Circulation heaters provide a readymade means to install electric
heating with a minimal amount of
time and labor. This is
accomplished by combining
heating elements, vessel, insulation,
terminal enclosure, mounting
brackets and inlet and outlet
connections into a complete
assembly.
Made from NPT screw plug or ANSI
flange heater assemblies mated
with a pressure vessel (tank),
circulation heaters are designed to
heat forced-circulation air, gases or
liquids. Ideal for either in-line or
side-arm operations, these
assemblies direct fluids past
FIREBAR
elements, to deliver fast response
and even heat distribution.
Watlow can meet virtually all your
circulation heater assembly needs
with made-to-order units. Made-toorder units can be made from a
wide range of heating element
sheath materials, wattages, vessel
sizes and materials, pressure
ratings, terminal enclosures and
controls.
Performance Capabilities
• Watt densities to 120 W/in
(18.6 W/cm2)
• Wattages to one megawatt
•UL
recognition to 480VÅ(ac) and
600VÅ(ac) respectively
• Ratings to 600 lb pressure class
• Incoloy®sheath temperatures to
1600°F (870°C)
• Passivated 316 stainless steel
sheath temperatures to 1200°F
(650°C)
• Steel sheath temperatures to
750°F (400°C)
• Copper sheath temperatures to
350°F (175°C)
®
or WATROD heating
®
and CSA component
2
Features and Benefits
• Standard screw plugs and
flanges feature a wide selection
of WATROD and FIREBAR
elements to meet specific
application requirements.
TypeSizes (inch)
NPT1
Screw Plugs
ANSI flanges3, 4, 5, 6, 8, 10, 12, 14
1
⁄4, 21⁄2
• Flange ratings meet recognizedagency standards. ANSI B16.5
Class 150 on:
Four or six inch FIREBAR
element flanges
Three to 14 inch WATROD
element flanges
• FIREBAR assemblies pack
more wattage in a smaller heater
bundle—replaces larger flanges
with round tubular elements, with
a smaller package.
• Compacted MgO insulationfilled elements maximize
dielectric strength, heat transfer
and life.
• One inch (25 mm) thermalinsulation, rated to 750°F
(400°C), reduces heat loss from
the vessel.
On stock chart units:
• Five to seven working days on all Assembly Stock
heaters
• 10 working days on special voltages and/or
wattages
insulation and heating vessel.
Comes with protective primer
coating.
• All catalog units rated to ANSIpressure Class 150. Pressure
vessels (tanks) are either carbon
or 316 stainless steel.
• NPT or ANSI Class 150 nozzleconnections make installation
easy. Inlet and outlet nozzle
connections are:
Threaded MNPT on eight inch
and smaller tanks
Class 150 flanged connections
on 10 inch and larger tanks
Circulation Heaters
UL®is a registered trademark of
Underwriter's Laboratories, Inc.
Incoloy®is a registered trademark of
Special Metals Corporation.
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Tubular and
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T
Process Assemblies
Circulation Heaters
Features and Benefits
• Mounting lugs are welded onto
the tank wall of all 21⁄2
and larger units. Lugs are flush
with outer insulation jacket and
provide mounting support.
Applications
• Water:
Deionized
Demineralized
Clean
Potable
Process
Options
Terminal Enclosures
General purpose (NEMA 1) terminal
enclosures, without thermostats, are
supplied on all Watlow circulation
heaters. Moisture and explosion
resistant ratings are available to
meet specific application needs. For
screw plug terminal enclosures,
inch NPT
• Flange mounting holes straddle
centerline to comply with industry
standards.
• Standard, general purpose
(NEMA 1) terminal enclosures
offer easy access to terminal
wiring.
• Industrial water rinse tanks
• Hydraulic oil, crude, asphalt
• Lubricating oils at API specified
watt densities
• Heat transfer oil
refer to pages 322 to 324. For
flange terminal enclosures, refer to
pages 340 to 341.
Stand-off Terminal Enclosures
Stand-off terminal enclosures help
protect terminal enclosures against
excessive temperatures. For details,
refer to page 340.
®
• UL
and CSA component
recognition under file numbers
E52951 and 31388 respectively.
See pages 268 to 271 for details.
• Branch circuits are subdivided
by National Electric Code (NEC)
requirements to a maximum of
48 amps per circuit.
• Paraffin
• Caustic cleaners
• Nitrogen, hydrogen and other
air/gas systems
• Superheating steam
CSA Certified Enclosures
To meet agency recognition
requirements, CSA certified
moisture and/or explosion resistant
terminal enclosures are available.
Consult your Watlow representative
for details.
Thermostats
To provide process temperature
control, Watlow offers optional
single and double pole thermostats.
Process Thermocouple in Nozzle
(Must specify which nozzle)
Thermostats are typically mounted
in the terminal enclosure. Optional
side mounting on vessel also
available.
Thermocouples
To sense process or element sheath
temperature, ASTM Type J or K
thermocouples are available.
Ref.Ref.Dimension
Tank SizeNozzle Size"A"
1
1
⁄4
2 1⁄2
31 NPT8 3⁄16
41
52 NPT11 1⁄16
62
82
For 10 inch and larger tanks consult factory for dimension.
3
⁄4 NPT8 3⁄16
1 NPT8
1
⁄2 NPT10 3⁄8
1
⁄2 NPT13 3⁄8
1
⁄2 NPT14 3⁄8
See Screw Plug Immersion
Heaters, page 324, and Flange
Immersion Heaters, on page 342
for details.
See Screw Plug Immersion
Heaters, page 325 and Flange
Immersion Heaters, on page 342
for details.
3
⁄16
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Circulation Heaters
Options
Continued
Branch Circuits
Branch circuits are subdivided by
National Electrical Code (NEC)
requirements to a maximum of
Wattages and Voltages
Watlow routinely supplies circulation
heaters with 120 to 480VÅ(ac) as
well as wattages from 500 watts to
one megawatt. If required, Watlow
will configure circulation heaters
48 amps per circuit. Consult factory
for circuit requirements other than
those listed in the stock charts.
with voltages and wattages outside
these parameters.
For more information on special
voltage and wattage configurations,
consult your Watlow representative.
Circulation Heaters
Sheath Materials
The following sheath materials are
available on WATROD and
FIREBAR heating elements:
Baffles
Direction of Flow
Pressure Vessels
All standard pressure vessel (tank)
materials are rated to 150 lb and
made from:
• Carbon steel
• 316 stainless steel
All catalog pressure vessels (tanks)
are steel unless otherwise noted.
Standard Sheath Materials
WATRODIncoloy
FIREBARIncoloy
®
316 stainless steel
Steel
Copper
®
Baffles mounted on the heating
element bundle enhance and/or
modify liquid or gas flow for better
heat transfer.
316 stainless steel pressure
vessels (tanks) are passivated on all
wetted surfaces. Available from
Assembly Stock on 2
1
⁄2 inch NPT
and four or six inch ANSI flange
circulation heaters.
Made-to-order units can be made in
a variety of materials, flange sizes
and pressure classes.
Made-to-Order Sheath Materials
WATROD304 stainless steel
FIREBAR304 stainless steel
Monel
®
Exotic Sheath Materials
Consult your Watlow representative
for details and availability.
For critical sheath temperature and
low flow conditions, baffles may be
required.
Consult your Watlow representative
for details.
To order, specify pressure
vessel (tank) size, material and
pressure class.
ANSI ratings to 600 lb are available
for high-pressure applications. For
pressure class ratings above
600 lb, as well as other vessel
materials, consult Watlow Process
Systems in Troy, Missouri.
Monel®is a registered trademark of
Special Metals Corporation.
Passivated Finish
For critical applications, passivation
will remove free iron from all wetted
surfaces.
Consult factory for details.
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Circulation Heaters
Options
ontinued
C
Gaskets
Rubber, asbestos-free and spiral
wound gaskets are available for all
heater flange, and inlet and outlet
flange sizes.
Watlow recommends ordering
spares in case replacement
becomes necessary.
and Outlet Nozzle Connections
Inlet
All inlet and outlet materials are
compatible with the pressure vessel
material and pressure class rating.
Vessel sizes from 11⁄4 to eight inches
are typically configured with MNPT
(Male National Pipe Thread)
nozzles. Optional NPT and flange
sizes can be supplied to mate with
existing piping.
To order, specify gasket type,
flange size/rating and process
operating temperature.
For details on gasket materials and
temperature ratings, see page 343.
10 inch and larger vessels are
supplied with Class 150 inlet and
outlet flanges. Optional Class 300 or
Class 600 can be provided to mate
with existing piping.
To order, specify type, size andpressure class rating for both inlet
and outlet nozzle/flange
connections.
High Temperature Thermal Insulation
To further minimize heat loss, the
pressure vessel’s standard one inch
thermal insulation wrap may be
replaced with thicker or higher
temperature insulation. For more
information, consult your Watlow
representative.
Protective Steel Jacket (Shroud)
To protect circulation heaters from
weather or wash-down conditions,
fully welded (weatherproof) or
partially welded (standard) outer
protective steel jackets are
available. Standard steel, or madeto-order 304 or 316 stainless steel
Support Saddles
To mate with an existing installation,
customized support saddle(s)
and/or mounting lugs are available.
To order, specify insulation
thickness, standard or high
temperature insulation and
temperature rating.
Vessels may be supplied with a
primer coating without insulation.
To order, specify no insulation.
can be supplied. Jacket diameter is
dependent upon thermal insulation
thickness.
To order, specify protective steel
jacket, material type and
weatherproof, if desired.
To order, specify mounting lugs or
support saddles and supply a
dimensional drawing.
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Circulation Heaters
Maximum V elocities
The rate at which a gas or liquid
flows through inlet and outlet pipes
is critical to maintaining the desired
output temperature. Pressure drop
through the circulation heater must
be considered to properly size
blowers or pumps. The Maximum
Velocity to Avoid Excessive
Pressure Drop chart gives
recommended maximum velocities,
in feet per second and meters per
second of gas or liquid being
heated and nominal pipe size.
Vessel Orientation
Guidelines
Correctly orienting the heating
vessel assures lower terminal
enclosure temperatures and
element immersion. Detailed
instructions on vessel orientation are
contained in the Installation andMaintenance Instructions that
accompanies all circulation heaters.
The following are guidelines for
vessel orientation in liquid and gas
heating applications.
Maximum Velocity to Avoid Excessive Pressure Drop
FluidNominal Pipe SizeMaximum Velocity
inchft/sec(m/sec)
GasesAll200(61.0)
Liquid4 and smaller10(3.0)
Liquid6-815(5.0)
Liquid10-1219(6.0)
Liquid14-1621(6.4)
Liquid18-2023(7.0)
Liquid2424(7.3)
Liquids
Orient circulation heater:
• Horizontally with inlet and outlet
pipes pointing up
• Vertically with the terminal
enclosure up and the inlet pipe
on the bottom
These orientations ensure the
heating elements will be immersed
at all times and help prevent
premature failure.
Air or Gases
Orient circulation heater:
• Horizontally with the inlet nozzle
closest to the terminal enclosure.
• Vertically with terminal enclosure
at the bottom of the tank. Use the
nozzle nearest the bottom as the
inlet connection.
If installation constraints do not
allow mounting in accordance with
these guidelines, consult your
Watlow representative.
Circulation Heaters
Application Hints
• Select the recommended heating
element sheath material and watt
density for the substance being
heated. Use the SupplementalApplications Chart on pages
263 to 266. If unable to
determine the correct heating
element type and material,
consult your Watlow
representative.
• Assure selecting proper vessel by
considering the pressure or flow
rate, process temperature and
corrosiveness of the media being
heated. If assistance with vessel
selection is required, consult your
Watlow representative.
• For maintenance/replacement
procedures, retain an area twice
the circulation heater’s overall
length to permit easy removal
and inspection of screw plug or
flange heater assemblies.
• Choose a FIREBAR assembly
when you require:
A smaller package
More kilowatts or lower watt
density in an equally sized
WATROD circulation tank.
• Minimize problems associated
with low flow or low liquid level
conditions with a low liquid level
sensor and/or sheath high-limit
control.
• Ensure wiring integrity by making
sure terminal enclosure
temperature does not exceed
400°F (205°C).
• Protect against electrical shock
by properly grounding the unit
per NEC requirements.
• One or more circulation heaters
may be connected in series to
achieve the desired total kilowatt
or temperature output.
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3
3
/4
"
(95 mm)
4
"
(100 mm)
Ref
A
Ref
6
7
/16
"
(164 mm)
3
/4
"
NPT Inlet & Outlet
B
Ref
3
1
/8
"
(79 mm)
Ref
C
1
/2
"
NPT
Process Assemblies
Circulation Heaters
Replacement Heater Assemblies
To help assure minimum process
downtime, it’s advisable to order
and keep on hand a replacement
flange or screw plug heater
assembly.