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HEATREX Pipe Insert Heaters are designed to provide years of
trouble free operation if properly installed and maintained.
Please read and follow these instructions for installing and
maintaining the heater.
Pipe Insert Heaters provide an effective way to heat large storage
tanks. The heating element design allows removal and servicing
of the heating element without draining the tank.
HEATER CONSTRUCTION
The heating elements are open coil design and consist of heavy
gauge nickel‐chromium alloy supported by ceramic insulators.
The ceramic insulators are fastened to a strip of heavy sheet
metal.
PIPE / TUBE CONSTRUCTION
The heaters shall be installed in a tube or pipe of sufficient wall
thickness to prevent the tube from distorting from the heat
generated. The tubes shall be constructed so that the heating
elements may be removed without draining the tank. When
specified, HEATREX can provide heater pipes (798 series).
For additional product offerings, refer to HEATREX catalog
literature on Process Heating such as Circulation Heaters,
Immersion Heaters, or Tubular Heating Elements. Refer to HX87‐
2000‐83 for Industrial Control Panel IOM.
A variety of designs, sizes, and mounting configurations are
available. The heater watt density and design features must be
closely matched to the application.
HEATREX recommends installation be performed by qualified
personnel familiar with the National Electrical Code and all local
codes and standards. It is the responsibility of the installer to
verify the safety and suitability of the installation
DO NOT mount heaters in an atmosphere containing
combustible gases, vapors, dusts, or fibers unless properly
marked as suitable for the condition. Refer to section below for
special instructions for Hazardous Areas.
Hazardous voltages are present in this equipment. Lock out and
tag the branch circuit disconnect switch before working on this
heater.
Maintenance INSTRUCTIONS FOR 797 &
CAUTION
WARNING
WARNING
INSTALLATION, OPERATING &
798 SERIES PIPE INSERT HEATERS
GENERAL
Life of the heating element is directly related to its surface
temperature.
Failure to follow HEATREX recommendations could result in
premature failure and/or serious equipment damage.
Temperature regulating devices, temperature limiting controls,
and low liquid level controls are recommended for use with pipe
insert heaters, to control the heating process and safeguard the
heater from excessive temperatures that can cause damage.
Also, damage to fluid could occur if the heater is allowed to
exceed the maximum film temperature recommended by the
manufacturer. Heaters can be provided with sheath sensing
thermocouples when requested.
HEATREX Pipe Insert Heaters can be specially designed for use in
hazardous areas as specified in Article 500 through 516 of the
National Electrical Code. Refer to the heater nameplate or
HEATREX Application Data for classification of the heater
provided. See section below labeled Hazardous Areas for specific
requirements.
It is the ultimate responsibility of the user to verify that the
construction materials provided by HEATREX are suitable for
use with the process fluid. Specifically, corrosion issues must
be reviewed. Refer to HEATREX Application Data for heater
construction materials and design conditions.
INSTALLATION
Handling and Storage
Care must be taken to avoid damage to the heater during storage
and handling. When HEATREX provides heaters with pipes, the
heating element is shipped in the pipe. If the heater pipe is user
supplied, the heating element will be shipped in cardboard
shipping tubes.
Protect the heater from weather damage during storage.
Cardboard shipping tubes are not suitable for outdoor storage.
It is recommended to store the heater in a cool dry area to help
prevent the heating element ceramic spacers from drawing
moisture.
1
CAUTION
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Related Manuals for Heatrex 797 SERIES
Summary of Contents for Heatrex 797 SERIES
- Page 1 INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS FOR 797 & 798 SERIES PIPE INSERT HEATERS GENERAL HEATREX Pipe Insert Heaters are designed to provide years of Life of the heating element is directly related to its surface trouble free operation if properly installed and maintained. temperature. Please read and follow these instructions for installing and CAUTION maintaining the heater. Failure to follow HEATREX recommendations could result in Pipe Insert Heaters provide an effective way to heat large storage premature failure and/or serious equipment damage. tanks. The heating element design allows removal and servicing of the heating element without draining the tank. Temperature regulating devices, temperature limiting controls, HEATER CONSTRUCTION and low liquid level controls are recommended for use with pipe ...
- Page 2 Mechanical Instructions remove ceramic chips, etc. Site Selection If the heater pipe is not supplied by HEATREX, ensure the pipe Review the NEMA Type rating of the heater noted on the length is correct by measuring the heating element overall length HEATREX Application Data. Do not install a heater in an area not (OAL), the cold length from the start of the coiled wire to the consistent with its rating. front end of the heating element (CL), and the length of the Allow sufficient free space around heater installation site. Work heater pipe not including the pipe cap (PL). space for heater maintenance should be at least three feet in The pipe length PL must be greater than or equal to OAL. When front and on either side of the heater. The minimum pull space locating the heater pipe in the tank, the distance from the front for the heating element installation or removal from the end of the pipe to the exterior tank wall must be less than or pipe/tube should be at least four feet. The heating element is equal to CL to ensure the heated area is in the fluid. designed to be flexible and can be curved if necessary. Heating Element Installation & Removal Electric heaters are capable of developing high temperatures. Therefore, extreme care should be taken to To remove the heating element from a heater pipe or shipping tube, first remove the fastening nut at the terminal end. Hold avoid mounting heaters in an atmosphere containing the ceramic insulator firmly in order to avoid undue pressure on combustible gases, vapors, dusts, or fibers unless properly the ceramic and possible breakage. If obstructions are marked as suitable for the condition. encountered, rotate the heater slightly back and forth while Heater Orientation pulling out. This style of heater is intended for horizontal use only. The open Since heating elements can be of considerable length, it may not coil resistance wire must not be mounted in a vertical orientation always be possible to remove the element in a straight line, due or failure could occur from the coil sagging. ...
- Page 3 Insulation Wiring to the heater should be permanently installed in metallic or non‐metallic electrical grade conduit in accordance with all WARNING applicable electrical codes, and should include a grounding Surfaces of the heater pipe extending beyond the user’s conductor if non‐metallic conduit is used. vessel may be extremely hot. Avoid contact to prevent Field supply wiring must be rated for 600Vac. Use copper personnel injury or fire. conductors. The electrical installation should include a service disconnect The customer may prefer to insulate the flange or pipe at the switch in sight of the heater, as well as branch circuit over‐ tank for personnel safety and energy conservation. current protection and over‐temperature protection (if a remote control panel was not provided with the heater). WARNING Do not insulate the terminal enclosure or the first 2” of the Where thermocouple extension wire is required between the pipe. Dangerous over‐heating of the terminal box wiring heater and control panel, verify it is connected with proper could result. polarity as shown on the wiring diagram. Failure to do so may result in an uncontrolled heater. Refer to the wiring diagram for The heating elements are provided with a “cold section” where the required wire type. Shielded wire is recommended to reduce signal interference. ...
- Page 4 HEATREX recommends that all safety interlocks be tested during Pipe Maximum initial startup to ensure they properly disable the heater. After Material Pipe Temperature 10 days of operation, retighten all electrical connections. Steel 750° F Stainless Steel 304 1400° F On flanged heaters, re‐tighten heater flange bolts after the heater has completed one or two heating cycles. MAINTENANCE must be considered before attempting to replace coils. Field CAUTION replaced heating coils must be installed properly or failure may Troubleshooting and repairs should only be attempted by occur. qualified maintenance personnel. If field‐replacing one or more heating coils, mechanical connections at the end ceramics need to be removed. Remove the burned out coil from both ends by pulling lightly, and at the WARNING same time turning the coil back and forth. Check the ceramics Hazardous voltages are present in this equipment. Lock out near the area where the burnout occurred. Broken ceramics and tag the branch circuit disconnect switch before working ...
- Page 5 ALWAYS considered to be present. Division 2 means the hazard Never apply power to a heater in a hazardous atmosphere unless is only present under abnormal conditions. The Group defines all terminal box covers are properly installed with all cover bolts. the explosiveness of the hazard. The Temperature Code specifies All conduits entering the heater terminal box must be sealed the temperature at which a hazard will ignite. within 18” of the heater using an explosion‐proof conduit seal. Any unused openings must be properly sealed with a steel pipe HEATREX can provide designs suitable for all of the above plug. Follow the NEC for specific conduit requirements such as conditions, but a heater should never be placed in an the requirement for Rigid Conduit. environment not noted on the heater nameplate. To ensure proper flamepath, all threaded conduits must use NEVER operate the heater in an atmosphere with an ignition rated fittings and be tight, with a minimum of 5 good threads code temperature LOWER THAN the nameplate rating. The user engaged. Any machined metal‐to‐metal surfaces on terminal must determine the actual area classification. boxes must be handled carefully to prevent scratches which may Special design considerations for electric heaters used in void the explosion‐proof rating. hazardous locations: WARNING - Risk of Explosion 1. Locate all electrical connections in an appropriate enclosure. Operating the heater at a voltage higher than the 2. Prevent surface temperatures of the heater from exceeding nameplate value may result in elevated temperatures ...
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