FIREBAR®heating elements provide added heating
performance over standard round tubular heating
elements—especially for immersion applications in
petroleum based liquids requiring high kilowatts.
The FIREBAR’s unique flat surface geometry packs more
power in shorter elements and assemblies, along with a
host of other performance improvements. These include:
• Minimizing coking and fluid degrading
• Enhancing the flow of fluid past the element’s surface
• Improving heat transfer with a significantly larger
FIREBAR elements are available in single- and
double-ended constructions with one inch or
5
⁄8 inch heights. These two configuration variables make
it possible to use FIREBAR elements instead of round
tubular elements in virtually all applications.
FINBAR™ is a special version of the one inch,
single-ended FIREBAR. FINBAR is specially modified
with fins to further increase surface area for air and
gas heating applications. Details are contained in the
FINBAR section, starting on page 110.
Double-Ended Performance Capabilities
One Inch
• Watt densities to 120 W/in2(18.6 W/cm2)
• Incoloy®sheath temperatures to 1400°F (760°C)
• 304 stainless steel sheath temperatures to
• Voltages to 240VAC
• Amperages to 48 amperes per heater or 16 amperes
5
⁄8 Inch
• Watt densities to 90 W/in2(13.9 W/cm2)
• Incoloy®sheath temperatures to 1400°F (760°C)
• Voltages to 240VAC
• Amperages to 32 amperes per heater or 16 amperes
to carry heat from the sheath
boundary layer allowing much more liquid to flow up
and across the sheath’s surface
1200°F (650°C)
per coil
per coil
One Inch Double-Ended FIREBAR Element and
5
⁄8 Inch Double-Ended FIREBAR Element and
Lead Configurations
Lead Configurations
Single-Ended Performance Capabilities
One Inch
• Watt densities to 60 W/in2(9.3 W/cm2)
• Incoloy®sheath temperatures to 1400°F (760°C)
• 304 stainless steel sheath temperatures to
1200°F (650°C)
• Voltages to 240VAC
• Amperages to 48 amperes per heater or 16 amperes
per coil
5
⁄8 Inch
• Watt densities to 80 W/in2(12.4 W/cm2)
• Incoloy®sheath temperatures to 1400°F (760°C)
• Voltages to 240VAC
• Amperages to 16 amperes per heater
WATLOW
®
91
Tubular Heaters
FIREBAR Double-Ended Heaters
Specifications
ApplicationsDirect immersion; water, oils, etc.Direct immersion; water, oils, etc.
Clamp-on; hoppers, griddlesClamp-on; hoppers, griddles
Forced air heating (Also see FINBAR, page 110)Forced air heating
Radiant heatingRadiant heating
Watt DensityStock:up to 90(13.9)Stock:up to 90(13.9)
W/in2(W/cm2)Made-to-Order (M-t-O):up to 120 (18.6)Made-to-Order (M-t-O)up to 90(13.9)
Surface Area Per Linear In. (cm)2.3 in2(14.8 cm2)1.52 in2(9.80 cm2)
Cross Section
Height1.010(25.7)0.650(16.5)
± 0.015/0.010 in. (0.381/0.254 mm)
Thickness0.235(5.9)0.235(5.9)
± 0.005/0.001 in. (0.127/0.025 mm)
Sheath Material—Max.Stock:Incoloy
Operating temperatureM-t-O:Incoloy
Sheath LengthStock:15 to 114(381 to 2896)Stock:15 to 51(381 to 1295)
in. (mm)M-t-O:11 to 180(280 to 4572)M-t-O:11 to 115(280 to 2920)
Straightness Tolerance
Major axis in./ft (cm/m):0.062(0.52)0.062(0.52)
Minor axis in./ft (cm/m):0.062(0.52)0.062(0.52)
No-Heat Length (Refer to page 105)1 in. min., 12 in. max. (25/305 mm)1 in. min., 12 in. max. (25/305 mm)
Max. Voltage—Amperage240VAC—48A240VAC—32A
Max. Hipotential1480VAC1480VAC
Max. Current Leakage Per Coil (cold)3mA3mA
Max. Amperage Per Coil16A16A
Phase(s)1-ph parallel/series, 3-ph delta/wye1-ph parallel/series
Resistance Coils3 or 22
Ohms/In./Unita0.270Ω min.—2.833Ω max.0.040Ω min.—4.250Ω max.
Ohms/In./Coila0.080Ω min.—8.500Ω max. per coil0.080Ω min.—8.500Ω max. per coil
TerminationsFlexible lead wiresFlexible lead wires
Sheath LengthStock:11 to 461⁄4(280 to 1175)Stock:111⁄2 to 52(280 to 1321)
in. (mm)M-t-O:11 to 120(280 to 3048)M-t-O:11 to 116(280 to 2946)
Straightness Tolerance
Major axis in./foot (cm/m):0.062(0.52)0.062(0.52)
Minor axis in./foot (cm/m):0.062(0.52)0.062(0.52)
No-Heat Length (Refer to page 105)
Top Cold End1 in. min., 12 in. max. (25/305 mm)1 in. min., 12 in. max. (25/305 mm)
Bottom (blunt end) Cold End1 ph- 0.5 min., 2 in. max. (13/51 mm)Only available at 1.25 in.
3 ph- 0.75 min., 2 in. max. (19/51 mm)N/A
Max. Voltage—Amperage240VAC—48A240VAC—16A
Max. Hipotential1480VAC1480VAC
Max. Current Leakage (cold)3mA3mA
Max. Amperage Per Coil16A16A
Phase(s)1-ph, 3-ph wye1-ph
Resistance Coils3 or 11
Ohms/In./Unit0.200Ω min.—14.00Ω max.
TerminationsFlexible lead wiresThreaded studFlexible lead wires
Streamline, 0.235 x 1.010 in. (5.9 x 25.6 mm) normal
to flow dimension
• Reduces drag
70 percent greater surface area per linear inch
compared to a 0.430 in. (11 mm) diameter round
tubular heater
• Reduces watt density or packs more kilowatts in
smaller bundles
Compacted MgO insulation
• Maximizes thermal conductivity and dielectric strength
Nickel-chromium resistance wires
• Precision wound
0.040 in. (1 mm) thick MgO walls
• Transfers heat more efficiently away from the
resistance wire to the sheath and media—conducts
heat out of the element faster
Three resistance coil design
• Configurable to either one- or three-phase power,
readily adapts to a variety of electrical sources and
wattage outputs
Lavacone seals
• Provides protection against humid storage conditions,
moisture retardant to 221°F (105°C)
Single-Ended
Single-ended termination
• Simplifies wiring and installation
Streamline, 0.235 x 1.010 in. (5.9 x 25.6 mm) normal
to flow dimension
• Reduces drag
70 percent greater surface area per linear inch
• Reduces watt density from that of the 0.430 in.
(11 mm) diameter round tubular
Slotted end
• Provides installation ease in clamp-on applications
Lavacone seals
• Provides protection against humid storage conditions,
moisture retardant to 221°F (105°C)
s
5
⁄8 inch Features and Benefits
Double-Ended
Special sheath dimensions, 0.235 x 0.650 in.
(5.9 x 16.5 mm)
• Results in a lower profile heater
10 percent greater surface area per linear inch
• Reduces watt density from that of the 0.430 in.
(11 mm) diameter round tubular heater
0.040 in. (1 mm) thick MgO walls
• Transfers heat efficiently away from the resistance
wire to the heated media—conducts heat out of the
element faster
Lavacone seals
• Provides protection against humid storage conditions,
moisture retardant to 221°F (105°C)
Single-Ended
Single-ended termination
• Simplifies wiring and installation
Special sheath dimensions, 0.235 x 0.650 in.
(5.9 x 16.5 mm)
• Results in a lower profile heater for more wattage in
a smaller package
Slotted end
• Provides installation ease in clamp-on applications
Lavacone seals
• Provides protection against humid storage conditions,
moisture retardant to 221°F (105°C)
94
WATLOW
®
Tubular Heaters
0.430 in.
0.235 in.
FIREBAR Single/Double-Ended Heate
Performance Features
FIREBAR’s flat tubular element geometry produces
performance features and benefits not possible with
traditional round tubular technology. The following
describes how and why the FIREBAR is functionally
superior for many applications—especially those
requiring large wattage with low watt density.
By using the FIREBAR element it will:
• Lower the element’s watt density
• Reduce element size and keep the same watt density
• Increase element life by reducing sheath temperature
Flat Shape Produces Lower Sheath Temperature
The FIREBAR element operates at a lower sheath
temperature than a round tubular element of equal
watt density because of three factors.
1. Flat Surface Geometry
FIREBAR’s flat, vertical geometry is streamline. The
liquid’s flow past the heating element’s surface is not
impaired by back eddies inherent in the round tubular
shape. The FIREBAR’s streamline shape results in fluids
flowing more freely with more heat carried away from
the sheath.
rs
Comparative Widths
Watt Density and Surface Area Advantages
The surface area per linear inch of a 1 in. FIREBAR is
70 percent greater than the 0.430 in. (11 mm) diameter
round tubular element. The5⁄8 in. FIREBAR is nearly
10 percent greater.
2. Normal to the Flow
The element’s width (thickness) of both 1 inch and
5
⁄8 inch FIREBAR elements is just 0.235 in. (5.9 mm).
Compared to a 0.430 in. (11 mm) round tubular
element, this relative thinness further reduces drag
on liquids or gases flowing past the heater.
3. Buoyancy Force
The FIREBAR element’s boundary layer, or vertical side,
is greater than virtually all round tubular elements. This
is 1.010 and 0.650 in. (25.6 and 16.5 mm) for the one
inch and5⁄8 in. FIREBARs respectively, compared to a
0.430 in. (11 mm) diameter on a round tubular
element. The FIREBAR element’s increased height,
relative to flow, increases the buoyancy force in
viscous liquids. This buoyancy force can be as much as
10 times greater depending on the FIREBAR element
and liquid used.
WATLOW
®
Surface Area Per
Linear inch (cm)
Element Typein
1 in. FIREBAR2.30 in
5
⁄8 in. FIREBAR1.52 in
0.430 in. Round1.35 in
2
2
2
2
(cm2)
(5.84 cm2)
(3.86 cm2)
(3.43 cm2)
Flat vs. Round Geometry Comparisons
The unique flat surface geometry of the FIREBAR
element offers more versatility in solving heater problems
than the conventional round tubular element. The
following comparisons show how the FIREBAR element
consistently outperforms round tubular heaters.
FIREBAR elements can:
• Reduce coking and fluid degrading
• Increase heater power within application space
parameters
• Provide superior heat transfer in clamp-on applications
resulting from greater surface area contact
• Lower watt density
Reducing watt density or sheath temperature extends life.
The FIREBAR element allows you to do either, without
sacrificing equipment performance … as is proven by the
accompanying Heater Oil Test, Air Flow and Watt Densityvs. Sheath Temperature graphs.
95
Tubular Heaters
Oil Temperature —°F
Sheath Temperature —°F
700
650
600
550
500
450
400
350
300
150200250300350400450500
1 Inch FIREBAR Heater
0.430 Inch Round Tubular
350
325
300
275
250
225
200
175
150
75100125150175200225250
Sheath Temperature —°C
Oil Temperature —°C
40 W/
i
n
2
(
6.2 W/
cm
2
)
30 W
/i
n
2
(4.7 W
/
cm
2
)
40 W/i
n
2
(6.2
W/
cm
2
)
30 W
/i
n
2
(
4.7 W/cm
2
)
FIREBAR Single/Double-Ended Heater
Technical Data
The FIREBAR Heater Oil Test graph compares sheath
temperatures of 40 W/in2(6.7 W/cm2) flat and round
tubular elements. The FIREBAR element consistently
operates at a lower sheath temperature than the round
tubular element, even when light oils are tested at
different temperatures. This reduces the chance that
coking and fluid degradation will occur.
In fact, the FIREBAR element’s sheath temperature
at 40 W/in2(6.7 W/cm2) is lower than a 30 W/in
(4.6 W/cm2) round tubular element.
2
s
FIREBAR Heater Oil Test
Heater Size and Power
The Heater Size Comparison chart shows, at the same
wattage and watt density, the FIREBAR element is
38 percent shorter than a 0.430 in. (11 mm) round
tubular element. The FIREBAR element requires less
space in application and equipment designs.
The Heater Power Comparison chart demonstrates equal
watt density, element length and increased total wattage
for the FIREBAR element. The power in the FIREBAR
element is 70 percent greater.
96
Heater Size Comparison
Heated Length
Elementin. (mm)Wattage W/in2(W/cm2)
1 in. FIREBAR Element 197⁄8(504.8)100023(3.6)
0.430 in. Round
Tubular Element321⁄4(819.0)100023(3.6)
Heater Power Comparison
Heated Length
Elementin. (mm)Wattage W/in2(W/cm2)
1 in. FIREBAR Element321⁄4(819.0)170023(3.6)
0.430 in. Round
Tubular Element321⁄4 (819.0)100023(3.6)
WATLOW
®
Tubular Heaters
45
40
35
30
25
20
15
10
5
2004006008001000
Platen Temperature —°F
Watt Density —W/in
2
200°F
4
00
°F
6
00°F
8
00
°F
1
000°F
Sheath Temperature
Subtract 20% of Indicated Watt
Density for 2 Element FIREBAR
7
6
5
4
3
2
1
100200300400500
Platen Temperature —°C
1
00°C
2
00°C
30
0
°C
400°C
500°
C
600
Sheath Temperature
Subtract 20% of Indicated Watt
Density for 2 Element FIREBAR
1400
1200
1000
800
600
400
200
1020304050
Watt Density—W/in
2
Sheath Temperature —°F
60
0
1600
1800
1234
Watt Density—W/cm
2
9
800
700
600
500
400
300
200
Sheath Temperature —°C
0
900
1000
100
5678
Air
SAE 3
0
C
o
ok
i
ng O
i
l
Wate
r
FIREBAR Single/Double-Ended Heater
Technical Data (Continued)
Clamp-On Applications
Direct immersion in the liquid may not always be
practical. In these instances the FIREBAR element can
be clamped to a tank wall. Heat from the FIREBAR is
conducted to the tank wall and into the media.
Platen Heating (˚F)
Allowable Watt Densities of FIREBARs in Clamp-on-Application
s
FIREBAR elements are also economical platen heaters.
The Platen Heating graph shows FIREBAR’s large, flat
surface area allows it to operate at twice the watt
density of round tubular elements … without sacrificing
heater life.
Clamps should be placed approximately 6 in. (150 mm)
apart and torqued down with 60 in-lbs (6.8 Newton
meters).
Platen Heating (˚C)
Allowable Watt Densities of FIREBARs in Clamp-on-Application
Watt Density vs. Sheath Temperature
The Watt Density vs. Sheath Temperature graph features
sheath temperature curves for commonly heated
substances. A FIREBAR element’s watt density will result
in the sheath temperature shown at the intersecting point
of its vertical watt density line and substance curve.
WATLOW
®
Watt Density vs. Sheath Temperature
97
Tubular Heaters
1800
1600
1400
1200
1000
800
600
400
200
51015202530354045505560
Watt Density —W/in
2
Sheath Temperature —°F
Max. Recommended Sheath Temperature
1 FPS
4 FPS
9 FPS
16 FPS
20 FPS
900
800
700
600
500
400
300
200
100
12345678910
Watt Density—W/cm
2
Sheath Temperature—°C
0.3 MPS
1.2 MPS
2.7 MPS
4.9 MPS
6.1 MPS
1000
Max. Recommended
Sheath Temperature
FIREBAR Single/Double-Ended Heater
Technical Data (Continued)
Air Heating
The Air Flow/Watt Density/Sheath Temperature graph
shows the relationship between air flow, watt density and
sheath temperature. Keep in mind that lower sheath
temperature yields longer heater life.
To use the Air Flow graph,determine the air flow in feet
per second (or meters per second). Then follow the curve
to find the recommended sheath temperature and
watt density.
Air Flow/Watt Density/Sheath Temperature (°F)
Air Flow
s
Air Flow Normal to Sheath Geometry
Air Flow/Watt Density/Sheath Temperature (°C)
Air Flow
Moisture Resistant Seals
A lavacone seal is provided to prevent moisture and
contaminants from entering the heater. Upon request,
optional silicone rubber (RTV) and epoxy resin seals may
be ordered.
Silicone Rubber (RTV) Seal
Silicone rubber RTV seals are1⁄8 in. (3.2 mm) moisture
barriers surrounding the terminal pins at the end of the
sheath. Silicone rubber is effective to 392°F (200°C).
Epoxy Resin Seal
Epoxy resin seals are1⁄8 in. (3.2 mm) moisture barriers
surrounding the terminal pins at the end of the sheath.
Epoxy resin is effective to 194°F (90°C) or 356°F (180°C),
and recommended for water heating applications.
98
Application Hints
• Choose a FIREBAR heating element instead of an
assembly, when the application requires lower
wattages or smaller system packages.
• Keep terminations clean, dry and tight.
• Extend the heated section completely into the media
being heated at all times to maximize heat transfer and
heater life.
• Do not locate the end of the heated length within a
bend, unless the radius is 3 in. (76 mm) or larger.
• Ensure termination temperatures do not exceed 392°F
(200°C) or the maximum temperature rating of the end
seal, whichever is lower.
WATLOW
®
Tubular Heaters
FIREBAR Single/Double-Ended Heater
All FIREBAR heaters are available with a variety of
s
termination options. Contact your Watlow representative
Sil-A-Blend™ 200°C lead wire
Sil-A-Blend™ 200°C lead wire
A2
A3
Sil-A-Blend™ 200°C lead wire
A4
Sil-A-Blend™ 200°C lead wire
B1TGGT 250°C lead wire1ParallelYesYesYesYes
B2TGGT 250°C lead wire1SeriesYesNoYesNo
B3TGGT 250°C lead wire3DeltaYesNoNoNo
B4TGGT 250°C lead wire3WyeYesYesNoNo
The following illustrations detail the recommended major
and minor axis bend parameters for FIREBAR
elements. These illustrations show the relationship
between the type of bend and the location of heat and
no-heat sections. See the next two pages for the
15 common bend formations.
Note: Watlow does not recommend field bending
FIREBAR elements. If the element must be bent in the
field, please contact your Watlow representative for
assistance.
FIREBAR elements can be formed into spirals,
compounds, multi-axis and multi-plane configurations
from 15 common bends. Custom bending with
tighter tolerances can be made to meet specific
application needs.
Formation is limited by bending parameters specified in
the illustrations of major and minor axis bends on the
previous page. On these illustrations, please note the
no-heat end location.
Minor AxisMajor AxisMajor AxisMinor Axis
Figure 1B
Figure 1A
Figure 3A
The no-heat end junction must be located a minimum of
1 in. (25 mm) from any bend. If these parameters are not
followed, the heater may fail prematurely.
Illustrated below are the common bends that can be
ordered for all FIREBAR heating elements.
To order a common bend, specify the figure number
and critical dimensions.
Note: The alpha characters and symbols are used to
designate specific dimensions within each illustration.
Figure 2A
Figure 2B
Figure 4BFigure 4AFigure 3B
Figure 5A
Figure 7A
WATLOW
Figure 5B
R
1
R
2
R
1
L
A
®
H
Figure 7B
Figure 6A
Figure 8A
Figure 6B
Figure 8B
101
Tubular Heaters
L
R
1
R
2
H
A
K
B
R
1
R
1
R
3
R
4
R
2
X Hairpins
<°
(Angle)
R
1
L
B
H
K
R
1
A
R
2
H
K
R
1
R
2
L
B
A
L
R
1
R
2
A
H
R
1
R
1
R
2
X Hairpins
R
3
K
L
A
H
R
1
R
1
R
1
R
2
R
2
X Hairpins
R
3
K
L
R
1
R
2
A
H
R
1
R
1
R
2
X Hairpins
A
H
L
R
1
R
1
R
1
R
2
R
2
X Hairpins
L
H
A
K
B
R
1
R
1
R
1
R
3
R
4
R
2
R
2
X Hairpins
R
1
K
H
A
G
K
A
R
1
H
L
R
1
R
2
A
H
L
K
R
1
R
1
R
2
FIREBAR Single/Double-Ended Heaters
Bend Formation (Continued)
Minor AxisMajor AxisMajor AxisMinor Axis
Figure 9A
Figure 9B
Bend Figure
11B
Not Available
On Major Axis
Figure 10A
Bend Figure
10B
Not Available
On Major Axis
Figure 12BFigure 12AFigure 11A
Figure 15A
102
Figure 13BFigure 13A
Figure 15B
Figure 14AFigure 14B
WATLOW
®
Tubular Heaters
1
5
/8 in. -
10 UNC
0.753 in.
(19 mm)
0.940 in.
(23.9 mm)
0.187 in.
(4.8 mm)
2.25 in.
(57 mm)
0.125 in. Max.
No Threads
9
/16 in.
(14.3 mm)
Wall
Washer
Nut
Gasket
2.625 in.
(66.7 mm)
(2) 0.25 in.
(6 mm) Dia.
1.5 in.
(38 mm)
3.25 in.
(83 mm)
1.75 in.
(45 mm)
4.875 in.
(123.8 mm)
1.75 in.
(45 mm)
3 in.
(76 mm)
5.5 in.
(140 mm)
(2) 0.25 in.
(6 mm) Dia.
(2) 0.25 in.
(6 mm) Dia.
1.75 in.
(45 mm)
1.125 in.
(28.6 mm)
1.75 in.
(45 mm)
FIREBAR Single/Double-Ended Heaters
Mounting Brackets
Steel brackets provide element mounting in
non-pressurized applications. In air heating applications,
an 18-gauge aluminized steel bracket is press fitted to
the element. A1⁄4 in. (6 mm) thick steel bracket is brazed
or welded liquid-tight to the element for liquid heating.
Upon request, stainless steel brackets can be provided.
Special sizes also available.
The bracket is located1⁄2 in. (13 mm) from the sheath’s
end,1⁄16 in. (1.6 mm) if welded. Available on5⁄8 in.
(15.9 mm) FIREBAR as made-to-order only.
To order, specify mounting bracket as well as type,
location, material and size.
Type 1
Water-Tight Double-Leg Threaded Fitting
5
A threaded 1
flange on the heater sheath provides rigid, leak-proof
mounting through tank walls. This fitting allows both legs
of the heater to pass through the same opening. A
gasket, plated steel washer and hex nut are included.
The threaded end of the bulkhead is mounted flush with
the sheath’s end, unless otherwise specified. Available
on 1 inch FIREBAR only (brazed only, available).
To order, specify water-tight double-leg threadedfitting.
⁄8 in.-10 UNC stainless steel fitting with
Type 2
Type 3
WATLOW
®
Surface Finish
Bright Annealing
Bright annealing is a process that produces a smooth,
metallic finish. It is a special annealed finish created in a
non-oxidizing atmosphere. This finish is popular in the
pharmaceutical and foodservice/beverage markets.
To order, specify bright annealing.
Passivation
During manufacturing, particles of iron or tool steel may
be embedded in the stainless steel or alloy sheath. If not
removed, these particles may corrode and produce rust
spots. For critical sheath applications, passivation will
remove free iron from the sheath.
To order, specify passivation.
103
Tubular Heaters
15
/16 in. (23.8 mm)
3
/4 in.
(19 mm)
3
/16 in.
(4.8 mm)
Wall
Washer
Nut
Gasket
11/4 in.
(32 mm)
Extended Capabilities For
FIREBAR Single/Double-Ended Heaters
XTE
E
APABILITY
C
NDED
Internal Thermocouples
To provide protection against element over-temperature
conditions, 1 in. (25 mm) double-ended FIREBAR
elements can be ordered with ASTM Type K
thermocouples. This is accomplished by eliminating the
center resistance coil and embedding the thermocouple
junction inside the sheath. Thus, thermocouples are
available only on two resistance coil, 1 in. (25 mm)
FIREBAR elements.
To order, specify:
• Type K thermocouple
• Distance the junction is to be located from the
element’s end
• Lead length
Thermocouple Types
Recommended
®
Temp. Range
°F(°C)
0 to 2000
(-20 to 1100)
ASTM
Type
KChromel
➀ Type K thermocouples are rated 32 to 2282°F (0 to 1250°C).
Watlow does not recommend exceeding the temperature range
shown on this chart.
• Internal thermocouple (dual end only, single or dual coil
• Custom wattage tolerance (±5%)
Mounting Brackets
Threaded Bulkheads
A threaded stainless steel bushing with flange on the
heater sheath provides rigid, leak-proof mounting
through tank walls. A gasket, plated steel washer and
hex nut are included (brazed only, available).