Watlow FIREROD Specifications

Cartridge/Insertion Heaters

FIREROD® Cartridge Heaters

The Watlow engineering excellence and is supported by almost 60 years of solid industry performance across a broad range of simple and complex applications. As the premier choice in swaged cartridge heating, thousands of industrial manufacturers continue to choose Watlow as their trusted thermal partner and certified cartridge heater supplier.

Built using premium materials and tight manufacturing controls, the FIREROD heater provides superior heat transfer, uniform temperatures, resistance to oxidation and corrosion and a long life even at high temperatures. Every system component that leaves our manufacturing facilities meets our strict quality assurance specifications, in addition to those set forth by leading standards and regulating industries.

FIREROD® cartridge heater incorporates

To meet our customer’s individual needs, there are many delivery options available for FIREROD heaters.

Performance Capabilities

• Part temperatures up to 1400°F (760°C) on alloy 800 sheath

• Watt densities up to 400 W/in2 (62 W/cm2)

• Maximum voltage up to 480V

Features and Benefits

Nickel-chromium resistance wire

• Ensures even and efficient distribution of heat to

the sheath Conductor pins

• Provide a metallurgical bond to the resistance wire

• Ensure a trouble-free electrical connection

Magnesium oxide insulation of specific grain and purity

• Results in high dielectric strength and contributes to

faster heat-up Alloy 800 sheath

• Resists oxidation and corrosion from heat, many

chemicals and atmospheres

Minimal spacing between the element wire and sheath

• Results in lower internal temperature

• Accommodates a design with fewer or smaller heaters

operating at higher watt densities

International Organization for Standardization (ISO) 9001 certified

• Provides confidence that quality and reliability

expectations are met

Sheath

Resistance Wire

End Piece

Lead Wires

MgO

Insulation

Conductor

Pins

No Heat

Section

UL® and CSA approved flexible stranded wires

• Lead insulation rated to temperatures up to 480°F (250°C)

Patented lead adapter (LA) method

• Allows same day shipment on more than 150,000 configurations of stock FIREROD heaters and lead combinations

Typical Applications

• Semiconductor chamber heating

• Semiconductor wire and die bonding

• Freeze protection and deicing of equipment in cold climates or applications

• Humidity control

• Patient comfort heating used in medical devices

• Mold die and platen heating

• Seal bars used in packaging equipment

• Test sample heating in gas chromatography equipment

WATLOW

Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Applications and Technical Data

Tolerances

Diameter

• 1 in. (25 mm) units: ±0.003 in. (±0.08 mm)

• All other units: ±0.002 in. (±0.05 mm)

Sheath Length

• All units up to 41/2 in. (114 mm) long: ±3/32 in. (±2.4 mm)

•

/8 in. diameter units over 41/2 in. (114 mm)

long: ±3%

• All other units over 41/2 in. (114 mm) long: ±2%

Length Measurements

Pin Style and Potted FIRERODs

PTFE or Potted Seal

Heater Length

PTFE - Swaged-in Leads FIRERODs

Wattage

• 1/8 in. units: +10%, -15%

• All other units: +5%, -10%

Resistance

• 1/8 in. units: +15%, -10%

• All other units: +10%, -5% Resistance changes with temperature. There are three

circumstances under which resistance can be measured:

1. Room temperature (before use): nominal ohms are 90% of Ohm’s law calculation.

2. Room temperature (after use): nominal ohms are 95% of Ohm’s law calculation.

3. At temperature (during use): depending on application nominal ohms are approximately 100% of Ohm’s law.

Note: Resistance and wattage values are approximate

depending on application conditions.

Component Recognition File Numbers

• UL® component rated to 240VAC

(file number E52951)

• CSA component rated to 240VAC

(file number LR7392)

• VDE component rated to 240VAC

(file number 10062-4911-0006) Note: Not all options or combinations of options are covered. UL®, CSA, VDE and CE marking is available upon request.

Heater Length (excludes lead end turnover)

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Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Applications and Technical Data

Dimensional Data

This table shows minimum/maximum sheath lengths for available FIREROD diameters.

FIREROD Diameter Length

Nominal in. in. (mm) in. (mm) in. (mm)

1/4 0.246 (6.3) 7/8 (22.2) 36 (915) 3/8 0.371 (9.4) 7/8 (22.2) 48 (1220) 1/2 0.496 (12.6) 7/8 (22.2) 60 (1520) 5/8 0.621 (15.8) 11⁄4 (25.0) 72 (1830) 3/4 0.746 (18.9) 11⁄4 (25.0) 72 (1830) 1 0.996 (25.3) 11/4 (32.0) 72 (1830)

Indicates recommended maximum sheath length; however, longer lengths may be available.

Actual Min. Max.

/8 0.122 (3.1) 7/8 (22.2) 12 (305)

Camber

Camber is defined as the maximum deviation of the heater’s centerline from straight. FIREROD camber within allowable tolerances is verified via passage through a cylindrical gauge of specified length and diameter. Normally, slight camber does not present a problem since the heater will flex enough to fit into a straight, close-fit hole.

Camber Measurement

Camber

Allowable Camber Versus Length

0.200

0.180

0.160

0.140

0.120

0.100

0.080

0.060

0.040

Max. Allowable Camber (in.)

0.020

0.000

Max. camber = 0.020 in. x (length in feet)2 or 0.005 in., whichever is greater.

Heater Length (in.)

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Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Applications and Technical Data (Continued)

Electrical Data

The table below will assist you in selecting the correct FIREROD heater for your application, according to available voltage, amperage and wattage.

Dia.

Please note, some combinations of minimum and maximum wattages are not available on the same heater diameter. If your application exceeds the limitations shown, contact your Watlow representative.

/4 in. (6 mm)

Nominal No-Heat

FIREROD Diameter

in.

/8 240 3.1 — 8 5 360 720 — — —

/4 240

/8 240 6.7 65 35 25 800 1600 — — —

/2 240 9.7 40 25 20 1160 2320 — — —

/8 480 23.0 35 20 15 2760 5520 11,000

/4 480 23.0 30 15 10

Volts Max.

480 23.0 — 15 10

Ampere

①

Max.

4.4

(25 mm)

Number Of Circuits

1 in.

100 55 40 525 1050 — — —

⑥

Diameter

in. 1-phase 3-phase

/4 3 1

1 5 2

Heated Length

Min. Watts @ 120V

③

/4 in. (6 mm)

Nominal No-Heat

Heater Length Max. Watts

/2 in.

(38 mm)

2 in.

(50 mm)

120V

1-phase

2760

a Determined by the current carrying capacity of internal parts and

lead wire. Alternate material may be available.

2 For 1/4 in. (6 mm) units with thermocouple maximum amperage

is 3.1A.

3 Determined by the limitation of space for resistance winding.

For minimum wattage of 240VAC multiply value by four.

4 Higher wattages are available using more than one set of power

12 in. (305 mm)

240V

1-phase

480V

1-phase

240V

3-phase

5 5

5520 11,000 9550 19,100

5520 11,000

9550

leads. Multiply the wattage from the table by the applicable factor.

5 Contact your Watlow representative for data. 6 On 3/4 in. (19 mm) diameter units, either three single-phase circuits

or one three-phase delta or wye circuit is available. On 1 in. (25 mm) diameter units, either five single-phase or two three-phase delta circuits are available.

7 A minimum charge per line item applies.

480V

3-phase

19,100

Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Maximum Allowable Watt Density

The following four charts detail maximum allowable watt densities for applications that use metal, steam, air or gas heating. Please review the charts and applicable data to determine the correct watt density for your application.

Correction Factors

These graphs depict FIRERODs used in steel parts, therefore, for stainless steel, aluminum or brass, refer to applicable correction factors:

1. For stainless steel, enter the graph with a fit

0.0015 in. (0.04 mm) larger than actual fit.

2. For aluminum and brass, enter the graph with a temperature 100°F (38°C) above actual temperature.

0.100

0.090

0.080

0.070

0.060

0.050

0.040

Maximum Allowable Watt Density—Heating Metals

Heating Metals

The Maximum Watt Density— Heating Metals chart will display the maximum hole fit or recommended watt density of the heater. Enter the chart with either known variable, part-fit-in-hole dimension or W/in2. Then, find the application temperature by reading up or over on the chart.

If the fit of the heater in the hole dimension is not known, it can be easily determined. Subtract the minimum diameter of the FIREROD (nominal diameter minus tolerance) from the maximum hole diameter. For example, the hole fit is 0.006 in. (0.15 mm) for a hole diameter of

0.500 in. (13 mm) minus a heater diameter of 0.496 in. (12.6 mm) ±0.002 in. (0.05 mm). For FIREROD heaters in square holes or grooves, contact your Watlow representative for the fit in hole dimension.

Hole

Fit

Cartridge Heater

0.030

0.020

0.010

0.009

Fit in Hole—in.

0.008

0.007

0.006

0.005

0.004

0.003

0.002

0.001 10

200°F (93°C)

400°F (204°C)

1000°F (538°C)

1400°F (760°C)

30 40 50 60 7080100 200 300 400 500 600 800 1000

Watt Density—W/in

1200°F (649°C)

600°F (316°C)

800°F (427°C)

Fit in hole = maximum hole I.D. minus minimum heater O.D.

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Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Maximum Allowable Watt Density (Continued)

Watt Density vs. Ambient Air Temperature

The Watt Density vs. Ambient Air Temperature graph shows the maximum allowable watt density when one FIREROD is operated in air or similar gas.

For FIRERODs grouped in a single row, with no less than one diameter between elements, multiply value from the graph by 0.95. When a reflector is placed behind the heaters, multiply the maximum allowable watt density value from the graph by 0.85.

Sheath Temperature in Ambient Air

The Sheath Temperature in Ambient Air graph indicates the watt density required to bring a pre-oxidized FIREROD to a given sheath temperature when operated in 70°F (21°C) ambient air.

At 44 W/in 1450°F (784°C). At this temperature, a one-year life is expected if cycling is not too frequent.

Higher temperatures result in reduced heater life.

(6.8 W/cm2), the sheath temperature is

1600

1400

1200

1000

800

600

Ambient Temperature—°F

400

200

2000

1500

1000

Maximum Allowable Watt

Density vs. Ambient Air

10 20 30 40 50 60

Watt Density—W/in

FIREROD

Sheath Temperature When

Operated in 70°F Ambient Air

Not Pre-oxidized

Pre-oxidized

Watt Density in Moving Air

The Watt Density in Moving Air graph shows the maximum allowable watt density of a FIREROD in moving air.

The air movement is expressed in feet per minute (FPM). If the air flow is known in cubic feet per minute (CFM), divide the CFM by the net-free area around the heater (ft2). The net-free area is the total area of the enclosure minus the area occupied by the heater.

500

FIREROD Sheath Temperature—°F

10 20 30 40 50 60

Watt Density—W/in

Maximum Allowable

Watt Density in Moving Air

4500

Entering Air Up To 200°F

4000

3500

3000

2500

2000

1500

FIREROD–Parallel To Air Flow

1000

Air Velocity Past Heater—FPM

500

20 40 60 80 100 120

Watt Density—W/in

FIREROD–Perpendicular To Air Flow

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140

Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Lead and Diameter Information

Standard Lead Specifications

Heater

Diameter

in. (mm)

/8 (3) 300 24 0.044 - 0.058 24 solid 0.036 - 0.044

/4 (6) 300 22 0.066 - 0.078 22 0.050 - 0.058

/8 (10) 300 22 0.076 - 0.088 20 0.056 - 0.064

/2 (13) 300 18 0.089 - 0.101 20 0.074 - 0.084

/8 (16) 600 18 0.108 - 0.124 18 0.097 - 0.113

/4 (19) 600 18 0.108 - 0.124 14 0.097 - 0.113

Max.

Voltage

1 (25)1 600 18 0.095 - 0.109 14 0.087 - 0.101 N/A N/A

Lead length tolerances: 1 to 36 in. (25 to 914 mm) = -

/2 in. (13 mm), +11/2 in. (38 mm) > 36 to 72 in. (914 to 1829 mm) = -1, +3 in. (-25 + 76 mm) 1 Stainless steel hose and braid tolerances: same as lead wire. Units constructed with 480V require MGT or PTFE leads. If connecting

heaters in series above 300V, MGT leads are also required.

Standard

Lead Gauge

Fiberglass

Size Tolerance

Fiberglass

Standard

Lead Gauge

PTFE

Size

Tolerance

PTFE

Stainless Steel

Ratings: GGS, 300V, 482°F (250°C)

MGT, 600V, 842°F (450°C) PTFE, 600V, 392°F (200°C) Silicone rubber, 600V, 302°F (150°C)

1 A minimum charge per line item applies.

Hose

I.D.

/32

/16

Stainless Steel

Braid

I.D.

/16

Additional Lead Specifications

Lead Gauge

Nickel Ampacity

N.C.C. Ampacity

26 2.5 4.2 6.0 24 stranded 3.1 5.2 7.5 24 solid 3.1 5.2 7.5 22 4.4 7.2 10.5 20 N/A N/A 14.0 18 7.6 12.6 18.0 16 9.7 16.1 23.0 14 12.5 21.0 30.0 12 16.8 28.0 40.0 10 23.0 38.5 55.0

SPC/NPC

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Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Lead Adapter (LA)

Options

Patented LA Modification Method

The lead adapter (LA) modification process is a powerful tool for providing a wide range of finished heater configurations very quickly. The LA process allows the base FIREROD heater to be modified into a multitude of configurations. The base FIREROD heater can be selected to meet customers’ individual needs. The base heater can then be customized by adding various finishing options like lead length, lead protection, flanges, locating rings and right-angle constructions.

Right Angle

Swaged-in Flexible Leads

No-Heat Extensions

PTFE Seal and Leads

Silicone Rubber Seal and Leads

Flange

Locating Ring

Threaded Fitting

Stainless Steel Braid

Stainless Steel Hose

Right Angle Stainless Steel Hose

Right Angle Stainless Steel Braid

WATLOW

Cartridge/Insertion Heaters

™

FIREROD Cartridge Heaters

Lead Adapter (LA)

Options

Two- or Five-Day Lead Times

Watlow’s FAST TRACK program allows made-to-order FIREROD cartridge heaters to be shipped in two or ﬁve days. You can design a FIREROD to meet your unique applications. You can choose the size, voltage, wattage, termination options and your preferred lead time. To take advantage of this program contact your Watlow representative.

Options

Swaged-in leads

PTFE seal and leads

Right angle leads

Stainless steel hose

Right angle hose

Stainless steel braid

Right angle braid

Straight hose with PTFE seal and leads

Right angle hose with PTFE seal and leads

Straight braid with PTFE seal and leads

Right angle braid with PTFE seal and leads

Right angle PTFE seal and leads

Ground lead

FS ﬂange

FM ﬂange

FL ﬂange

Single stainless steel ﬁtting

Additional lead end no-heat length

Note: Maximum heater length is 24 inches.

/4 Inch

/8 Inch

/2 Inch

/8 Inch

3 3 3 3 3

3 3 3 3 3 3 3 3 3 3 3 3 3 3

3 3 3 3 3 3 3 3 3

3 3 3 3

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

3 3 3 3 3 3 3 3 3 3 3 3

/4 Inch

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Cartridge/Insertion Heaters

FIREROD Cartridge Heaters

Termination Options

LA Swaged-in Flexible Leads

Min. No-Heat

LA swaged-in flexible leads are used in applications where a high degree of flexing exists or the leads must be bent sharply adjacent to the heater without exposing or breaking the conductor. The stranded wire leads are connected internally and exit through the lead end. The overall length of the heater is extended by

/4 in. (6 mm). To order, specify length adder code E

bringing the total lead end no-heat to 1/2 in. (13 mm). This LA option is not available on 1/8 in. (3 mm) diameter

FIRERODs. On 1/8 in. (3 mm) diameter FIRERODs, leads are connected externally using a solid conductor lead wire. If stranded wire is desired on 1/8 in. (3 mm) diameter units, contact your Watlow representative.

in.

(13 mm)

LA PTFE Seal and Leads

Min. No-Heat

The LA PTFE seal and leads protect the heater against moisture/contamination from lubricating oil, cleaning solvents, plastic material or fumes and organic tapes. This seal is effective to 392°F (200°C) under continuous operation.

Please note when ordering this option, that a minimum no-heat section is required to allow for construction. Additional no-heat may be required to keep the seal below effective temperatures. The minimum lead end no-heat required is 1 in. (25 mm). The LA cap adds

/4 in. (19 mm) to the overall length of the heater. To

order, specify option code T.

1 in.

(25 mm)

LA Silicone Rubber Seal and Leads

No-Heat Extensions

Right Angle (Swaged-in) Leads

No-Heat

Length

Swaged-in Leads

No-heat extensions are recommended in applications where leads may be exposed to excessive heat and require a cooler lead end. They are also used when heat is not required along the entire length of the FIREROD.

No-heat extensions are available for most LA options in diameters of 3/8, 1/2, 5/8 and 3/4 in. (10, 13, 16 and 19 mm). These extensions are designed to provide a total no-heat length of 1, 11/2, 2 or 21/2 in. (25, 38, 51 or 65 mm) at the lead end of FIRERODs only. Contact your Watlow representative for available LA options.

Min. No-Heat

1 in.

(25 mm)

The LA silicone rubber seal and leads protect the heater against moisture and contamination from lubricating oil, cleaning solvents, plastic material, fumes and organic tapes. This seal is effective to 302°F (150°C) under continuous operation.

/4 in. (19 mm) to the overall length. To order, specify

option code P.

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Cartridge/Insertion Heaters

Min. No-Heat

1 in.

(25 mm)

Min. No-Heat

1 in.

(25 mm)

Min. No-Heat

1 in.

(25 mm)

FIREROD Cartridge Heaters

Termination Options

(Continued)

LA Straight Stainless Steel Hose LA Straight Stainless Steel Braid

Min. No-Heat

An LA straight stainless steel hose provides the best protection against abrasion from sharp edges. It also offers ease of handling and wiring in abrasive environments. Unless specified a 12 in. (305 mm) hose is supplied. Leads are 2 in. (51 mm) longer than the hose but, longer leads are available.

The minimum lead end no-heat required is 3/4 in. (19 mm). This option adds 1/2 in. (13 mm) to the overall length. To order, specify option code H.

LA Straight Stainless Steel Hose with PTFE Leads and Seal

Min. No-Heat

The LA straight stainless steel braid is designed to protect leads from abrasion against sharp edges. It is the most flexible Watlow protective lead arrangement.

Unless specified, a 12 in. (305 mm) braid is supplied. Leads are 2 in. (51 mm) longer than the braid, but longer leads are available.

The minimum lead end no-heat required is 3/4 in. (19 mm). This option adds 1/2 in. (13 mm) to the overall length. To order, specify option code C.

LA Straight Stainless Steel Braid with PTFE Leads and Seal

Min. No-Heat

An LA straight stainless steel hose with PTFE leads and seal is the ultimate combination for providing abrasion protection and a moisture resistant seal. Unless specified, a standard 12 in. (305 mm) hose is supplied. Leads are 2 in. (51 mm) longer than the hose, but longer leads are available. This seal is effective up to 392°F (200°C) under continuous operation.

The minimum lead end no-heat required is 1 in. (25 mm). This option adds 3/4 in. (19 mm) to the overall length. To order, specify option code G.

The LA straight stainless steel braid with PTFE leads and seal is Watlow’s most flexible lead protection with a moisture resistant seal. Unless specified, a 12 in. (305 mm) braid is supplied. Leads are 2 in. (51 mm) longer than the braid, but longer leads are available. This seal is effective up to 392°F (200°C) under continuous operation.

The minimum lead end no-heat required is 1 in. (25 mm). This option adds 3/4 in. (19 mm) to the overall length. To order, specify option code F.

WATLOW

Cartridge/Insertion Heaters

Min. No-Heat

FIREROD Cartridge Heaters

Right Angle Options

LA Right Angle Leads

Min. No-Heat

LA right angle leads are used in applications with a high degree of flexing and when space limitations are critical. Stranded lead wires are connected internally (swaged-in) and exit at a 90 degree angle at the end of the heater.

To order, specify option code R.

Dia. In. (mm)

Minimum No-Heat Required

/16 (21) 3/4 (19) 13/16 (21) 13/16 (21) 13/16 (21)

in. (mm)

To order right angle leads with PTFE leads and seals, specify option code B.

LA Right Angle Stainless Steel Hose

LA Right Angle Stainless Steel Hose with PTFE Leads and Seal

Min. No-Heat

An LA right angle stainless steel hose with PTFE leads and a seal is the ultimate combination for providing abrasion protection and a moisture resistant seal with wiring convenience. Unless specified, a 12 in. (305 mm) hose is supplied. Leads are 2 in. (51 mm) longer than the hose but longer leads are available. This seal is effective to 392°F (200°C) under continuous operation.

The minimum lead end no-heat required is 11/2 in. (38 mm). This option adds 11/4 in. (32 mm) to overall length on stock units.

To order, specify option code M. Note: This option is not available on 1/4 in. (6 mm)

diameter.

1½ in.

(38 mm)

Min. No-Heat

1 in.

(25 mm)

An LA right angle stainless steel hose is provided for wiring convenience. Like the LA straight stainless steel hose, it protects leads from abrasion against sharp edges. Unless specified, a 12 in. (305 mm) hose is supplied. Leads are 2 in. (51 mm) longer than the hose, but longer leads are available.

Adder length in. (mm)3/4 (19)3/4 (19)3/4 (19)7/8 (22)

Min. no-heat in. (mm) 1 (25) 1 (25) 1 (25) 11/8 (29)

Diameter

To order specify option code W. Note: This option is not available on 1/4 in. (6 mm)

diameter.

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Watlow FIREROD Specifications

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