Heater Selection Matrix
Heater Selection Matrix
Heater Selection
           Matrix
                                                                                                                                                                              Customer Assistance
           Heating: Solids
                                                                                                                        Typical
          Heater                       Application Description                                Sheath                Maximum Watt      Maximum Operating         Catalog
           Type                                                                              Materials                 Densities        Temperatures             Page
                                                                                                                    W/in2 (W/cm2)         °F  (°C)
       ①Figures shown are typical watt density ranges. Band size and thermal characteristics of the material heated will determine recommended watt density.
       ➁Applications and heater constructions differ. Consult the application section in this catalog for more detailed application information.
       ➂These are typical maximum watt densities. Heater clamping, environmental conditions and material being heated will determine recommended watt densities.
        Kapton® is a registered trademark of E. I. du Pont de Nemours & Company. Incoloy® and Inconel® are registered trademarks of the Special Metals Corporation.
                                                                                                                                                                          5
Intro pages     11/28/00       2:31 PM       Page 6
       Heater Selection
       Matrix
       Heating: Liquids/Surface Heating and Immersion
                                                                                                                    Typical
            Heater                     Application Description                               Sheath             Maximum Watt       Maximum Operating           Catalog
             Type                                                                           Materials              Densities         Temperatures               Page
                                                                                                                W/in2 (W/cm2)          °F  (°C)
       Heating: Gases
                                                                                                                    Typical
            Heater                     Application Description                               Sheath             Maximum Watt       Maximum Operating           Catalog
             Type                                                                           Materials              Densities         Temperatures               Page
                                                                                                                W/in2 (W/cm2)          °F  (°C)
             Cable     Cable heaters are sinuated or wound into coils which can      Inconel® or
                       be inserted into a pipe or vessel to heat flowing air or      Stainless Steel              30      (4.6)       1200       (650)             57
                       gases. Cable heaters readily lend themselves to appli-
                       cations where space is restricted.
           Cartridge   Mounted in pipes or vessels through which gases pass.         Incoloy® or                                         Consult
                       Can be placed in protection tubes, making access and          Stainless Steel              400     (62)           Watlow                    75
                       wiring easier.
                                                                                                                                                           CONTINUED
       ➂These are typical maximum watt densities. Heater clamping, environmental conditions and material being heated will determine recommended watt densities.
       ➃Per application
       6
Intro pages    11/28/00       2:31 PM      Page 7
      Heater Selection
      Matrix
                                                                                                                                                                      Customer Assistance
      Heating: Gases                         Continued
                                                                                                                   Typical
         Heater                      Application Description                               Sheath              Maximum Watt         Maximum Operating   Catalog
          Type                                                                            Materials               Densities           Temperatures       Page
                                                                                                               W/in2 (W/cm2)            °F  (°C)
         Ceramic     Used to construct chambers and furnaces through which          Molded Ceramic Fiber          30       (4.6)      2200   (1205)       141
          Fiber      gases are passed. Heaters function as high temperature
                     radiant heaters surrounding transfer pipes or other
                     special vessels.
         Flexible    Applied to the surface of a pipe or vessel containing gases.   Kapton®                        5       (0.8)       390    (200)       189
                     Well suited for curved surfaces and irregular shaped           Neoprene                       2       (0.3)       250    (120)       191
                     objects. Excellent for use in enclosures.                      Silicone Rubber                5       (0.8)       500    (260)       169
         Multicell   Multiple elements placed in a duct or vessel through           Inconel®                     *60d      (9.3)      2100   (1150)       195
                     which gases pass. Designs also available to heat pass          Incoloy®
                     tube externally to isolate gas from the element. Excellent
                     for use in high temperature/high pressure applications.
           Strip     Generally modified with the addition of fins to increase       Aluminized Steel with
                     surface area. Commonly used for air heating, drying             refractory insulation       ^60e      (9.3)      1200    (650)       241
                     ovens and space heaters.                                       Stainless Steel with
                                                                                     mica insulation             ^20e       (3)       1000    (540)       233
                                                                                    Stainless Steel with
                                                                                     mineral insulation         ^100c      (15.5)     1400    (760)       229
                                                                                    Zinc-coated Steel
                                                                                     with mica insulation        ^20e       (3)        900    (480)       233
         Tubular     Multiple elements mounted in an array and placed in a          Flat:   Incoloy®              30       (4.6)      1400    (760)       299
                     duct or vessel through which gases pass. Flat tubular                  Stainless Steel       30       (4.6)      1200    (650)       299
                     elements can be modified with the addition of fins to          Round: Incoloy®               30       (4.6)      1600    (870)       273
                     increase surface area.                                                 Inconel®              30       (4.6)      1800    (980)
      ➃ Per application
      ➄ These are typical maximum watt densities. Ambient temperature and flow will determine recommended watt density.
      Heating: Vacuums
                                                                                                                   Typical
         Heater                      Application Description                                Sheath             Maximum Watt         Maximum Operating   Catalog
          Type                                                                             Materials              Densities           Temperatures       Page
                                                                                                               W/in2 (W/cm2)            °F  (°C)
      ➃ Per application
      ➄ Non-magnetic stainless steel available.
                                                                                                                                                                  7
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W A T L O W
          Reference Data
          Formulas, Conversions
          and Engineering
          Constants
                   Volts                                                         E                         Amperes
                                                                WR               R
       Volts =      Watts X Ohms                                                                        Amperes =   Volts
                                                  W                                      W                          Ohms
                                                  I
                                                                                                                                  Reference Data
       Volts =     Watts                                                                 R
                  Amperes                                                                               Amperes =   Watts
                                                                                                                    Volts
       Volts =    Amperes X Ohms
                                            IR                 E I
                                                               (Volts)       (Amps)
                                                                                               W
                                                                                               E
                                                                                                        Amperes =   Watts
                                                                                                                    Ohms
                                                               (Ohms)        (Watts)
                                             E                                                 EI
                   Ohms
            Ohms = Volts
                                             I                 R W                                         Watts
                                                                                                        Watts = Volts
                                                                                                                      2
                  Amperes                                                                                       Ohms
                                                   W                                     I2R
                        Volts2                                                                          Watts = Amperes2 X Ohms
            Ohms =                                 I2
                        Watts                                   E2
                                                                2            2
                                                                              E2                        Watts = Volts X Amperes
            Ohms = Watts                                        W             R
                   Amperes2
                                                      ()
                                            W2 = W1 X E2
                                                      E1
                                                           2
                                                                          Total Watts
                                            3 Phase Amperes =
                                                                         Volts X 1.732
                                                                                                                            427
ref data text   11/22/00   10:36 AM   Page 428
      Reference Data
      Formulas,                                  Typical 3 Phase Wiring Diagrams and Equations for Resistive Heaters
      Conversions and                            Definitions
      Engineering                                For Both Wye and Delta             Wye and Delta Equivalents
      Constants                                  (Balanced Loads)                   WDELTA = 3 WWYE
                                                 VP = Phase Voltage                 WODELTA = 2⁄3 WDELTA
                                                 VL = Line Voltage                  WOWYE = 1⁄2 WWYE
                                                 IP = Phase Current
                                                 IL = Line Current
                                                 R = R1 = R2 = R3 =
                                                    = Resistance of each branch
                                                 W = Wattage
                                                                                                                           IPO
                                                                   IP
                                                             R2                VP                                R2                       VPO
                                                                                         VL                                                         VL
                                                        R1                                                 R1
                                                                  R3
                                                                                                                          ILO
                                                                          IL
                                                                                                                I P01
                                                   R1              R2                                 R1
                                                                                    VP                                                      VP
                                                             IP
                                                                                              VL             I P03                                       VL
                                                             R3                                                      R3
                                                                                                                                  I L02
                                                                    IL                                                    I L03
       428
ref data text   11/22/00   10:36 AM   Page 429
W A T L O W
       Reference Data
                                                                                                 ➀
       Quick Estimates of                        Kilowatt-Hours to Heat Steel
       Wattage                                                                                           Temperature Rise °F
                                                   Amount
       Requirements                                of Steel            50°        100°                200°         300°          400°      500°           600°
       The following tables can be used              (lb.)                                           Kilowatts to Heat in One Hour
       to make quick estimates of wattage
                                                      25               0.06       0.12                0.25         0.37           0.50      0.65           0.75
       requirements.                                  50               0.12       0.25                0.50         0.75           1.00      1.25           1.50
                                                     100               0.25       0.50                1.00         1.50           2.00      2.50           3.00
                                                     150               0.37       0.75                1.50         2.25           3.00      3.75           4.50
                                                     200               0.50       1.00                2.00         3.00           4.00      5.00           6.00
                                                     250               0.65       1.25                2.50         3.75           5.00      6.25           7.50
                                                     300               0.75       1.50                3.00         4.50           6.00      7.50           9.00
                                                     400               1.00       2.00                4.00         6.00           8.00     10.00          12.00
                                                                                                                                                                       Reference Data
                                                     500               1.25       2.50                5.00         7.50          10.00     12.50          15.00
                                                     600               1.50       3.00                6.00         9.00          12.00     15.00          18.00
                                                     700               1.75       3.50                7.00        10.50          14.00     17.50          21.00
                                                     800               2.00       4.00                8.00        12.00          16.00     20.00          24.00
                                                     900               2.25       4.50                9.00        13.50          18.00     22.50          27.00
                                                    1000               2.50       5.00               10.00        15.00          20.00     25.00          30.00
                                                 ➀ Read across in table from nearest amount                       Includes a 20% safety factor to compensate for
                                                 in pounds of steel to desired temperature rise                   high heat losses and/or low power voltage.
                                                 column and note kilowatts to heat in one hour.                   For Steel: Use table or metric equation.
                                                                                                                   kW = Kilograms X Temperature Rise (°C)
                                                                                                                           5040 X Heat-up Time (hrs.)
                                                 Kilowatt-Hours to Heat Oil                 ➁
                                                                                                                                                                 429
ref data text     11/22/00      10:36 AM      Page 430
       Reference Data
                                                                                                             ➀
       Quick Estimates of                                       Kilowatt-Hours to Heat Water
       Wattage                                                   Amount of Liquid                                 Temperature Rise °F
       Requirements                                                    ft3      Gallons
                                                                                              20°      40°       60°        80°       100°         120°      140°
                                                                                                             Kilowatts to Heat in One Hour
                                                                   0.66               5       0.3      0.5        0.8       1.1        1.3          1.6       1.9
                                                                   1.3               10       0.5      1.1        1.6       2.1        2.7          3.2       3.7
                                                                   2.0               13       0.8      1.6        2.4       3.2        4.0          4.8       5.6
                                                                   2.7               20       1.1      2.2        3.2       4.3        5.3          6.4       7.5
                                                                   3.3               25       1.3      2.7        4.0       5.3        6.7          8.0       9.3
       ➀ Read across in table from nearest amount in               4.0               30       1.6      3.2        4.8       6.4        8.0          9.6      12.0
       gallons of liquid to desired temperature rise               5.3               40       2.1      4.0        6.4       8.5       11.0         13.0      15.0
       column and note kilowatts to heat in one hour.              6.7               50       2.7      5.4        8.0      10.7       13.0         16.0      19.0
                                                                   8.0               60       3.3      6.4        9.6      12.8       16.0         19.0      22.0
      For Heating Flowing Water:
                                                                   9.4               70       3.7      7.5       11.2      15.0       19.0         22.0      26.0
          kW = GPM X Temperature Rise (°F) X 0.16                 10.7               80       4.3      8.5       13.0      17.0       21.0         26.0      30.0
          OR                                                      12.0               90       5.0     10.0       14.5      19.0       24.0         29.0      34.0
                                                                  13.4              100       5.5     11.0       16.0      21.0       27.0         32.0      37.0
          kW = Liters/min. X Temperature Rise (°C) X 0.076
                                                                  16.7              125       7.0     13.0       20.0      27.0       33.0         40.0      47.0
      For Heating Water in Tanks: Use equation or table.          20.0              150       8.0     16.0       24.0      32.0       40.0         48.0      56.0
         kW = Gallons X Temperature Rise (°F)                     23.4              175       9.0     18.0       28.0      37.0       47.0         56.0      65.0
                     375 X Heat-up Time (hrs)                     26.7              200      11.0     21.0       32.0      43.0       53.0         64.0      75.0
                                                                  33.7              250      13.0     27.0       40.0      53.0       67.0         80.0      93.0
          OR
                                                                  40.0              300      16.0     32.0       47.0      64.0       80.0         96.0     112.0
          kW = Liters X Temperature Rise (°C)                     53.4              400      21.0     43.0       64.0      85.0      107.0        128.0     149.0
                   790 X Heat-up Time (hrs)                       66.8              500      27.0     53.0       80.0     107.0      133.0        160.0     187.0
                                                         100     1.7          3.3     5.0      6.7     8.3    10.0       11.7      13.3    15.0      16.7     20.0
                                                         200     3.3          6.7    10.0     13.3    16.7    20.0       23.3      26.7    30.0      33.3     40.0
                                                         300     5.0         10.0    15.0     20.0    25.0    30.0       35.0      40.0    45.0      50.0     60.0
                                                         400     6.7         13.3    20.0     26.7    33.3    40.0       46.7      53.3    60.0      66.7     80.0
                                                         500     8.3         16.7    25.0     33.3    41.7    50.0       58.3      66.7    75.0      83.3    100.0
                                                         600    10.0         20.0    30.0     40.0    50.0    60.0       70.0      80.0    90.0     100.0    120.0
                                                         700    11.7         23.3    35.0     46.7    58.3    70.0       81.7      93.3   105.0     116.7    140.0
                                                         800    13.3         26.7    40.0     53.3    66.7    80.0       93.3     106.7   120.0     133.3    160.0
                                                         900    15.0         30.0    45.0     60.0    75.0    90.0      105.0     120.0   135.0     150.0    180.0
       Use the maximum anticipated airflow.             1000    16.7         33.3    50.0     66.7    83.3   100.0      116.7     133.3   150.0     166.7    200.0
       This equation assumes insulated duct
                                                        1100    18.3         36.7    55.0     73.3    91.7   110.0      128.3     146.7   165.0     183.3    220.0
       (negligible heat loss). 70°F inlet air and
       14.7 psia.                                       1200    20.0         40.0    60.0     80.0   100.0   120.0      140.0     160.0   180.0     200.0    240.0
                                                    For Air:
                                                    Use equation or table.
                                                       kW = CFM➀ X Temperature Rise (°F)
                                                                         3000
                                                          OR
                                                       kW = Cubic Meters/Min➀ X Temperature Rise (°C)
                                                                               47
                                                    For Compressed Air:
                                                      kW = CFM➁ x Density➁ X Temperature Rise (°F)
                                                                             228
                                                         OR
                                                         kW = Cubic Meters/Min➁ X Temperature Rise (°C) X Density (kg/m3)➁
                                                                                             57.5
W A T L O W
          Reference Data
          Formulas,                              Commonly Used Geometric Areas And Volumes
          Conversions and                        Areas and Dimensions of Plane Figures
                                                 The following illustrations show the areas of plane figures, the surfaces of solids,
          Engineering                            and the volumes of solids.
          Constants
                                                                                  Square,
                                                                                  Rectangle,
                                                                                  Parallelogram                                          Circular Ring
                                                                              a                                  d                       A = area.
                                                                                  A = area.                              r
                                                                                                            R        D                   A = (R2 - r2)
                                                                                  A = ab
                                                      b                                                                                    = 0.7854 (D2 - d2)
                                                                                  Note that dimension
                                                                                  a is measured at right
                                                                                  angles to line b.
                                                                                                                                                                   Reference Data
                                                                                  Triangle                                               Cube or
                                                          h
                                                                                                                                         Square Prism
                                                                                  A = area.                              b
                                                                                                                                         V = volume
                                                                                  A = bh                                         c
                                                                                       2                         a                       A = area of surface.
                                                                  b
                                                                                                                                         V = abc
                                                                                                                                         A = 2ab + 2ac + 2bc
                                                              a                                                                          Cylinder
                                                                                  Trapezoid                                              V = volume; S = area
                                                                                                                                         of cylindrical surface.
                                                                                  A = area.                                          r
                                                 h                                                                                       V = r2 h = d2 h
                                                                                      (a + b)h                                                          4
                                                                                  A=
                                                                                          2                                              S = 6.28rh = 3.14dh
                                                                                                             h                   d       Total area A of
                                                              b                                                                          cylindrical surface
                                                                                                                                         and end surfaces:
                                                                                                                                         A = 6.28r(r + h)
                                                                                                                                           = 3.14d(1/2 d + h)
                                                                                  Regular
                                                                      a
                                                                                  Polygon                                                Cone
                                                                              s                                                      r
                                                          R                                                                              V = volume; A = area
                                                                                  A = area
                                                                                                                                         of conical surface.
                                                          r
                                                                                  n = number of sides
                                                                                  s = length of side         h                   d       V = 1/3 r2 h
                                                                                  a = 360° ÷ n                                           A = r r2 + h 2
                                                                                      nsr ns R2 - s2
                                                                                  A= 2 = 2           4
                                                                                                                                         Sphere
                                                                                  Circle
                                                                                                                                         V = volume; A = area
                                                                                  A = area;                                              of surface.
                                                              d                   C = circumference.             d
                                                                                                                             r                   3     3
                                                                      r                                                                  V= 4 r = d
                                                                                  A = r2 = d2                                                  3     6
                                                                                           4                                             A = 4 r 2 = . d2
                                                                                  C=2 r= D
                                                                  l               Circular Sector
                                                                                  A = area
                                                                                  l = length of arc;
                                                                                  a = angle, in degrees.
                                                                      r
                                                                  a               r = radius
                                                                                  l = r a 3.14
                                                                                        180
                                                                                  A = 1/2 rl
                                                                                  a = 57.3 l
                                                                                          r
                                                                                                                                                            431
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      Reference Data
      Formulas,
      Conversions and
      Engineering
      Constants
       Conversion Factors
                               To Convert To...                                         Multiply...                  By...
CONTINUED
       432
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W A T L O W
          Reference Data
          Formulas,
          Conversions and
          Engineering
          Constants
           Conversion Factors Continued
                                    To Convert To...                                           Multiply...                   By...
                                                                                                                                               Reference Data
                Gallons/minute                            (gpm)            Cubic meters/hour                 (m3/h)         4.403
                Gallons/minute                            (gpm)            Liters/second                     (l/s)          15.85
                Grams                                     (g)              Ounces                            (oz)            28.35
                Grams                                     (g)              Pounds                            (lb)            453.6
                Grams/cubic centimeter                    (g/cm3)          Kilograms/cubic meter             (kg/m3)         0.001
                Grams/cubic centimeter                    (g/cm3)          Pounds/cubic foot                 (lb/ft3)       0.01602
                Grams/cubic centimeter                    (g/cm3)          Pounds/cubic inch                 (lb/in3)        27.68
                Inches                                    (in)             Centimeters                       (cm)           0.3937
                Inches                                    (in)             Millimeters                       (mm)           0.03937
                Inches Mercury                            (in Hg)          Atmospheres                       (atm)           29.92
                Inches Mercury                            (in Hg)          Torr                                               25.4
                Joules                                    (J)              British Thermal Units             (BTU)           1055
                Joules                                    (J)              Calories                          (cal)          4.187
                Joules                                    (J)              Watt-hours                        (WH)            3600
                Joules/second                             (J/s)            British Thermal Units/hour        (BTU/h)        0.2931
                Joules/second                             (J/s)            Watts                             (W)               1
                Kilocalories/hour                         (kcal/h)         BTU/hour                          (BTU/h)         0.252
                Kilograms                                 (kg)             Pounds                            (lb)            0.4536
                Kilograms/cubic meter                     (kg/m3)          Grams/cubic centimeter            (g/cm3)          1000
                Kilograms/cubic meter                     (kg/m3)          Pounds/cubic foot                 (lb/ft3)        16.02
                Kilograms/square centimeter               (kg/cm2)         Pounds/square inch                (psi)          0.07031
                Kilojoules                                (kJ)             Watt-hours                        (WH)             3.6
                Kilojoules/kilogram                       (kJ/kg)          British Thermal Units/pound       (BTU/lb)        2.326
                Kilojoules/kilogram—°C                    (kJ/kg—°C)       British Thermal Units/pound—°F    (BTU/lb—°F)     4.187
                Kilometers/hour                           (km/h)           Miles/hour                        (MPH)           1.609
                Kilopascals                               (kPa)            Pounds/square inch                (psi)           6.895
                Kilowatts                                 (kW)             British Thermal Units/hour        (BTU/h)       0.0002931
                Kilowatts                                 (kW)             Watts                             (W)             0.001
                Kilowatt-hours                            (kWH)            British Thermal Units             (BTU)         0.0002931
                Kilowatt-hours                            (kWH)            Watt-hours                        (WH)             0.001
                Liters                                    (l)              Cubic Feet                        (ft3)           28.32
                Liters                                    (l)              Cubic Meters                      (m3)             1000
                Liters                                    (l)              Gallons, U.S.                     (gal)            3.785
                Liters/second                             (l/s)            Cubic feet/minute                 (CFM)           0.4719
                Liters/second                             (l/s)            Gallons/minute                    (GPM)          0.06309
CONTINUED
                                                                                                                                         433
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      Reference Data
      Formulas,
      Conversions and
      Engineering
      Constants
       Conversion Factors Continued
434