IMMERSION HEATERS
HAZARDOUS AREA SCREW PLUG
INDEX
Hazardous Area Screw Plug Heaters
pag. 06
Heater Selection
pag. 07
Screwed selection table FLT / FLT-D range
8 w/ins2 - 1.25 w/cm2
pag. 08
Screwed selection table FLT / FLT-D range
10.5 w/ins2 - 1.65 w/cm2
pag. 09
Screwed selection table FLT / FLT-D range
12.5 w/ins2 - 1.95 w/cm2
pag. 10
Screwed selection table FLT / FLT-D range
20.5 w/ins2 - 3.2 w/cm2
pag. 11 - 12
Screwed selection tables FLT / FLT-D range
60 w/ins2 - 9.3 w/cm2
pag. 13 - 14
Information
pag. 16
The following information
pag. 17
Immersion electric heaters: data sheet
pag. 19
Hazardous Area Flanged Heaters
pag. 20
Hazardous Selection
pag. 21
Construction
pag. 22
00 - 03 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
Hazardous Area Screw Plug Heaters
Heater Selection
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 finest 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.
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 flanged catalogue.
• Over the side/vat heaters for installing over the side of an open tank. See catalogue.
COMPANY CERTIFICATIONS
FM 11235
9191.IRCR
PRODUCT TRADEMARKS
IT-75.12-6975 IT-75.12-6975
12/054P_IND 12/055P_IND
EN 15085-2
ISO 3834-3
Compliance with the
mark of each specific
product must be
properly reviewed with
our Sales Department.
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 specifications liable to modification. Tables of types and dimensions
of heaters listed in this catalogue are, therefore, subject to change without prior notification. In any case, our technical office 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 specific 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 can’t find what you want in our stock heaters or in our standard design, then we will custom build the heater to your exact
requirements.
Definition of Terms
Assembly Stock:
Standard Design:
Custom Built:
Components are held in stock and require assembly time before being available for packing/dispatch.
Manufactured from in house standard designs, these require time for the generation of manufacturing instructions
and quality control procedures before packing/dispatch.
These require design, engineering, manufacturing, quality control and approval prior to packing/dispatch.
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/ins2 (9.3 w/cm2)
• Sea water - Titanium at 25 w/ins2 (3.87 w/cm2)
• Ethylene glycol solution - Incoloy 800 at 15÷20 w/ins2 ( 2.33 ÷3.1 w/cm2)
• Mild steel/stainless steel at 15 and 20 w/ins2 (2.32 and 3.1 w/cm2)
• Medium oils - mild steel at 12 w/ins2 (1.86 w/cm2)
• Heavy oils - mild steel at 8 w/ins2 (1.24 w/cm2)
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 fluid, 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/flange materials, enclosures, head/flange 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 first heater type choice on base to different applications.
Application
Water & Very
Mild Solution
Corrosive & High
Viscous Solutions
Oil heating
Specialty
Heaters
00 - 04 - 0116
Different solutions
Concentration
Materials
Specific Power
Plug Material
Solution or
Heater Type
Alkaline or
Acid Content
(% by volume)
Sheath
Material
Watt Density
(W/in2)
(W/cm2)
Screw Plug
Material
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
45
7
Stainless Steel
23
3.5
Stainless Steel
15
2.3
Stainless Steel
23
15
3.5
2.3
Steel
45
23
12
60
7
3.5
1.86
9.3
Demineralized,
Deionize Water
Mild corrosive
Solutions
Severe corrosive
Solution
Low Viscosity Oil
Medium Viscosity Oil
Process Water
Demineralized Water
Low Viscosity Oil
Pipe Insert
5-15%
>16%
pH5 to pH9
Clean Water
Incoloy
Stainless Steel
Incoloy
Stainless Steel
Incoloy
Stainless Steel
Mild Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Incoloy
Copper
Brass
Stainless Steel
Steel
Steel
Brass
00 - 05 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
Construction
Certified Explosion-Proof-Exd’
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/ins2 or w/cm2) 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/ins2 (1.24, 1.86, 2.32, 3.10, 3.87
and 9.30 w/cm2). Heaters with special watts densities can be made to meet customer’s individual requirement. Consult Zoppas Industries
Heating Element Technologies Sales Department for suggested watts ratings and sheath materials for a wide range of applications.
For hazardous areas, explosion-proof screwed immersion heaters are supplied, tested by the Notified Body CESI by European Standard
EN 60079-0 and 60079-1.
Certification 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 212°F (100°C), 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).
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 flameproof heaters, but special mild steel, stainless steel or titanium bosses can be fitted.
Supply Safety Thermostat
TABLE 1 (Screwed head sizes for immersion heaters)
ISO
Type
Part No.
Range
Note
Safety
570968671
+52°C ±3°C
Manual reset
Safety
570943160
+85°C ±3°C
Manual reset
Safety
571092931
+90°C ±4°C
Manual reset
Safety
571093491
+123°C ±4°C
Manual reset
Head Diameter
BSP
NPT
1½
•
•
Safety
571223670
+150°C ±4°C
Manual reset
1¼
•
•
Safety
570857302
+0°C ÷200°C
Manual reset
2
•
•
Safety
570895640
+20°C ±3°C
Manual reset
2¼
•
•
2½
•
•
Optional Regulation Thermostat
45
•
77
•
Terminal Enclosure
To protect the element/cable connection, a terminal enclosure is fitted to the heater. The type standard is waterproof to IP 65 and
certified 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.
Type
Part No.
Range
Note
Regulation
571064270
-30°C÷+30°C
SPDT
Regulation
570142140
+4°C÷+40°C
SPDT
Regulation
570977491
+30°C÷+90°C
SPDT
Regulation
571275710
+30°C÷+120°C
SPDT
Regulation
571086111
+50°C÷+250°C
SPDT
Regulation
571086111
+50°C÷+320°C
SPDT
Regulation
570898460
+20°C÷+500°C
SPDT
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 certificates are not supplied as standard
but are available on request.
00 - 06 - 0116
00 - 07 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
8 w/ins2 - 1.25 w/cm2
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
10.5 w/ins2 - 1.65 w/cm2
Applications
L
Standard features
•
•
•
•
•
•
•
FLT TYPE
L
FLT TYPE
165
6
X
12
L
FLT-D TYPE
FLT-D TYPE
mm.
Ins.
mm.
Ins.
mm.
Ins.
FLT TYPE
X=0
Class ATEX
Fluid T°C
50÷300
T3
201÷350
Class ATEX
Safety T°C.
50÷250
T2
Fluid T°C
Termostat
T°C regulation
101÷200
Class ATEX
T4
Class ATEX
T2
Safety T°C.
Safety T°C.
20÷500
0÷200
Termostat
T°C regulation
20÷500
Termostat
T°C regulation
Fluid T°C
201÷350
0÷120
Class ATEX
T3
FLT-D 300 TYPE
X=300
Fluid T°C
Safety T°C.
50÷300
FLT-D 150 TYPE
X=150
Dia.
Elements
≤100
Termostat
T°C regulation
50÷250
FLT TYPE
X=0
No. Elem.
Fluid T°C
101÷200
Ins.
Maximum
Immersed
Length
Phase
Class ATEX
T4
mm.
Voltage
Safety T°C.
0÷200
kW
Termostat
T°C regulation
Explosion-proof Ex’d’
0÷120
Fluid T°C
Dia.
Elements
≤100
Maximum
Immersed
Length
No. Elem.
Phase
Voltage
kW
Explosion-proof Ex’d’
Safety T°C.
12
rugged industrial construction
stainless steel elements
1 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
20÷500
X
L
Termostat
T°C regulation
6
Ø108
165
12
Ø108
rugged industrial construction
stainless steel elements
2 ¼” brass screwed plug
1 explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout Thermostat for regulation
Thermowell optional
165
• Medium viscosity oils, non-flowing heat transfer oil etc.
Ø108
Standard features
•
•
•
•
•
•
•
12
20÷500
165
• Heavy duty oils, raw crude oils, naphta, aniline etc.
Ø108
Applications
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
0.75
230
1
995
39¼
1
10
0.4
1REBACF28001
1REBACF29001
1REBACR57001
0.5
230
1
650
26¼
1
8.5
0.33
1REBACF34001
1REBABF35001
1REBACR60001
0.75
230
1
515
20¼
1B
10
0.4
1REBACF30001
1REBACF31001
1REBACR58001
0.5
230
1
340
13½
1B
8.5
0.33
1REBACF36001
1REBACF37001
1REBACR61001
1.0
230
1
1295
51
1
10
0.4
1REBACF28002
1REBACF29002
1REBACR57002
1.0
230
1
1205
47½
1
8.5
0.33
1REBACF34002
1REBACF35002
1REBACR60002
1.0
230
1
665
26¼
1B
10
0.4
1REBACF30002
1REBACF31002
1REBACR58002
1.0
230
1
620
24½
1B
8.5
0.33
1REBACF36002
1REBACF37002
1REBACR61002
1.5
230
1
1905
75
1
10
0.4
1REBACF28003
1REBACF29003
1REBACR57003
1.5
230
1
970
38¼
1B
10
0.4
1REBACF30003
1REBACF31003
1REBACR58003
2.0
230
1
2525
99½
1
10
0.4
1REBACF28004
1REBACF29004
1REBACR57004
2.0
230
1
1280
50½
1B
10
0.4
1REBACF30004
1REBACF31004
1REBACR58004
2.25
400
3
995
39¼
3
10
0.4
1REBACF32001
1REBACF33001
1REBACR59001
3.0
400
3
1295
51
3
10
0.4
1REBACF32002
1REBACF33002
1REBACR59002
4.5
400
3
1905
75
3
10
0.4
1REBACF32003
1REBACF33003
1REBACR59003
6.0
400
3
2525
99½
3
10
0.4
1REBACF32004
1REBACF33004
1REBACR59004
00 - 08 - 0116
*1B= 1 Element U bent
00 - 09 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
12.5 w/ins2 - 1.95 w/cm2
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
20.5 w/ins2 - 3.2 w/cm2
165
Applications
L
rugged industrial construction
stainless steel elements
2 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
165
• Heat transfert oil, Alkaline solution, Vapour degasing.
Standard features
•
•
•
•
•
•
•
FLT TYPE
6
X
12
L
Ø108
165
12
L
rugged industrial construction
stainless steel elements
2 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
FLT TYPE
165
6
X
12
L
Ø108
Standard features
•
•
•
•
•
•
•
12
Ø108
• Medium viscosity oils, non-flowing heat transfer oil etc.
Ø108
Applications
FLT-D TYPE
FLT-D TYPE
Safety T°C.
20÷500
Class ATEX
Termostat
T°C regulation
20÷500
1
680
26¾
1
10
0.4
1REBACF28007
1REBACF29007
1REBACR57007
230
1
370
14½
1B
10
0.4
1REBACF30007
1REBACF31007
1REBACR58006
1.0
230
1
880
34¾
1
10
0.4
1REBACF28008
1REBACF29008
1REBACR57008
0.75
230
1.0
230
1
460
18¼
1B
10
0.4
1REBACF30008
1REBACF31008
1REBACR58007
1.0
230
1.5
230
1
1295
51
1
10
0.4
1REBACF28009
1REBACF29009
1REBACR57009
1.5
1.5
230
1
665
26¼
1B
10
0.4
1REBACF30009
1REBACF31009
1REBACR58008
1.5
1.5
400
3
485
19¼
3
10
0.4
1REBACF32005
1REBACF33005
1REBACR59005
2.0
230
1
1670
65¾
1
10
0.4
1REBACF28010
1REBACF29010
1REBACR57010
2.0
230
1
855
33¾
1B
10
0.4
1REBACF30010
1REBACF31010
Fluid T°C
Class ATEX
230
0.75
T2
0.75
Safety T°C.
1REBACR58005
20÷500
1REBACR57006
1REBACF31006
Termostat
T°C regulation
1REBACF29006
1REBACF30006
20÷500
1REBACF28006
0.4
Fluid T°C
0.4
10
201÷350
10
1B
Class ATEX
1
13¾
T3
24½
350
Safety T°C.
620
1
50÷300
1
230
50÷250
230
0.67
Fluid T°C
0.67
Termostat
T°C regulation
1REBACR57005
101÷200
1REBACF29005
39¼
Class ATEX
1REBACF28005
485
T4
0.4
1
Safety T°C.
10
230
0÷200
1
0.5
Termostat
T°C regulation
Ins.
Dia.
Elements
0÷120
FLT-D 300 TYPE
X=300
≤100
FLT-D 150 TYPE
X=150
Phase
mm.
FLT TYPE
X=0
Maximum
Immersed
Length
No. Elem.
T2
Fluid T°C
201÷350
Class ATEX
Safety T°C.
50÷300
T3
Termostat
T°C regulation
50÷250
Fluid T°C
101÷200
Class ATEX
Safety T°C.
0÷200
T4
Termostat
T°C regulation
0÷120
Fluid T°C
≤100
Explosion-proof Ex’d’
Voltage
Ins.
Dia.
Elements
kW
mm.
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Ex’d’
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
FLT-D 300 TYPE
X=300
1
10
0.4
1REBACF28013
1REBACF29013
1REBACR57012
1
10
0.4
1REBACF28014
1REBACF29014
1REBACR57013
32
1
10
0.4
1REBACF28015
1REBACF29015
1REBACR57014
16¾
1B
10
0.4
1REBACF30015
1REBACF31015
1REBACR58011
12¾
3
10
0.4
1REBACF32011
1REBACF33011
1REBACR59011
12¾
1
10
0.4
1REBACF28016
1REBACF29016
1REBACR57015
545
33¾
1B
10
0.4
1REBACF30016
1REBACF31016
1REBACR58012
mm.
Ins.
1
440
17½
1
565
22¼
230
1
810
230
1
425
1.5
400
3
340
2.0
230
1
1065
1REBACR58009
2.0
230
1
2.0
400
3
620
24¼
3
10
0.4
1REBACF32006
1REBACF33006
1REBACR59006
2.25
400
3
440
17½
3
10
0.4
1REBACF32012
1REBACF33012
1REBACR59012
2.25
400
3
680
26¾
3
10
0.4
1REBACF32007
1REBACF33007
1REBACR59007
3.0
230
1
1540
60¾
1
10
0.4
1REBACF28017
1REBACF29017
1REBACR57016
3.0
230
1
2525
99½
1
10
0.4
1REBACF28011
1REBACF29011
1REBACR57011
3.0
230
1
790
31¼
1B
10
0.4
1REBACF30017
1REBACF31017
1REBACR58013
3.0
230
1
1280
50½
1B
10
0.4
1REBACF30011
1REBACF31011
1REBACR58010
3.0
400
3
565
22¼
3
10
0.4
1REBACF32013
1REBACF33013
1REBACR59013
3.0
400
3
880
34¾
3
10
0.4
1REBACF32008
1REBACF33008
1REBACR59008
4.0
400
1
2025
79¾
1
10
0.4
1REBACF28018
1REBACF29018
1REBACR57017
6.0
400
3
1670
65¾
3
10
0.4
1REBACF32009
1REBACF33009
1REBACR59009
4.0
400
1
1030
40½
1B
10
0.4
1REBACF30018
1REBACF31018
1REBACR58014
9.0
400
3
2525
99½
3
10
0.4
1REBACF32010
1REBACF33010
1REBACR59010
4.5
400
3
810
32
3
10
0.4
1REBACF32014
1REBACF33014
1REBACR59014
*1B= 1 Element U bent
00 - 010 - 0116
*1B= 1 Element U bent
00 - 011 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
SCREWED SELECTION TABLE
FLT / FLT-D RANGE
20.5 w/ins2 - 3.2 w/cm2
SCREWED SELECTION TABLES
FLT / FLT-D RANGE
60 w/ins2 - 9.3 w/cm2
Applications
Applications
Standard features
Standard features
•
•
•
•
•
•
L
Ø108
rugged industrial construction
stainless steel elements
2 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
rugged industrial construction
Incoloy 800 elements
1 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermowell Thermostat manual reset cutout
FLT TYPE
165
6
X
12
L
FLT-D TYPE
mm.
Ins.
mm.
Ins.
Safety T°C.
Class ATEX
50÷300
T3
Termostat
T°C regulation
Fluid T°C
101÷200
50÷250
Class ATEX
T4
Class ATEX
T2
Safety T°C.
Safety T°C.
20÷500
0÷200
Termostat
T°C regulation
20÷500
Termostat
T°C regulation
Fluid T°C
201÷350
0÷120
Class ATEX
T3
FLT-D 300 TYPE
X=300
Fluid T°C
Safety T°C.
50÷300
FLT-D 150 TYPE
X=150
Dia.
Elements
≤100
Termostat
T°C regulation
50÷250
FLT TYPE
X=0
No. Elem.
Fluid T°C
101÷200
Ins.
Maximum
Immersed
Length
Phase
Class ATEX
T4
mm.
Voltage
Safety T°C.
0÷200
kW
Termostat
T°C regulation
Explosion-proof Ex’d’
0÷120
Fluid T°C
Dia.
Elements
≤100
Maximum
Immersed
Length
No. Elem.
Phase
Voltage
Explosion-proof Ex’d’
kW
•
•
•
•
•
•
•
12
165
• Industrial water heating
Ø108
• Heat transfert oil, Alkaline solution, Vapour degasing
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
5
400
1
2525
99½
1
10
0.4
1REBACF28019
1REBACF29019
1REBACR57018
1.0
230
1
340
13¼
1
8.5
0.335
1REBACF38001
1REBACF39001
5
400
1
1280
50½
1B
10
0.4
1REBACF30019
1REBACF31019
1REBACR58015
1.5
230
1
350
13 ¾
1
8.5
0.335
1REBACF38002
1REBACF39002
6
400
3
1055
41½
3
10
0.4
1REBACF32015
1REBACF33015
1REBACR59015
2.0
230
1
450
17 ¾
1
8.5
0.335
1REBACF38003
1REBACF39003
9
400
3
1540
60¾
3
10
0.4
1REBACF32016
1REBACF33016
1REBACR59016
3.0
230
1
650
25 ½
1
8.5
0.335
1REBACF38004
1REBACF39004
12
400
3
2025
79¾
3
10
0.4
1REBACF32017
1REBACF33017
1REBACR59017
3.0
230
1
350
13 ¾
1B
8.5
0.335
1REBACF40004
1REBACF41004
15
400
3
2525
99½
3
10
0.4
1REBACF32018
1REBACF33018
1REBACR59018
00 - 012 - 0116
*1B= 1 Element U bent
00 - 013 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
SCREWED SELECTION TABLES
FLT / FLT-D RANGE
60 w/ins2 - 9.3 w/cm2
Applications
L
Ø108
Standard features
rugged industrial construction
Incoloy 800 elements
2 ¼” brass screwed plug
Explosion-proof terminal enclosure with stand-off
Thermostat regulation
Thermostat manual reset cutout
Thermowell optional
FLT TYPE
165
6
X
12
L
Ø108
•
•
•
•
•
•
•
12
165
• Industrial water heating
FLT-D TYPE
mm.
Ins.
Class ATEX
T3
Fluid T°C
101÷200
Safety T°C.
Class ATEX
T4
50÷300
Safety T°C.
0÷200
Termostat
T°C regulation
Termostat
T°C regulation
0÷120
50÷250
Fluid T°C
Dia.
Elements
≤100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Ex’d’
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE
X=150
1.5
230
1
340
13¼
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
22¼
1
10
0.4
1REBACF42005
1REBACF43005
3.0
230
1
340
13¼
1B
10
0.4
1REBACF44005
1REBACF45005
4.0
400
1
730
28¼
1
10
0.4
1REBACF42006
1REBACF43006
4.0
400
1
385
15¼
1B
10
0.4
1REBACF44006
1REBACF45006
4.5
400
3
340
13¼
3
10
0.4
1REBACF46002
1REBACF47002
5.0
400
1
890
35
1
10
0.4
1REBACF42007
1REBACF43007
5.0
400
1
465
18½
1B
10
0.4
1REBACF44007
1REBACF45007
6.0
400
1
1055
41½
1
10
0.4
1REBACF42008
1REBACF43008
6.0
400
1
545
21½
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
40½
3
10
0.4
1REBACF46007
1REBACF47007
18.0
400
3
1110
43¾
3
10
0.4
1REBACF46008
1REBACF47008
*1B= 1 Element U bent
00 - 014 - 0116
00 - 015 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
INSTRUCTION
USE AND MAINTENANCE
THE FOLLOWING INFORMATION IS THE MINIMUM NECESSARY FOR SAFE
USE. WE CAN SUPPLY MORE INFORMATION AFTER EVALUATION BY OUR
TECHNICAL DEPARTMENT ABOUT DIFFERENT SITUATIONS.
Dangerous Areas Electric Heaters
1• Security instructions
FLT 80 ; FLT 95
Ex II 2G d IIC T1÷T4
ATEX 94/9/CE Directive
CEI EN 60079-0 ; CEI EN 60079-1 Standards
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 T4÷T1, 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
classified against the explosion risk like 1 and 2 zone (gas).
Special condition for a secure use
• To avoid an extreme temperatures on the fluid, 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.
2• 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.
3• Nominal features
12
L
Ø108
Ø108
165
Protection mode
Protection degree
ATEX Code
Max voltage
Max current
Nominal frequency
Ambient temperature
FLT TYPE
125
X
12
L
Ø108
Ø108
165
FLT-D TYPE
:
:
:
:
:
:
:
Ex d IIC T4÷T1
IP 65
II2G
750 V
64 A
50/60 Hz
minus 20°C, plus 40°C (refer to factory if outside this range)
→
→
→
→
→
→
survey organization number ATEX (CESI)
group II (surface)
category 2
explosive atmosphere with gas, steam and fog
protection mode, gas group
temperature class
4• Marking
Πxxxx x II 2 G
Xxxx
II
2
G
Ex d IIC
T4÷T1
See following Table
125
S.p.A. DIVISIONE
VITTORIO VENETO (TV) ITALIA
II 2G
HEATERS TO IMMERSION N°/YEAR
xxxX
ATTENTION:
Ex.d II C T
TYPE FLT
CODE
W
V
Use cable for operating temperature >
A
°C
DO NOT OPEN WHILE ENERGIZED
00 - 016 - 0116
00 - 017 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
5• Installation
When installing hazardous area certified 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 certification of this product.
IMMERSION ELECTRIC HEATERS: DATA SHEET
Heater
Zoppas Industries model No.
Quantity
Type of heater
screwed
flanged
vat
Power supply
Volt
Hz
Phase
Floating star or delta
Y
Terminal enclosure
165
12
Solution to be heated
L
∆
Explosion-proof (Ex d)
Concentration and characteristics
Ø108
Ø108
Working conditions
Working temperature
FLT TYPE
125
Working pressure
Max. immersed length
Vat Heater
165
X
12
Tank dimensions
L
Minimum liquid level
Ø108
Ø108
Environmental conditions
Particular requirement if any
FLT-D TYPE
125
Internal/external T°C
Other comments if any
Controls
Power supply
Control position
Heater control requirements
Volt
Hz
in heater
Thermostat
Phase
Remote control panel
Thermostat cutout
Thermocouple
Secial control features required
Environmental conditions
Internal/external T°C
Particular requirement if any
Other comments if any
00 - 018 - 0116
00 - 019 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
Hazardous Area Flanged Heaters
Heater Selection
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 finest 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.
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.
COMPANY CERTIFICATIONS
FM 11235
9191.IRCR
PRODUCT TRADEMARKS
IT-75.12-6975 IT-75.12-6975
12/054P_IND 12/055P_IND
EN 15085-2
ISO 3834-3
Compliance with the
mark of each specific
product must be
properly reviewed with
our Sales Department.
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 specifications liable to modification. Tables of types and dimensions
of heaters listed in this catalogue are, therefore, subject to change without prior notification. In any case, our technical office 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 specific 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 can’t find what you want in our stock heaters or in our standard design, then we will custom build the heater to your exact
requirements.
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/ins2 (9.3 w/cm2)
• Sea water - Titanium at 25 w/ins2 (3.87 w/cm2)
• Ethylene glycol solution - Incoloy 800 at 15÷20 w/ins2 ( 2.33 ÷3.1 w/cm2)
• Light oils - mild steel/stainless steel at 15 and 20 w/ins2 (2.32 and 3.1 w/cm2)
• Medium oils - mild steel/stainless steel at 12 w/ins2 (1.86 w/cm2)
• Heavy oils - mild steel/stainless steel at 8 w/ins2 (1.24 w/cm2)
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 fluid, 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/flange materials, enclosures, head/flange 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.
Definition of Terms
Assembly Stock:
Standard Design:
Custom Built:
Components are held in stock and require assembly time before being available for packing/dispatch.
Manufactured from in-house standard designs, these require time for the generation of manufacturing instructions
and quality control procedures before packing/dispatch.
These require design, engineering, manufacturing, quality control and approval prior to packing/dispatch.
Application
Water & Very
Mild Solution
Corrosive & High
Viscous Solutions
Oil heating
Specialty
Heaters
00 - 020 - 0116
Different solutions
Concentration
Materials
Specific Power
Solution or
Heater Type
Alkaline or
Acid Content
(% by volume)
Sheath
Material
Watt Density
(W/in2)
(W/cm2)
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
45
7
23
3.5
15
2.3
23
15
3.5
2.3
45
23
12
60
7
3.5
1.86
9.3
Demineralized,
Deionize Water
Mild corrosive
Solutions
Severe corrosive
Solution
Low Viscosity Oil
Medium Viscosity Oil
Process Water
Demineralized Water
Low Viscosity Oil
Pipe Insert
5-15%
>16%
pH5 to pH9
Clean Water
Incoloy
Stainless Steel
Incoloy
Stainless Steel
Incoloy
Stainless Steel
Mild Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Incoloy
Copper
00 - 021 - 0116
IMMERSION HEATERS HAZARDOUS AREA SCREW PLUG
7 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.
European ATEX Directive 94/9/CE Electrical and non-­‐electrical equipment and protection system �x ……...    NOTES
Ex    Use of equipment in Type of Potentially explosive atm protection see CE Marking following list Identification number of Notified body, when appropriate TYPE
VOLUME
SURFACE
POWER
FLGT
dm3 (min-max)
m3 (min-max)
W
FLGT 50
0.22÷0.45
0.026÷0.041
---
N.A.
FLGT75
0.7÷1.4
0.052÷0.081
---
N.A.
FLGT100
0.9÷1.7
0.036÷0.095
---
N.A.
FLGT125
1.3÷2.5
0.084÷0.122
---
N.A.
FLGT150
1.6÷3.2
0.097÷0.139
---
N.A.
FLGT175
2.5÷4.8
0.126÷0.180
20
---
FLGT200
3.2÷6.2
0.150÷0.212
20
---
FLGT250
7.5÷12.5
0.254÷0.331
40
---
FLGT300
10.5÷18
0.326÷0.417
60
---
FLGT350
15÷25
0.430÷0.536
80
---
FLGT400
18.5÷32
0.519÷0.639
100
---
FLGT450
24÷40
0.619÷0754
100
---
z Equipment roup: Equipment GG
roup: ffor or ssurface urface Equipment category I mines M1 – Very high level M2 – High level Type of explosive Atmospheres (group II) G D Gas Dust vapours Zone Zone II surface 1 – Very hihg level 0 20 2 – High level 3 – Normal 1 21 2 22 CATEGORY OF EQUIPMENT 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 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 -­‐20÷40°C For Dust Class put the maximum surface temperature after the “T” example T100°C Cat. M2-­‐2G M2-­‐2G M2-­‐2G STANDARDS AND TYPE OF PROTECTION Electrical equipment for gas (G) Code EN Rule General requirements 60079-­‐0 o Oil immersion 60079-­‐6 p Pressurized apparatus 60079-­‐2 q Powder filling 60079-­‐5 M2-­‐2G d Flameproof enclosure 60079-­‐1 e M2-­‐2G Increased safety 60079-­‐7 ia M2-­‐2G Intrinsic safety 60079-­‐11 ib M2-­‐2G Intrinsic safety 60079-­‐11 m M2-­‐2G Encapsulation 60079-­‐18 n 3G Protection type “n” 60079-­‐15 1G Category 1G 60079-­‐26 M1 Category M1 50303 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 00 - 022 - 0116
00 - 023 - 0116
Worldwide Local Supplier
NOTE:
Headquarters
ZOPPAS INDUSTRIES Partner
• Experience Zoppas Industries increasing efficiency using
lean enterprise across all facilities and departments.
Manufacturing
facilities
• Access our state-of-the-art laboratory facilities with over 30 years’
design experience.
• Benefit 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.
• Benefit 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.
• Benefit from Zoppas Industries products third-party certification, such as
UL and VDE: marking applied on customer’s request.
We at ZOPPAS INDUSTRIES put you in the front seat of globalization - sourcing your local needs globally.
COMPANY CERTIFICATIONS
FM 11235
00 - 024 - 0116
9191.IRCR
PRODUCT TRADEMARKS
IT-75.12-6975 IT-75.12-6975
12/054P_IND 12/055P_IND
EN 15085-2
ISO 3834-3
Compliance with the mark of each specific product
must be properly reviewed with our Sales Department.
NOTE:
RICA - Via Podgora, 26 - 31029 Vittorio Veneto (TV) - Italy
Tel. +39 0438 9101 - Fax +39 0438 912272 - 912236
www.zoppasindustries.com - rica@zoppas.com