Tubular Heaters Electric Process Heaters by Hampton Controls

Tubular Heaters by Hampton Controls

The most versatile of all electric heating elements, the tubular heater is capable of being formed into virtually and configuration. The basic design consists of a helical coil of nickel-chromium resistance wire precisely centered in a metal sheath. The coil is surrounded by magnesium oxide powder which is vibration loaded to insure even density throughout the length of the heater.

This entire assembly is then reduced to the finished diameter, compacting the MgO and "freezing" the coil in the center of the heater. The range of ratings, sizes, materials and terminations available makes the tubular heater adaptable to many industrial, commercial and scientific applications.

Easy installation with a uniform finish Can be formed by hand
No special installation tools required
Up to 75% sheath contact with round and square hotflex
Rapid heat-up times
3-dimensional groove geometry possible
Industry’s smallest bending radius
Hotflex’s flexibility enables heat to be located where it is needed; an improvement over rigid cartridge heaters

Stored in a straight condition to save storage space
Patented technology ensures industry leading heat transfer
heaters when recommended groove geometry is followed
Minimal temperature difference between heater sheath and heated tool
Reduced energy costs: tool mass can be reduced

Liquid immersion (with threaded fittings / flanges)
Free Air / Radiant
Clamped on
Wrapped around
Cast into aluminum, bronze, or cast iron
Installed into machine grooves or drilled holes in metal parts

Technical key features
Sheath material	stainless steel or Incoloy
Sheath temperature of heating element	max. 700 °C / 1290 °F
Standard connection voltage	230 V
High voltage restistance*	1000 V AC
Insulation resistance*	5 MOhm at 500 V DC
Leakage current*	< 0.5 mA at 253 V AC
Wattage tolerance	± 10 %
Length tolerance	± 1.5 %
*tested at environmental temperature

Installation example and Ideal heat transfer

Installation without special tools

Installed, round groove geometry

Options

Bendable unheated zones
Individual length
Individual connection options

Connection voltage from 12 V to 480 V
Individual wattage

Hampton Flexible Tubular Heaters

Hampton Controls offers a full selection of tubular heaters and make the heating of complex platens, shapes, and machines, possible. The Hampton Tubular Heaters are completely flexible, and may be shaped at will around pipes, along platen paths, and other challenging shapes.

These are excellent replacements for traditional Tubular Heaters, which are not flexible and must be custom made in most cases. Simplify your machine design, or reduce the maintenance time and cost by using flexible tubular heaters.

We offer the most expedited shipping of in stock flexible Tubular heaters in the market.

Flexible Tubular 6.5 mm

Diameter: 6.5 +/-0.1 mm
Sheath temperature of heating element: max. 700 C
Wattage tolerance: +/-10%
High voltage resistance (cold): 1,000 V-AC in straight condition
Sheath surface load: max. 10 W/cm2 according to application (depending on heated length)
Minimum bending radius: Rmin = 6.5 mm (internal) Connection options: M 2.5 with set of nuts and washers made of stainless steel.

Sheath material: stainless steel
Connection voltage: max. 250 V, standard: 230 V
Insulation resistance (cold): 5 M at 500 V-DC
Leakage current (cold): 0.5 mA at 253 V-AC
Extension factors: By bending and fitting the flexible Tubular becomes slightly longer. This extension is reproduce-able.
Max. total length straight: 1,500 mm

Flexible Tubular 8 mm

Sheath material: Stainless Steel.Sheath temperature of heating element: Max. 700 C. Voltage: 240 V.
High voltage strength (cold) in straight condition: 1000 V-AC.
Leakage current (cold) at 253 V-AC 0,5 mA
Sheath surface load: Max. 15 W/cm2 (according to application).
Unheated zones: Min. 30 mm/30 mm +/- 5 mm.
Connection options: M4 with set of nuts and washers made of stainless steel.
Note: Multi bending at the same point could damage the Flexible Tubular!
Extension factors: by bending and fitting the Flexible Tubular, it becomes slightly longer. This extension is reproduceable.
Not bendable zones: Min. 35 mm/35 mm.

power tolerance (cold) +/- 10 %.

Insulation resistance (cold) at 500 V-DC 5 M ohms

Max. length straight 2600 mm

Length tolerance straight: +/- 1,5 %

Minimum bending radius (internal): R = 10 mm.

Flexible Tubular 8.5 mm

Diameter: 8.5 +/-0.1 mm, 8.0 +/-0.1 mm resp. 8.2 +/-0.1 mm on option.
Sheath material: stainless steel
Sheath temperature of heating element: max. 700 C
Connection voltage: max. 250 V, standard: 230 V
Wattage tolerance: +/-10%
High voltage resistance (cold): 1,000 V-AC in straight condition
Insulation resistance (cold): 5 M at 500 V-DC
Sheath surface load: max. 15 W/cm2 according to application (depending on heated length)

Leakage current (cold): 0.5 mA at 253 V-AC
max. total length straight: 2,600 mm
Extension factors By bending and fitting the Flexible Tubular becomes slightly longer. This extension is reproduceable.
Connection options: M 2.5 with set of nuts and washers made of stainless steel.
Minimum bending radius: Rmin = 10 mm (internal)

Flexible Tubular 6x6

Profile: 6 x 6 +/- 0.1 mm
Sheath material: stainless steel
Sheath temperature of heating element: max. 700 C
Connection voltage: max. 250 V, standard: 230 V
Wattage tolerance: +/- 10%
High voltage resistance (cold): 1,000 V-AC in straight condition
Insulation resistance (cold): 5 M at 500 V-DC
Leakage current (cold): 0.5 mA at 253 V-AC

Max. total length straight: 1,500 mm
Extension factors: By bending and fitting the Flexible Tubular becomes slightly longer. This extension is reproduceable.
Sheath surface load: max. 10 W/cm2 according to application (depending on heated length)
Minimum bending radius: Rmin = 6.5 mm (internal)
Connection options: M 2.5 with set of nuts and washers made of stainless steel.

Flexible Tubular 8 x 8

Profile: 8 x 8 +/-0.1 mm,
Sheath material: stainless steel
Sheath temperature of heating element: max. 700 C
Connection voltage: max. 250 V, standard: 230 V
Wattage tolerance: +/- 10% High voltage resistance (cold): 1,000 V-AC in straight condition
Leakage current (cold): 0.5 mA at 253 V-AC
Max. total length straight: 2,600 mm
Extension factors: By bending and fitting the Flexible Tubular becomes slightly longer. This extension is reproduceable.

Insulation resistance (cold): 5 M at 500 V-DC
Sheath surface load: max. 15 W/cm2 according to application (depending on heated length)
Minimum bending radius: Rmin = 10 mm (internal)
Connection options: M 2.5 with set of nuts and washers made of stainless steel.

Ceramic Terminal Conector

*Pluging Heat*
Temp. restist. 230°C / 445°F
Short term max. 280°C / 535°F
14x21x25 mm / 5.51x8.27x9.84

Standard: threaded pins
M 2.5

Option: M 4 from 8.0 mm
with set of nuts and washers

Plain Ni-leads

with ceramic beads insulation, up to 600 °C / 1110 °

Insulated Ni-leads

Glass silk: up to 320 °C / 605 °F
PTFE: up to 260 °C / 500 °F
Silicon: up to 180 °C / 350 °F
Option: eyelet connector M4

High temperature mineral fiber

insulated Ni-leads,with ceramic sealed tube section

Flat plug

W = 6.3 mm / 0.248 inch

Terminations

Diameter (in.)	Sheath Materials Available	Maximum Voltage	Maximum Amperage	Maximum Length (in.)	Minimum Factory Bend Radius (in.)	Minimum Field Bend Radius (in.)
.200	Incoloy	240	12	98"	1/4"	3/4"
.260	Steel, Incoloy	250	15	188"	5/16"	1-1/4"
.315	Steel, 316 SS, Incoloy	480	30	294"	3/8"	1"
.330	Steel, 316 SS, Incoloy	480	30	294"	3/8"	1-1/4"
.375	steel, 316ss, Incoloy	480	30	294"	9/16"	2"
.430	Steel, 304 SS, 316 SS Incoloy	600	40	312"	7/16"	1-3/8"
.475	Steel, 304 SS, 316 SS Incoloy	600	40	312"	1/2"	1-3/8"

Sheath Temperature

Guidelines

Sheath Material	Sheath Temperature (Max.)
Steel	750°F
Stainless	1200°F
Incoloy	1600°F

Material Being Heated	Maximum Recommended Watt Density	Recommended Sheath Material
Air to 750°F	30	Steel
Air to 1200°F	40	304 SS or 316 SS
Air to 1600°F	40	Incoloy
Tap Water	60	316SS or Incoloy
Distilled Water	60	304SS, 316SS, or Incoloy
Deionized Water	60	316SS
Hot Runner Molds (Manifolds)	60	304SS or 316SS
Light Oils, Greases, Heat Transfer Fluids	23	Steel
Medium Weight Oils	15	Steel
Heavy Weight Oils	8	Steel
Caustic Solutions	23	Incoloy

End Seals Tubular heaters use Magnesium Oxide (MgO) as an insulator between the heating coil and the sheath. MgO is hygroscopic, and will absorb and retain water molecules from its surroundings.

This is an undesired characteristic as any humidity inside the heater will corrode the resistance wire, degrade the resistance of the heater, and even allow an arc between the sheath and the resistance wire.

To prevent moisture from affecting the performance of the heater, a variety of end seals are available. Listed below are our standard recommendations. Combinations of these end seals are available as are other options not listed here.

End Seal	Type	Max. Cont. Use Temp.	Typical or General Usage / Application
Cement	P	2000 °F	Extremely high temperature applications, for low vapor transmission rates
Silicone Barrier	MS	600 °F	Porous, moisture resistant, general usage on tubular products.
Epoxylite	EX	600 °F	Hermetic, long term stable insulation resistance.
High Temp Silicone Rubber	VH	450 °F	Moisture / Chemical Resistant. General Sealing.
Silicone Rubber	V	350 °F	Moisture / Chemical Resistant. General Sealing.
Epoxy	E	266 °F	Hermetic, long term stable insulation resistance.
Rubber Molded End Seal	RU	250 °F	Hermetic, long term stable insulation resistance. Full terminal

Alternate Seals Available Upon Request

Threaded Fittings

Threaded bulkhead fittings can be supplied on the terminal ends of tubular elements.
A gasket washer permits liquid tight installation in tank walls for immersion heating of water, oil, and other liquids.
Watertight gasket and lock nut are included.

Element Dia. (in.)	Thread Size	Tank Wall Hole Dia.	Thread Length	Hex A.F.	Rd. Diameter	Specify Material
.260	7/16” - 20	15/32”	5/8”	5/8”	-----	Stainless Steel
.315	1/2” - 20	17/32”	1/2”	-----	3/4”	Stainless Steel
.430	5/8” - 18	21/32”	13/16”	7/8”	-----	Stainless Steel
.475	5/8” - 18	21/32”	13/16”	7/8”	-----	Stainless Steel

Other Options

Brackets
Locating Rings
Washers
“Bright Sheath Passivation” + Nitric Acid Bath + Glass Bead Bright Finish

.315 inch Diameter

60W per square inch, 316SS
23W per square inch, Incoloy
23 W per square inch, Steel

Volts	Watts	Lenght (in.)	Heated Lenght (in.)	Unheated (in., each end)	Part #
120	500	12.50	8.50	2	TU31L-0125A
240	500	12.50	8.50	2	TU31L-0125B
120	750	16.75	12.75	2	TU31L-0167A
240	750	16.75	12.75	2	TU31L-0167B
120	1000	21.00	17.00	2	TU31L-0210A
240	1000	21.00	17.00	2	TU31L-0210B
240	1250	25.00	21.00	2	TU31L-0250A
120	1500	29.00	25.00	2	TU31L-0290A
240	1500	29.00	25.00	2	TU31L-0290B
240	2000	38.00	34.00	2	TU31L-0380A
240	2500	46.00	42.00	2	TU31L-0460A
240	3000	55.00	51.00	2	TU31L-0550A
240	4000	71.00	67.00	2	TU31L-0710A

.475 inch Diameter

48W per
square
inch, Incoloy
23W per
square
inch, Incoloy
23W per
square
inch, Steel
15W per
square
inch, Steel
8W per
square
inch, Steel

Watts	Length (in.)	Heated Length (in.)	Unheated Length (in., each end)	120V	240V	480V
1000	23.00	14.00	4.5	TU48Y-0230A	TU48Y-0230B	TU48Y-0230C
1500	30.00	21.00	4.5	TU48Y-0300A	TU48Y-0300B	TU48Y-0300C
2000	37.00	28.00	4.5	TU48Y-0300A	TU48Y-0370B	TU48Y-0370C
2500	47.00	35.00	6	TU48Y-0470A	TU48Y-0470B	TU48Y-0470C
3000	54.00	42.00	6	N/A	TU48Y-0540A	TU48Y-0540B
4000	68.00	56.00	6	N/A	TU48Y-0680A	TU48Y-0680B
5000	82.00	70.00	6	N/A	TU48Y-0820A	TU48Y-0820B
6000	96.00	84.00	6	N/A	TU48Y-0960A	TU48Y-0960B

Recommended groove geometry

Type hotflex	Groove dimensions [mm] w x h
6.0±0.1	6.1+0.1 x 7.1+0.1
Ø 6.5±0.1	6.0+0.1 x 6.5+0.1
Ø 8.0±0.1	7.7±0.05 x 8.0±0.1
8.0±0.1	8.1+0.1 x 9.1+0.1
Ø 8.2±0.1	7.9±0.05 x 8.2±0.1
Ø 8.5±0.1	8.2±0.05 x 8.5±0.1
Ø 10.0±0.1	9.7±0.05 x 10.0±0.1

Stock range Ø 6.5 mm
(230 V)

Stock range Ø 8.0 mm
(240 V*)

Stock ID	L [mm]	P [W]	Stock ID	L [mm]	P [W]
6500300	300	350	6300400	400	795
6500350	350	400	6300450	450	910
6500400	400	500	6300500	500	1025
6500450	450	600	6300550	550	1145
6500500	500	650	6300600	600	1260
6500550	550	700	6300650	650	1380
6500600	600	800	6300700	700	1495
6500650	650	850	6300750	750	1615
6500700	700	900	6300800	800	1730
6500750	750	1000	6300850	850	1845
6500800	800	1100	6300900	900	1960
6500850	850	1200	6300950	950	2080
6500900	900	1300	6301000	1000	2195
6500950	950	1350	6301050	1050	2316
6501000	1000	1400	6301100	1100	2430
6501050	1050	1450	6301150	1150	2545
6501100	1100	1500	6301200	1200	2665
6501150	1150	1550	6301250	1250	2780
6501200	1200	1600	6301300	1300	2895
6501250	1250	1650	6301350	1350	3015
6501300	1300	1700	6301400	1400	3130
6501350	1350	1800	6301450	1450	3245
6501400	1400	1900	6301500	1500	3365
6501450	1450	2000	6301550	1550	3480
6501500	1500	2100	6301600	1600	3600

Stock ID	L [mm]	P [W]	Stock ID	L [mm]	P [W]
6100300	300	650	6110500	500	780
6100350	350	750	6110550	550	860
6100400	400	900	6110600	600	950
6100450	450	1050	6110650	650	1000
6100500	500	1150	6110700	700	1100
6100550	550	1300	6110750	750	1190
6100600	600	1450	6110800	800	1250
6100650	650	1600	6110850	850	1350
6100700	700	1750	6110900	900	1430
6100750	750	1900	6110950	950	1500
6100800	800	2050	6111000	1000	1590
6100850	850	2200	6111050	1050	1650
6100900	900	2350	6111100	1100	1750
6100950	950	2500	6111150	1150	1830
6101000	1000	2650	6111200	1200	1900
6101050	1050	2800	6111250	1250	1990
6101100	1100	2930	6111300	1300	2070
6101150	1150	3060	6111350	1350	2070
6101200	1200	3190	6111400	1400	2150
6101250	1250	3320	6111450	1450	2230
6101300	1300	3450	6111500	1500	2300
6101350	1350	3580	--------	--------	--------
6101400	1400	3710	--------	--------	--------
6101450	1450	3840	--------	--------	--------
6101500	1500	3970	--------	--------	--------

Watts	Length (in.)	Heated Length (in.)	Unheated Length (in., each end)	120V	240V	480V
1000	41.00	29	6	TU48Y-0410A	TU48Y-0410B	TU48Y-0410C
1500	56.00	44	6	N/A	TU48Y-0560A	TU48Y-0560B
2000	70.00	58	6	N/A	TU48Y-0700A	TU48Y-0700B
2500	85.00	73	6	N/A	TU48Y-0850A	TU48Y-0850B
3000	99.00	87	6	N/A	TU48Y-0990A	TU48Y-0990B
4000	129.00	117	6	N/A	TU48Y-1290A	TU48Y-1290B
5000	158.00	146	6	N/A	TU48Y-1580A	TU48Y-1580B

Watts	Length (in.)	Heated Length (in.)	Unheated Length (in., each end)	120V	240V	480V
500	24.00	15	4.5	TU48S-0240A	TU48S-0240B	N/A
750	31.00	22	4.5	TU48S-0310A	TU48S-0310B	N/A
1000	41.00	29	6	TU48S-0410A	TU48S-0410B	TU48S-0410C
1500	56.00	44	6	TU48S-0560A	TU48S-0560B	TU48S-0560C
2000	70.00	58	6	TU48S-0700A	TU48S-0700B	TU48S-0700C
2500	85.00	73	6	TU48S-0850A	TU48S-0850B	TU48S-0850C
3000	99.00	87	6	N/A	TU48S-0990A	TU48S-0990B
4000	129.00	117	6	N/A	TU48S-1290A	TU48S-1290B
5000	158.00	146	6	N/A	TU48S-1580A	TU48S-1580B

Watts	Length (in.)	Heated Length (in.)	Unheated Length (in., each end)	120V	240V	480V
500	29.00	22	3.5	N/A	TU48S-0290A	N/A
667	39.00	30	4.5	N/A	TU48S-0390A	TU48S-0390B
833	46.00	37	4.5	N/A	TU48S-0460A	TU48S-0460B
1000	54.00	45	4.5	N/A	TU48S-0540A	TU48S-0540B
1333	69.00	60	4.5	N/A	TU48S-0690A	TU48S-0690B
1667	84.00	75	4.5	N/A	TU48S-0840A	TU48S-0840B
2000	98.00	89	4.5	N/A	TU48S-0980A	TU48S-0980B
2500	121.00	112	4.5	N/A	TU48S-1210A	TU48S-1210B
3000	143.00	134	4.5	N/A	TU48S-1430A	TU48S-1430B

Watts	Length (in.)	Heated Length (in.)	Unheated Length (in., each end)	120V	240V	480V
333	35.00	28	3.5	N/A	TU48S-0350A	N/A
500	49.00	42	3.5	N/A	TU48S-0490A	N/A
667	65.00	56	4.5	N/A	TU48S-0650A	TU48S-0650B
833	79.00	70	4.5	N/A	TU48S-0790A	TU48S-0790B
1000	93.00	84	4.5	N/A	TU48S-0930A	TU48S-0930B
1333	121.00	112	4.5	N/A	TU48S-1210C	TU48S-1210D
1667	149.00	140	4.5	N/A	TU48S-1490A	TU48S-1490B

Volts	Watts	Length (in.)	Heated Length (in.)	Unheated (in., each end)	Part #
120	500	29.00	22.00	3.5	TU31Y-0290A
240	500	29.00	22.00	3.5	TU31Y-0290B
120	750	40.00	33.00	3.5	TU31Y-0400A
240	750	40.00	33.00	3.5	TU31Y-0400B
120	1000	51.00	44.00	3.5	TU31Y-0510A
240	1000	51.00	44.00	3.5	TU31Y-0510B

Dimensions:
Depending on the number of bends the hotflex length can increase up to 1 %.

Type	L Min [mm]	L Max [mm]	Tube section Max [mm]	Min. bending radius internal	max. Sheath surface load [W/cm2]	max. wattage [W] at 230 V
6.0	300	1.800	24	6.5	10	2190
6.5	300	1.800	24	6.5	10	2190
8.0	300	2.600	10	10	15	5200
8.0	300	2.600	10	10	15	5200
8.2	300	2.600	10	10	15	5200
8.5	300	2.600	10	10	15	5200
10.0	300	2.600	10	10	12.5	5200

Volts	Watts	Length (in.)	Heated Length (in.)	Unheated (in., each end)	Part #
120	250	15.00	11.00	2	TU31S-0150A
240	250	15.00	11.00	2	TU31S-0150B
120	350	19.00	15.00	2	TU31S-0190A
240	350	19.00	15.00	2	TU31S-0190B
120	500	26.00	22.00	2	TU31S-0260A
240	500	26.00	22.00	2	TU31S-0260B
120	750	37.00	33.00	2	TU31S-0370A
240	750	37.00	33.00	2	TU31S-0370B
120	1000	48.00	44.00	2	TU31S-0480A
240	1000	48.00	44.00	2	TU31S-0480B
240	1250	59.00	55.00	2	TU31S-0590A
120	1500	70.00	66.00	2	TU31S-0700A
240	1500	70.00	66.00	2	TU31S-0700B

Order Your Tubular Heaters

Hampton Controls looks forward to serving you and supplying you with your Industrial Needs.

Feel free to call us if you need any assistance at: 724-861-0150

Type 1
Type 2
Type 3
Type 4
Type 5
Type 6
Type 7
Type 8

When possible, please provide a drawing to our design department to insure that heaters are manufactured to your specifications. If you do not have a drawing, you may choose one of the following standard configurations and supply us with the dimensions shown. Please see page 2 for minimum bending radiuses.