Watlow flange heaters are easy to install and maintain.
Designed for heating liquids and gases in tanks and
pressure vessels, flange immersion heaters are ideal for
applications requiring higher kilowatts.
Watlow flange heaters are made with WATROD or
FIREBAR tubular elements brazed or welded to a flange.
Stock flange heaters are equipped with a general purpose
terminal enclosure.
Flange heaters, with FIREBAR elements, also answer
the need for liquid immersion applications requiring high
kilowatts in small tanks. The FIREBAR element’s unique
flat surface geometry packs more power in a smaller
bundle, with lower watt density, making it especially
well-suited for petroleum-based liquid heating applications.
Performance Capabilities
• Watt densities up to 100 W/in2 (15.5 W/cm2)
• Wattages up to three megawatts
• UL® and CSA component recognition up to 600VAC
• Alloy 800/840 sheath temperatures up to 1600°F
(870°C)
• Passivated 316 stainless steel sheath temperatures up
to 1200°F (650°C)
• 304 stainless steel sheath temperatures up to
1200°F (650°C)
• Steel sheath temperatures up to 750°F (400°C)
• FIREBAR flange heaters deliver more kilowatts in
smaller bundles
• A conventional round tubular 10-inch ANSI flange can
be replaced by a 6-inch ANSI FIREBAR flange with
same immersed length
Flange
Conduit Opening
Terminal Enclosure
Thermowell
FIREBAR
Heating Element
Features and Benefits
ANSI and ANSI compatible 2, 21/2, 3 thru 48 inch
flanges
• Provides appropriate heater size-to-application and fit
Element sheath and flange materials
• Meets your application needs
Integral thermowells
• Provides convenient temperature sensor insertion and
replacement without draining the fluid being heated
Standard, general purpose terminal enclosure
• Offers easy access to wiring
WATLOW
®
WATROD Heating Element
Element support(s)
• Provides proper element spacing to maximize heater
performance and life
All units are inspected and/or tested
• Ensures element-to-flange pressure seals do not leak
Drilled and tapped eyebolt holes or lift lugs for eye
bolts on 10 inch and larger flange heaters
• Facilitates lifting during installation
WATROD hairpins are repressed (recompacted)
• Provides improved heater life, insulation resistance and
heat transfer
237
Immersion Heaters
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Features and Benefits (Continued)
FIREBAR flange heaters pack more kilowatts into a
smaller bundle
• Includes a conventional round tubular 10 in. (254 mm)
ANSI flange which can be replaced by a 6 in.
(152 mm) ANSI FIREBAR flange with the same
immersed length
Branch circuits are designed for 48 amperes per
circuit maximum
• Reduces risk of failure due to excessive temperatures
generated by high amperage
UL® and CSA component recognition under file
numbers E52951 and 31388 respectively
• Simplifies obtaining third-party recognition for
assembly
Typical Applications
• Water:
Deionized
Demineralized
Clean
Potable
Process
• Industrial water rinse tanks
• Vapor degreasers
• Hydraulic oil, crude, asphalt
• Lubricating oils at API specified watt densities
• Air and gas flow
• Caustic solutions
• Chemical baths
• Process air equipment
• Boiler equipment
• Freeze protection of any fluid
• Anti-freeze (glycol) solutions
• Paraffin
Options
Terminal Enclosures
General purpose terminal enclosures, without
thermostats, are standard on all flange immersion
heaters. Optional terminal enclosures include:
• General purpose with a single or double pole
thermostat.
• Moisture resistant. Available with or without a single
or double pole thermostat.
• Corrosion resistant. Available with or without a single
or double pole thermostat.
• Explosion resistant Class 1, Div. 1 and 2, Groups B, C,
D, T1 - T6. Available with or without a single or double
pole thermostat.
• Explosion/moisture resistant combinations. Available
with or without a single or double pole
thermostat.
Prior to ordering, refer to the terminal enclosure
dimensions on page 243. Order by adding the
appropriate suffix letter(s) to the base flange heater
part number, as shown on the Ordering information chart.
Heater part numbers and suffix letters are depicted on
the charts, pages 244 to 305. Specify class and group,
if applicable.
Caution
Explosion-resistant terminal enclosures are intended
to provide explosion containment in the electrical
termination/wiring enclosure only. No portion of the
assembly outside of this enclosure is covered under
this rating. Rating effectiveness may be compromised
by abuse or misapplication.
238
WATLOW
®
Immersion Heaters
Stand-offTerminalEnclosure
ConduitOpenings
Ref. 6in. (152 mm)Stand-offHeight
ANSI Flange
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Options (Continued)
Stand-off Terminal Enclosures
Ref. 6 in.
Conduit
Openings
Stand-off
Terminal
Enclosure
(150 mm)
Stand-off
Height
Stand-off terminal enclosures provide an air-insulating
barrier between the flange and terminal enclosure by
mounting the terminations and wiring away from the
flange. Stand-off terminal enclosures are recommended
whenever a process operating temperature exceeds
210°F (100°C). This helps minimize terminal enclosure
temperatures.
To order, specify stand-off terminal enclosure.
ANSI
Flange
Certified Enclosures
CSA, ATEX or IECEx certified enclosures protect wiring in
hazardous gas environments. These terminal enclosures,
covered under CSA file number 61707, ATEX certificate
# SIRA 10ATEX1155X or IECEx certificate # IECEx CSA
09.0010X are available on WATROD flange heaters. For
additional information, see page 567 and 568 or contact
your Watlow representative.
For products that will be installed in hazardous locations,
please provide the following information:
• Operating conditions
• Minimum and maximum ambient temperatures for the
installation location
• Mounting orientation
Watlow must understand this information so that an
appropriate design can be provided.
ASME Pressure Vessel Code Welding
Flange assemblies can be provided with an ASME
Section VIII, Div. I pressure vessel stamp upon request.
WATLOW
®
Thermostats
To provide process temperature control, Watlow offers
optional single pole, single throw (SPST) and double pole,
single throw (DPST) thermostats.
Unless otherwise specified, thermostats are mounted
inside the terminal enclosure. For details and ordering
information, refer to Thermostats on pages 534 to 537.
Please verify that the thermostat’s sensing bulb O.D. is
compatible with the flange heater’s thermowell I.D.
Thermocouples
ASTM Type J or K thermocouples offer more accurate
sensing of process and/or sheath temperatures. A
thermocouple may be inserted into the thermowell or
attached to the heater’s sheath.
Thermocouples are supplied with 120 in. (3050 mm)
leads (longer lead lengths available). Unless otherwise
specified, thermocouples are supplied with temperature
ranges detailed on the Thermocouple Types chart.
Using a thermocouple requires an appropriate
temperature and power controller. These must be
purchased separately. Watlow offers a wide variety of
temperature and power controllers to meet virtually all
applications. Temperature controllers can be configured
to accept process variable inputs, too. Contact your
Watlow representative for details.
To order, specify Type J or K thermocouple and lead
length. Indicate if the thermocouple is for process
temperature sensing or heater sheath high-limit
protection. Please specify if the flange heater will be mounted vertical or horizontal in the tank. If vertical,
specify if the housing is on top or bottom.
If the flange heater is part of an in-line circulation heating
application, indicate flow direction relative to the heater’s
enclosure.
Thermocouple Types
Recommended
ASTM Conductor Characteristics Temperature Range
Type Positive Negative °F (°C)
J Iron Constantan 0 to 1000 (-20 to 540)
(Magnetic) (Non-magnetic)
K Chromel
(Non-magnetic) (Magnetic)
① Type J and Type K thermocouples are rated 32 to 1382°F and
32 to 2282°F (0-750°C and 0-1250°C), respectively. Watlow does
not recommend exceeding temperature ranges shown on this chart
for the tubular product line.
®
Alumel® 0 to 2000 (-20 to 1100)
①
239
Immersion Heaters
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Options (Continued)
Wattages and Voltages
Watlow routinely supplies flange immersion heaters with
240 to 480VAC as well as wattages from 150 watts to
one megawatt.
Sheath Materials
The following sheath materials are available on WATROD
and FIREBAR flange heaters:
Standard Sheath Materials
WATROD Alloy 800, 840
316 SS
Steel
FIREBAR Alloy 800
Exotic Sheath Materials
Contact your Watlow representative for details and
availability.
External Finishing
Passivation
During the manufacturing process, particles of iron or
tool steel may become embedded in the stainless steel
or alloy sheath. If not removed, these particles may
corrode, produce rust spots and/or contaminate the
process. For critical sheath applications, passivation
will remove free iron from the sheath. To order,
specify passivation.
Other Finishes
Bright annealing available to meet cosmetic demands.
Flanges
Flange Sizes and Styles
Standard: 2①, 21/2①, 3 to 48 inch ANSI raised face/blind
flanges.
Made-to-Order: 16, 18, 20 and 24 inch in any
recognized configuration, as well as customer specified.
Over 48 inch ANSI flange, contact your Watlow
representative.
Flange Materials
Standard Carbon steel
316 SS
304 SS
Pressure Classes
Standard 150 lb
300 lb
600 lb
① ANSI bolt pattern only
Gaskets
Rubber, asbestos-free and spiral wound gaskets are
available for all flange sizes. Order by specifying gasket
type, flange size/rating, process operating temperature
and pressure.
To make the correct selection, see the Gasket Selection
chart. It provides a recommended gasket type and
effective temperature rating.
To use this chart, multiply operating temperature by the
operating pressure to arrive at “Maximum PSIG x °F.”
This is listed in the chart’s first column.
Gasket Selection
Maximum Temperature
PSIG x °F °F Gasket Type
Up to 15,000 300 Rubber
Over 250,000 700 Asbestos-Free
Over 250,000 ③Spiral Wound
Gasket
240
③ Depends on metal gasket material.
WATLOW
®
Immersion Heaters
Direction of Flow
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Options (Continued)
Baffles
Direction of Flow
For forced circulation applications, 316 stainless steel
baffles can be arranged on the heating element bundle
to enhance and/or modify fluid or gas flow for better
heat transfer.
For open tank or convection heating applications,
standard element supports will be supplied.
To order, specify baffles.
ANSI Raised Face Blind Flange,
150# Class Dimensions
• Select the recommended heating element sheath
material and watt density for the substance being
heated. Use the Supplemental Applications Chart on
pages 555 to 560. If unable to determine the correct
heating element sheath material and type, contact your
Watlow representative.
• Extend the element no-heat section completely into
the fluid being heated to help prevent premature heater
failure. See accompanying illustration for proper
no-heat section placement.
• Locate flange heater low in the tank, but above the
sludge level.
• Choose a FIREBAR element when your application
requires a smaller system package or lower watt
density.
• Ensure wiring integrity by keeping terminal enclosure
temperature below 400°F (205°C).
• Size power feeder wires in accordance with National
Electrical Code guidelines and other applicable codes.
• Keep electrical connections clean, dry and tight.
• Minimize problems associated with low liquid level
conditions by using low liquid level sensor or sheath
temperature high-limit control.
No-Heat
Section
WATLOW
• Periodically remove the flange assembly to inspect
and clean the heating element(s). This preventive
maintenance will reduce premature failure and optimize
heater performance.
• Refer to the Installation and Maintenance Instructions
for correct orientation of FIREBAR elements. This is
important in air applications with customer-supplied
circulation tanks. Correct element orientation to flow
minimizes pressure drop and increases buoyancy force
and heater performance.
®
241
Immersion Heaters
Extended Capabilities For
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Options
Enclosure Enhancements
• Enclosure heater to solve condensation and freeze
problems.
• Power distribution blocks to facilitate power feed line
wiring.
RTDs
If the process requires greater temperature sensing
accuracy than is possible with thermocouples, Watlow
can also supply RTDs in DIN or JIS calibrations. Contact
your Watlow representative for details.
Wattages and Voltages
If required, Watlow will make heaters with voltage up
to 600VAC and wattage beyond one megawatt. For
more information on special voltage and wattage
configurations, contact your Watlow representative.
xtEndEd
E
apability
C
Flanges
Flange Materials
Extended Exotic materials to
meet specific
application needs ①
Pressure Classes
Extended Over 600 lb ①
① Contact your Watlow representative
Sheath Materials
The following sheath materials are available on WATROD
and FIREBAR flange heaters:
Extended Sheath Materials
WATROD Titanium
304 and 321 SS
Hastelloy C276
Alloy 400 and 600
FIREBAR 304 SS
242
WATLOW
®
Immersion Heaters
'K'
4" = 7 7/8
5" = 8 7/8
6" = 9 7/8
8" = 12 1/8
10" = 14 5/8
12" = 17 1/4
14" = 19 3/8
75⁄8 in.
(193.7 mm)
5
¾ in.
(146 mm)
7
½ in. Ref.
(191 mm)
“F”
3 in. - 150# ANSI Flange
“D”
3" AND 4" FLANGE
'K'
5" = 8 7/8
6" = 9 7/8
8" = 12 1/8
10" = 14 5/8
12" = 17 1/4
14" = 19 3/8
7½ in. Ref.
(191 mm)
“F”
5
¾ in. Ref.
(146 mm)
7
5⁄8
in.
(193.7 mm)
“D”
95⁄16 in.
(237 mm)
“F”
“D”
“K”
4 in. - 150# ANSI Flange
WATROD and FIREBAR ANSI Flange
Immersion Heaters
Optional Moisture/Explosion Resistant
Enclosure Without Thermostat
Optional Moisture/Explosion Resistant
Enclosure With Thermostat
75⁄8 in.
(193.7 mm)
3 in. - 150# ANSI Flange
“D”
5⁄8
7
in.
(193.7 mm)
¾ in.
5
(146 mm)
7
½ in. Ref.
(191 mm)
“F”
4 to 14 in. - 150# ANSI Flange
“D”
“K”
77⁄8 in.
(200 mm)
“F”
“K”
Terminal Enclosure Dimensions
General Purpose & Moisture Resistant Enclosures
ANSI Flange
Size
in.
3
4
“F”
Thickness
in. (mm)
15
/16 (23.8)53/4
15
/16 (23.8)53/4
“K”
With
Thermostat
(146)
(146)
“K”
Without
Thermostat
See heater dwg.
See heater dwg.
“D”
in. (mm)
71/2
(191)
9 (229)
Note: 5 thru 12 in. (127 thru 305 mm) flange dimensions are on catalog
heater drawings.
Moisture/Explosion Resistant Enclosures
ANSI Flange
Size
in.
3
4
5
6
8
10
12
14
Optional General
Purpose/Moisture
Resistant Enclosure
“F”
Thickness
in. (mm)
15
/16 (23.8)N/AN/A 71/2 (191)
15
/16 (23.8)N/A
15
/16 (23.8)
1 (25.0)
11/8 (28.6)
13/16 (30.2)
11/4 (32.0)
13/8 (34.9)
“K”
With
Thermostat
“K”
Without
Thermostat
77/8(200.0)
87/8 (225.4)
97/8 (250.8)
87/8 (225.4)
97/8 (250.8)
121/8 (308.0) 121/8 (308.0)
145/8 (371.5) 145/8
(371.5)
171/4 (438.0) 171/4 (438.0)
193/8 (492.1) 193/8 (492.1)
in. (mm)
9 (229)
10 (254)
11 (280)
131/2
16 (407)
19 (483)
21 (534)
Optional Moisture
Resistant Enclosure
With Thermostat
“D”
(343)
With Thermostat
“K”
“K”
¾
in. Ref.
5
(146 mm)
7½ in. Ref.
(191 mm)
7⁄8 in.
7
(200 mm)
“F”
“D”
3 and 4 in. - 150# ANSI Flange
“D”
5 to 14 in. - 150# ANSI Flange
To order: Reference the Ordering Information on page 306
WATLOW
®
9
5⁄16 in.
“F”
(237 mm)
3 in. - 150# ANSI Flange
Note: Dimensions for all 5 to 14 in. flange heaters with General Purpose
or Moisture Resistant Enclosure with thermostats are identical to units
supplied without thermostats.
“D”
“F”
4 in. - 150# ANSI Flange
“D”
95⁄16 in.
(237 mm)
“F”
243
Immersion Heaters
2¾ in. O.D.
(70 mm)
¾ in. NPT Knockout
Thermowell
0.475 in. (12.1 mm)Dia. Element
4 in. (102 mm) Cold (Ref.)
45⁄8 in.
(117.5 mm)
35⁄8 in. Dia.
(92.1 mm)
“B”
®
WATROD and FIREBAR ANSI Flange
Immersion Heaters
®
Application: Clean Water
• 3 inch - 150 lb ANSI flange.
• WATROD elements
• Without thermostat
• General purpose or
moisture-resistant enclosures
• Single circuit
DescriptionVolts kWPh
• M - Manufacturing lead times
2
60 W/in
Steel Flange
3-Alloy 800
Elements
(9.3 W/cm2)