stock, assembly stock, standard design or custom built.
Whether your requirement is for a standard off the shelf product, or a totally custom made or bespoke design, Zoppas Industries puts
you in control of your electric process heating systems.
Warranty
All Zoppas Industries Heating Element Technologies products are engineered to extremely high quality standards and are normally covered
by full 12 month warranty from the date of dispatch from our factory.
Dimension
Dimensions throughout the catalogue are shown in millimeters and inches. The Zoppas Industries Heating Element Technologies company
policy of continuous product development and improvement renders specifcations liable to modifcation. Tables of types and dimensions
of heaters listed in this catalogue are, therefore, subject to change without prior notifcation. In any case, our technical offce is at your
disposal to your needs.
How To Use This Catalogue
This catalogue is designed to help you select the correct heater for your specifc application (see also the following table on applications).
By following the heater selection procedure and consulting the selection table you can quickly and easily identify the model number of
the heater.
In any case we recommend you to consult our Technical Department, always to your disposal, for the better resolution of your
problems.
If you cant fnd what you want in our stock heaters or in our standard design, then we will custom build the heater to your exact
requirements.
Defnition of Terms
Assembly Stock: Components are held in stock and require assembly time before being available for packing/dispatch.
Standard Design: Manufactured from in house standard designs, these require time for the generation of manufacturing instructions
and quality control procedures before packing/dispatch.
Custom Built: These require design, engineering, manufacturing, quality control and approval prior to packing/dispatch.
9191.IRCR IT-75.12.6975
UNI EN 15085-2
IT-75.12.6975
UNI EN ISO
3834-3 11/2006
FM 11235
COMPANY CERTIFICATIONS PRODUCT TRADEMARKS
Compliance with the
mark of each specific
product must be
properly reviewed with
our Sales Department.
00 - 03 - 0414
Heater Selection
1. Select Type of immersion heater
Screwed immersion heaters for installing through the tank or vessel wall. (pages X to Y)
Flanged heaters for similar applications as above where larger Kw loading are required, or we can supply with a vessel such as
circulation heaters. See fanged catalogue.
Over the side/vat heaters for installing over the side of an open tank. See catalogue.
2. Determine watts rating and sheath material
Consult Zoppas Industries Heating Element Technologies Sales Department for suggested watts rating and sheath materials.
Typical applications include:
Process water heating - Incoloy 800 at 60 w/ins
2
(9.3 w/cm
2
)
Sea water - Titanium at 25 w/ins
2
(3.87 w/cm
2
)
Ethylene glycol solution - Incoloy 800 at 1520 w/ins
2
( 2.33 3.1 w/cm
2
)
Mild steel/stainless steel at 15 and 20 w/ins
2
(2.32 and 3.1 w/cm
2
)
Medium oils - mild steel at 12 w/ins
2
(1.86 w/cm
2
)
Heavy oils - mild steel at 8 w/ins
2
(1.24 w/cm
2
)
Note: The suggested watts ratings and sheath materials should be used only as a guide. It is responsibility of the user to make the ultimate
choice based on their knowledge of the chemical composition of the medium or fuid, the chemical composition of the product being
processed and the controls which he maintains during the process.
3. Calculate Kw
Based on the heating up time, temperature change required, heat losses etc. Consult Zoppas Industries Heating Element Technologies
Sales Department for assistance.
4. Select nearest standard heater
Based on watts rating, kW and any dimensional constraints such as immersed length.
5. Specify voltage
Single or 3 phase, star/delta, number of circuit or steps and frequency, in Hz.
6. Specify all variations from standard
Sheath/fange materials, enclosures, head/fange sizes etc.
7. Choose heater controls
For simple on/off controls, the standard thermostats are listed in Optional Regulation Thermostat in the following page. On the following
table, you can do a frst heater type choice on base to different applications.
Different solutions Concentration Materials Specifc Power Plug Material
Application
Solution or
Heater Type
Alkaline or
Acid Content
(% by volume)
Sheath
Material
Watt Density
(W/in
2
) (W/cm
2
)
Screw Plug
Material
Water & Very
Mild Solution
Clean Water pH6 to pH8 Neutral Copper 45 7 Brass
Process Water or
Very Weak Solutions
pH5 to pH9
2-3%
Stainless Steel 45 7 Stainless Steel
Weak Solutions 5-6% Incoloy 45 7 Stainless Steel
Demineralized,
Deionize Water
-
Incoloy
Stainless Steel
45 7 Stainless Steel
Corrosive & High
Viscous Solutions
Mild corrosive
Solutions
5-15%
Incoloy
Stainless Steel
23 3.5 Stainless Steel
Severe corrosive
Solution
>16%
Incoloy
Stainless Steel
15 2.3 Stainless Steel
Oil heating
Low Viscosity Oil
Medium Viscosity Oil
-
Mild Steel
Stainless Steel
23
15
3.5
2.3
Steel
Specialty
Heaters
Process Water
Demineralized Water
Low Viscosity Oil
Pipe Insert
pH5 to pH9
-
-
Clean Water
Stainless Steel
Stainless Steel
Stainless Steel
Incoloy
Copper
45
23
12
60
7
3.5
1.86
9.3
Brass
Stainless Steel
Steel
Steel
Brass
00 - 04 - 0414
Construction
Heating Element
Zoppas Industries Heating Element Technologies heating elements consist of highest quality 80/20 nickel chrome resistance wire centered
in a metal sheath and insulated with compacted magnesium oxide. The elements are usually bent into a U shape or U back.
The element sheath material is normally:
Incoloy 800 and 825
Stainless steel grades 304 and 316
Titanium
Inconel 600 and 625
Mild steel
To prevent fouling or carbonization, the watts density (w/ins
2
or w/cm
2
) of the element should be limited according to application. Zoppas
Industries Heating Element Technologies standard watts densities include 8, 12, 15, 20, 25, and 60 w/ins
2
(1.24, 1.86, 2.32, 3.10, 3.87
and 9.30 w/cm
2
). Heaters with special watts densities can be made to meet customers individual requirement. Consult Zoppas Industries
Heating Element Technologies Sales Department for suggested watts ratings and sheath materials for a wide range of applications.
Screwed Head
The elements are brazed or welded into a threaded boss, which can have BSP, NPT or ISO thread forms as shown by table 1. Standard
head material is brass, and stainless steel for fameproof heaters, but special mild steel, stainless steel or titanium bosses can be ftted.
Terminal Enclosure
To protect the element/cable connection, a terminal enclosure is ftted to the heater. The type standard is waterproof to IP 65 and
certifed explosion-proof for hazardous areas. The terminal enclosure can include an regulation thermostat with adjustable range, with the
obligatory safety manual reset cutout thermostat (or thermowell manual controlled from control panel.
Head Diameter BSP NPT ISO
1
1
2
2
2
45
77
TABLE 1 (Screwed head sizes for immersion heaters)
00 - 05 - 0414
Certifed Explosion-Proof-Exd
For hazardous areas, explosion-proof screwed immersion heaters are supplied, tested by the Notifed Body CESI by European Standard
EN 60079-0 and 60079-1.
Certifcation covers Zones 1 and 2 hazardous areas, Gas Groups IIC, IIB and IIA and Temperatures Classes T1 - T4.
For applications where the operating temperature is less of than 212F (100C), the screwed head is an integral part of the terminal
enclosure. For higher temperatures the screwed head is separated from the enclosure by means of a stand-off (neutral extension).
Control
The control temperature (regulation) is performed by thermostat of which the characteristics of which are listed on table below.
Zoppas Industries Heating Element Technologies have to supply a safety thermostat manual reset into the terminal enclosure.
The thermocouple or PT100 can be supplied instead of the thermostats (on request).
Testing
In accordance with the proposed EN for industrial electric immersion heaters, all Zoppas Industries Heating Element Technologies screwed
immersion heaters undergo pressure, continuity, insulation resistance and dielectric tests. Test certifcates are not supplied as standard
but are available on request.
Type Part No. Range Note
Safety 570968671 +52C 3C Manual reset
Regulation 571064270 -30C+30C SPDT
Regulation 570142140 +4C+40C SPDT
Supply Safety Thermostat
Optional Regulation Thermostat
00 - 06 - 0414
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
8 w/ins
2
- 1.25 w/cm
2
Applications
Heavy duty oils, raw crude oils, naphta, aniline etc.
Standard features
rugged industrial construction
stainless steel elements
2 brass screwed plug
1 explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
l
e
m
.
Dia.
Elements
Explosion-proof Exd
F
l
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i
d

T
C
T
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y

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A
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X
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a
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y

T
C
.
C
l
a
s
s

A
T
E
X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
2
0
1
3
5
0
2
0
5
0
0
2
0
5
0
0
T
2
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
0.75 230 1 995 39 1 10 0.4 1REBACF28001 1REBACF29001 1REBACR57001
0.75 230 1 515 20 1B 10 0.4 1REBACF30001 1REBACF31001 1REBACR58001
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
00 - 07 - 0414
FLT / FLT-D RANGE
10.5 w/ins
2
- 1.65 w/cm
2
Applications
Medium viscosity oils, non-fowing heat transfer oil etc.
Standard features
Explosion-proof terminal enclosure with stand-off
Thermowell optional
*1B= 1 Element U bent
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
l
e
m
.
Dia.
Elements
Explosion-proof Exd
F
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d

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a
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A
T
E
X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
2
0
1
3
5
0
2
0
5
0
0
2
0
5
0
0
T
2
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
0.5 230 1 650 26 1 8.5 0.33 1REBACF34001 1REBABF35001 1REBACR60001
0.5 230 1 340 13 1B 8.5 0.33 1REBACF36001 1REBACF37001 1REBACR61001
1.0 230 1 1205 47 1 8.5 0.33 1REBACF34002 1REBACF35002 1REBACR60002
1.0 230 1 620 24 1B 8.5 0.33 1REBACF36002 1REBACF37002 1REBACR61002
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
00 - 08 - 0414
FLT / FLT-D RANGE
12.5 w/ins
2
- 1.95 w/cm
2
Applications
Medium viscosity oils, non-fowing heat transfer oil etc.
Standard features
Thermowell optional
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
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e
m
.
Dia.
Elements
Explosion-proof Exd
F
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i
d

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A
T
E
X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
2
0
1
3
5
0
2
0
5
0
0
2
0
5
0
0
T
2
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
00 - 09 - 0414
FLT / FLT-D RANGE
20.5 w/ins
2
- 3.2 w/cm
2
Applications
Heat transfert oil, Alkaline solution, Vapour degasing.
Standard features
Thermowell optional
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
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m
.
Dia.
Elements
Explosion-proof Exd
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d

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1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
2
0
1
3
5
0
2
0
5
0
0
2
0
5
0
0
T
2
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
00 - 010 - 0414
FLT / FLT-D RANGE
20.5 w/ins
2
- 3.2 w/cm
2
Applications
Heat transfert oil, Alkaline solution, Vapour degasing
Standard features
Thermowell optional
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
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e
m
.
Dia.
Elements
Explosion-proof Exd
F
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d

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A
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X
F
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S
a
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t
y

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C
.
C
l
a
s
s

A
T
E
X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
2
0
1
3
5
0
2
0
5
0
0
2
0
5
0
0
T
2
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
5 400 1 2525 99 1 10 0.4 1REBACF28019 1REBACF29019 1REBACR57018
5 400 1 1280 50 1B 10 0.4 1REBACF30019 1REBACF31019 1REBACR58015
00 - 011 - 0414
SCREWED SELECTION TABLES
FLT / FLT-D RANGE
60 w/ins
2
- 9.3 w/cm
2
Applications
Industrial water heating
Standard features
Incoloy 800 elements
Thermowell
k
W
V
o
l
t
a
g
e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
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e
m
.
Dia.
Elements
Explosion-proof Exd
F
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d

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A
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.
C
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A
T
E
X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
1.0 230 1 340 13 1 8.5 0.335 1REBACF38001 1REBACF39001
1.5 230 1 350 13 1 8.5 0.335 1REBACF38002 1REBACF39002
2.0 230 1 450 17 1 8.5 0.335 1REBACF38003 1REBACF39003
3.0 230 1 650 25 1 8.5 0.335 1REBACF38004 1REBACF39004
3.0 230 1 350 13 1B 8.5 0.335 1REBACF40004 1REBACF41004
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
00 - 012 - 0414
k
W
V
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t
a
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e
P
h
a
s
e
Maximum
Immersed
Length
N
o
.

E
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m
.
Dia.
Elements
Explosion-proof Exd
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A
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X
1
0
0
0
1
2
0
0
2
0
0
T
4
1
0
1
2
0
0
5
0
2
5
0
5
0
3
0
0
T
3
mm. Ins. mm. Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
1.5 230 1 340 13 1 10 0.4 1REBACF42002 1REBACF43002
2.0 230 1 405 16 1 10 0.4 1REBACF42003 1REBACF43003
2.5 230 1 485 19 1 10 0.4 1REBACF42004 1REBACF43004
3.0 230 1 565 22 1 10 0.4 1REBACF42005 1REBACF43005
3.0 230 1 340 13 1B 10 0.4 1REBACF44005 1REBACF45005
4.0 400 1 730 28 1 10 0.4 1REBACF42006 1REBACF43006
4.0 400 1 385 15 1B 10 0.4 1REBACF44006 1REBACF45006
4.5 400 3 340 13 3 10 0.4 1REBACF46002 1REBACF47002
5.0 400 1 890 35 1 10 0.4 1REBACF42007 1REBACF43007
5.0 400 1 465 18 1B 10 0.4 1REBACF44007 1REBACF45007
6.0 400 1 1055 41 1 10 0.4 1REBACF42008 1REBACF43008
6.0 400 1 545 21 1B 10 0.4 1REBACF44008 1REBACF45008
6.0 400 3 405 16 3 10 0.4 1REBACF46003 1REBACF47003
7.5 400 3 485 19 3 10 0.4 1REBACF46004 1REBACF47004
9.0 400 3 585 23 3 10 0.4 1REBACF46005 1REBACF47005
12.0 400 3 790 31 3 10 0.4 1REBACF46006 1REBACF47006
15.0 400 3 950 40 3 10 0.4 1REBACF46007 1REBACF47007
18.0 400 3 1110 43 3 10 0.4 1REBACF46008 1REBACF47008
SCREWED SELECTION TABLES
FLT / FLT-D RANGE
60 w/ins
2
- 9.3 w/cm
2
Applications
Industrial water heating
Standard features
Incoloy 800 elements
Thermostat regulation
Thermowell optional
L
1
0
8
12 165
L
1
0
8
12 165 6 X
FLT TYPE
FLT-D TYPE
00 - 013 - 0414
00 - 014 - 0414
INSTRUCTION
USE AND MAINTENANCE
Dangerous Areas Electric Heaters
FLT 80 ; FLT 95
Ex II 2G d IIC T1T4
ATEX 94/9/CE Directive
CEI EN 60079-0 ; CEI EN 60079-1 Standards
L
1
0
8
12 165
L
1
0
8
12 165 X
1
0
8
125
1
0
8
125
FLT TYPE
FLT-D TYPE
00 - 015 - 0414
THE FOLLOWING INFORMATION IS THE MINIMUM NECESSARY FOR SAFE
USE. WE CAN SUPPLY MORE INFORMATION AFTER EVALUATION BY OUR
TECHNICAL DEPARTMENT ABOUT DIFFERENT SITUATIONS.
Security instructions
Description
The Immersion Electric Heaters type FLT 80 and FLT 95 are arranged by one heater unit and one case for the electric connections.
The protection level is Exd IIC T4T1, IP65 with gasket.
The Immersion Electric Heaters type FLT 80 and FLT 95 must be installed in accordance with EN 60070-14 Standards and the
maintenance operations must be performed in accordance with EN 60070-17 Standards. The user has to know the risks deriving
from the electric current and from some gas or steam in the ambient.
Installation in Dangerous Area
The Immersion heaters, must be installed and kept in accordance with the plant standards and maintenance related to the environment
classifed against the explosion risk like 1 and 2 zone (gas).
Special condition for a secure use
To avoid an extreme temperatures on the fuid, every heater must be provided with a control temperature device different and
adjunctive in comparison with the same for normal function.
The heater can only operate with 50 mm of liquid above the element and should ideally be protected by a level switch.
Conformity to the directive 94/9/CE
The Immersion Electric Heaters type FLT 80 and FLT 95 are conformable to the Main Security Requirements expected from
European Directive 94/9/CE for the instruments of Group II, category 2G; this conformity is guaranteed by the respect of the
prescriptions of the Standards EN 60079-0 and 60079-1 as illustrated on the Conformity Declaration by the builder and attached to
these instructions.
Nominal features
Protection mode : Ex d IIC T4T1
Protection degree : IP 65
ATEX Code : II2G
Max voltage : 750 V
Max current : 64 A
Nominal frequency : 50/60 Hz
Ambient temperature : minus 20C, plus 40C (refer to factory if outside this range)
Marking
xxxx x II 2 G
Xxxx survey organization number ATEX (CESI)
II group II (surface)
2 category 2
G explosive atmosphere with gas, steam and fog
Ex d IIC protection mode, gas group
T4T1 temperature class
See following Table
1
2
3
4
HEATERS TO IMMERSION N/YEAR
Use cable for operating temperature >
TYPE FLT
ATTENTION:
Ex.d II C T II 2G
W V
C
A xxxX
CODE
S.p.A. DIVISIONE
VITTORIO VENETO (TV) ITALIA
DO NOT OPEN WHILE ENERGIZED
00 - 016 - 0414
Installation
When installing hazardous area certifed equipment it is the installers responsibility to comply with all local regulations and ensure
that installation staff are suitably trained.
Failing to comply safety regulations will invalidate both the warranty and hazardous area certifcation of this product.
5
L
1
0
8
12 165
L
1
0
8
12 165 X
1
0
8
125
1
0
8
125
FLT TYPE
FLT-D TYPE
00 - 017 - 0414
IMMERSION ELECTRIC HEATERS: DATA SHEET
Zoppas Industries model No.
Quantity
Type of heater screwed fanged vat
Power supply Volt Hz Phase
Floating star or delta Y
Terminal enclosure Explosion-proof (Ex d)
Solution to be heated Concentration and characteristics
Working conditions
Working temperature
Working pressure
Max. immersed length
Vat Heater Tank dimensions
Minimum liquid level
Environmental conditions Internal/external TC
Particular requirement if any
Other comments if any
Power supply Volt Hz Phase
Control position in heater Remote control panel
Heater control requirements Thermostat Thermostat cutout Thermocouple
Secial control features required
Environmental conditions Internal/external TC
Particular requirement if any
Other comments if any
Heater
Controls
00 - 018 - 0414
Hazardous Area Flanged Heaters
Our experience in designing, engineering and manufacturing Immersion Heaters, allows us to help you for all your heater needs standard
or special execution.
We also have a number of standard designs from which your special needs can be made up from stock components. As if that was not
enough, we custom build as well.
All our heaters are made of the fnest quality materials, precision engineered to exacting standards to give long life performance and low
maintenance costs.
We design and manufacture under our own quality system. We will collaborate with you to obtain optimum performance designing
together heater and control. In fact, with the increasing importance of control in electric process heating, the heater is fast becoming only
as good as the system that controls it. So In summary assembly stock, standard design or custom built. Whatever you are buying or
specifying needs, Zoppas Industries puts you in control of your electric process heating systems.
Warranty
All Zoppas Industries products are engineered to an extremely high quality standards and are normally covered by a full 12 month warranty
from the date of dispatch from our factory.
Dimension
Dimensions throughout the catalogue are shown in millimeters and inches. The Zoppas Industries Heating Element Technologies company
policy of continuous product development and improvement renders specifcations liable to modifcation. Tables of types and dimensions
of heaters listed in this catalogue are, therefore, subject to change without prior notifcation. In any case, our technical offce is at your
disposal to your needs.
How To Use This Catalogue
This catalogue is designed to help you select the correct heater for your specifc application (see also the following table on applications).
By following the heater selection procedure and consulting the selection table you can quickly and easily identify the model number of
the heater.
We recommend you to consult our Technical Department, always at your disposal, for the better resolution of your problems.
If you cant fnd what you want in our stock heaters or in our standard design, then we will custom build the heater to your exact
requirements.
Defnition of Terms
Assembly Stock: Components are held in stock and require assembly time before being available for packing/dispatch.
Standard Design: Manufactured from in-house standard designs, these require time for the generation of manufacturing instructions
and quality control procedures before packing/dispatch.
Custom Built: These require design, engineering, manufacturing, quality control and approval prior to packing/dispatch.
Compliance with the
product must be
9191.IRCR IT-75.12.6975
UNI EN 15085-2
IT-75.12.6975
UNI EN ISO
3834-3 11/2006
FM 11235
00 - 019 - 0414
Heater Selection
1. Select Type of immersion heater
Flanged heaters as above where larger Kw loading are required we can supply with vessel such as circulation heaters.
Over the side/vat heaters for installing over the side of an open tank.
2. Determine watts rating and sheath material
Consult Zoppas Industries (Heating Element Technologies-Sales Department) for suggested watts rating and sheath materials.
Typical applications include:
Process water heating - Incoloy 800 at 60 w/ins
2
(9.3 w/cm
2
)
Sea water - Titanium at 25 w/ins
2
(3.87 w/cm
2
)
Ethylene glycol solution - Incoloy 800 at 1520 w/ins
2
( 2.33 3.1 w/cm
2
)
Light oils - mild steel/stainless steel at 15 and 20 w/ins
2
(2.32 and 3.1 w/cm
2
)
Medium oils - mild steel/stainless steel at 12 w/ins
2
(1.86 w/cm
2
)
Heavy oils - mild steel/stainless steel at 8 w/ins
2
(1.24 w/cm
2
)
Note: The suggested watts ratings and sheath materials should be used only as a guide. It is the responsibility of the user to make the
ultimate choice based on their knowledge of the chemical composition of the medium or fuid, and the controls which he maintains during
the process.
3. Calculate Kw
Based on the heating up time, temperature change required, heat losses etc. Consult Zoppas Industries Heating Element Technologies
Sales Department for assistance.
4. Select nearest standard heater
Based on watts rating, kW and any dimensional constraints such as immersed length.
5. Specify voltage
Single or 3phase, star/delta, number of circuit or steps and frequency, in Hz.
6. Specify all variations from standard
Sheath/fange materials, enclosures, head/fange sizes etc.
7. Control options
The following page lists the different control thermostatsvailable.
8. Heater Selection
The following table can be used to do a provisional selection of heater rating and construction.
Different solutions Concentration Materials Specifc Power
Application
Solution or
Heater Type
Alkaline or
Acid Content
(% by volume)
Sheath
Material
Watt Density
(W/in
2
) (W/cm
2
)
Water & Very
Mild Solution
Clean Water pH6 to pH8 Neutral Copper 45 7
Process Water or
Very Weak Solutions
pH5 to pH9
2-3%
Stainless Steel 45 7
Weak Solutions 5-6% Incoloy 45 7
Demineralized,
Deionize Water
-
Incoloy
Stainless Steel
45 7
Corrosive & High
Viscous Solutions
Mild corrosive
Solutions
5-15%
Incoloy
Stainless Steel
23 3.5
Severe corrosive
Solution
>16%
Incoloy
Stainless Steel
15 2.3
Oil heating
Low Viscosity Oil
Medium Viscosity Oil
-
Mild Steel
Stainless Steel
23
15
3.5
2.3
Specialty
Heaters
Process Water
Demineralized Water
Low Viscosity Oil
Pipe Insert
pH5 to pH9
-
-
Clean Water
Stainless Steel
Stainless Steel
Stainless Steel
Incoloy
Copper
45
23
12
60
7
3.5
1.86
9.3
00 - 020 - 0414
CONSTRUCTION
Heating Element
Zoppas Industries Heating Element Technologies (ZIHET) heating elements consists of the highest quality 80/20 nickel chrome resistance
wire centered in a metal sheath and insulated with compacted magnesium oxide. The elements are usually bent into a U shape or U back.
Sheath Material:
Incoloy 800-825
Stainless steel grades 304 and 316
Titanium
Inconel 600 and 625
Mild steel
ZI can offer various options on sheath material to suit application.
To prevent fouling or carbonization, the watt density (w/ins
2
or w/cm
2
) of the element should be limited according to the application. IRCA
standard watts density:
4, 8, 12, 15, 20, 25, 40 and 60 w/ins
2
respectively 0.62, 1.24, 1.86, 2.32, 3.10, 3.87, 7.75, 9.30 w/cm
2
.
Heaters with special watts densities can be made to meet customers individual requirements.
Consult ZIs Technical Department for suggested watts ratings and sheath materials for a wide range of applications.
Element Supports
1. Full diameter plates:
For non-fow conditions, full diameter baffe plates are ftted to the elements to provide rigidity and maintain spacing between the elements.
2. 25% cut segmental baffes:
Used for fow applications, 25% cut segmental cross fow baffes are designed to aid heat transfer as well as support the elements. These
baffes direct the fow across the elements (over the lower and under the upper baffes) and offer very high heat transfer even under low
fow conditions.
3. Longitudinal support plates:
Instead of directing the fow across the element longitudinal, support plates are designed to direct the fow along the elements. Although
less suitable for low fow conditions, the supports are designed to minimize resistance to fow, ensuring that the pressure drop through
the heater is kept to a minimum.
Element Tube Plate/Flange Connection
Welded/brazed:
As standard for general purpose and as an alternative for process applications, the elements are brazed or welded directly to the tube
plate.
Terminal Enclosure
To protect the element/cable connections a terminal enclosure is ftted to the heater.
Certifed explosion - proof for hazardous areas.
Standard cabling or conduit can be wired into the terminal enclosure without the need for an intermediate junction box and high
temperature cables. As an optional extra, anti-condensation heaters can be ftted into some of the larger terminal enclosures to keep the
element terminations dry during periods of storage or inactivity. See Table 2 on page XX for the types of enclosures that can accommodate
anti-condensation heaters.

C1 Explosion-proof - Exd
For hazardous areas, explosion-proof fanged immersion heaters can be supplied, independently laboratory tested by the CESI by
European Standard EN 60079-0 and 60079-1.
Certifcation covers Zones 1 and 2 hazardous areas, Gas Groups IIC, IIB and IIA and Temperatures Classes T1 - T4.
For applications where the operating temperature is less than 158F (70C), the screwed head is an integral part of the terminal enclosure.
For higher temperatures the screwed head is separated from the enclosure by means of a stand-off (neutral extension).
Control
The control temperature (regulation) is performed by a thermostat of which the characteristics are listed on the table below.
Zoppas Industries have to supply a safety thermostat manual reset into the terminal enclosure.
Thermocouples or PT100 can be supplied instead of the thermostats (on request).
00 - 021 - 0414
Testing
All ZIHET controls systems and components are fully tested.
In accordance with the proposed EN for industrial electric immersion heaters, all Zoppas Industries Heating Element Technologies fanged
immersion heaters are subjected to pressure, continuity, insulation resistance and dielectric tests.
Test certifcates are not supplied as standard, but are available on request.
Regulation 571064270 -30C+30C SPDT
Supply Safety Thermostat
Optional Regulation Thermostat
00 - 022 - 0414
We can install anti condensation heaters within the terminal box, the anti condensation heater will require a separate supply and must
be feed via a separate gland and cable, anti condensation heaters must be de-energised when the heater is operational. the anti
condensation heater power is shown in the table below.
TYPE VOLUME SURFACE POWER NOTES
FLGT dm3 (min-max) m3 (min-max) W
FLGT 50 0.220.45 0.0260.041 --- N.A.
FLGT75 0.71.4 0.0520.081 --- N.A.
FLGT100 0.91.7 0.0360.095 --- N.A.
FLGT125 1.32.5 0.0840.122 --- N.A.
FLGT150 1.63.2 0.0970.139 --- N.A.
FLGT175 2.54.8 0.1260.180 20 ---
FLGT200 3.26.2 0.1500.212 20 ---
FLGT250 7.512.5 0.2540.331 40 ---
FLGT300 10.518 0.3260.417 60 ---
FLGT350 1525 0.4300.536 80 ---
FLGT400 18.532 0.5190.639 100 ---
FLGT450 2440 0.6190754 100 ---
00 - 023 - 0414
7

European ATEX Directive 94/9/CE
Electrical and non-electrical equipment and protection system

... Ex
Use of equipment in Type of
Potentially explosive atm protection see
CE Marking following list

Identification number of
Notified body, when appropriate

z

CATEGORY OF EQUIPMENT
STANDARDS AND TYPE OF PROTECTION
Electrical equipment for gas (G)

General requirements
Oil immersion
Pressurized apparatus
Powder filling
Flameproof enclosure
Increased safety
Intrinsic safety
Intrinsic safety
Encapsulation
Protection type n
Category 1G
Category M1
Code
o
p
q
d
e
ia
ib
m
n
EN Rule
60079-0
60079-6
60079-2
60079-5
60079-1
60079-7
60079-11
60079-11
60079-18
60079-15
60079-26
50303
Cat.
M2-2G
M2-2G
M2-2G
M2-2G
M2-2G
M2-2G
M2-2G
M2-2G
3G
1G
M1
Equipment for mines Group 1
Category M1
Level of protection: Very high level. Two types of protection, or
two independent faults-
Category M2
Level of protection: High level. One type of protection, Normal
operation

Equipment for surface Group II
Category 1
Level of protection: Very high level. Two types of protection or
two independent faults.
Category 2
Level of protection: High level. Common frequent malfunction.
Category 3
Level of protection: Normal. Required level of protection

Electrical equipment for dust (D)
Protection by enclosure ExtD EN 61241 1 1D
Protection by pressure ExpD EN 61241 4 2D
Protection by intrinsic safety ExiD EN 61241 11 1D
Protection by encapsutation ExmD EN 61241 18 1D

Equipment Group:
for surface
Equipment Group:
for surface
Equipment
category
I mines M1 Very high level
M2 High level
Type of explosive
Atmospheres
(group II)

Zone Zone
G D
Gas Dust
vapours
II surface 1 Very hihg level 0 20
2 High level
3 Normal 1 21
2 22
x
Group of gas
I Mines (Methane)
II Surface Industries
IIA Propane
IIB Ethylene
IIC Hydrogen
Acetylene

Temperature class
(group II)
Maximum
Surface
Temperature
Class [C]
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
Reference ambient
Temperature -2040C
For Dust Class put the
maximum surface
temperature after the
T example T100C

Worldwide Local Supplier
Manufacturing
facilities
Headquarters
We at ZOPPAS INDUSTRIES put you in the front seat of globalization - sourcing your local needs globally.
9191.IRCR 9196.IRC6 IT-75.12.6975
UNI EN 15085-2
IT-75.12.6975
UNI EN ISO
3834-3 11/2006
FM 11235
Compliance with the
product must be
Experience Zoppas Industries increasing efciency using
lean enterprise across all facilities and departments.
Access our state-of-the-art laboratory facilities with over 30 years
design experience.
Beneft from Zoppas Industries manufacturing and design facilities which
maintain Quality Management Systems according to ISO 9001, EN 9100
and Environmental Management System according to ISO 14001.
Access one of the widest Heating Element Technology product portfolios
in the world including completely integrated thermal assemblies
with sensors, connectors, enclosures, etc.
Beneft from Zoppas Industries global presence through design and
manufacturing facilities across Europe, North America, South America
and Asia - lowering your Total Cost of Ownership (TCO) including
reduced logistics, design, communication and support costs.
Access Zoppas Industries in-house design, development and R&D
capabilities, such as CAD 3D design, FEA, DOE, FMEA.
Beneft from Zoppas Industries products third-party certifcation, such as
UL and VDE: marking applied on customers request.
ZOPPAS INDUSTRIES Partner

00 - 024 - 0414
Worldwide Local Supplier
Manufacturing
facilities
Headquarters
RICA - Via Podgora, 26 - 31029 Vittorio Veneto (TV) - Italy
Tel. +39 0438 9101 - Fax +39 0438 912272 - 912236
www.zoppasindustries.com - rica@zoppas.com

Immersion Heaters Haz Area UK+USA

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