Immersion Heaters Haz Area UK+USA

IMMERSION HEATERS
HAZ AREA
IMMERSION HEATERS HAZ AREA
Hazardous Area Screw Plug Heaters

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.
COMPANY CERTIFICATIONS
FM 11235
9191.IRCR
IT-75.12.6975
UNI EN 15085-2
PRODUCT TRADEMARKS
IT-75.12.6975
UNI EN ISO
3834-3 11/2006
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 cant 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:
00 - 02 - 0414
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.
Heater Selection
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.
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 1520 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
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
Brass
Process Water or
Very Weak Solutions
pH5 to pH9
2-3%
Stainless Steel
45
Stainless Steel
Weak Solutions
5-6%
Incoloy
45
Stainless Steel
45
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
DemineralizedWater
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 - 03 - 0414
Construction
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 customers individual requirement. Consult Zoppas Industries
Heating Element Technologies Sales Department for suggested watts ratings and sheath materials for a wide range of applications.
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.
TABLE 1 (Screwed head sizes for immersion heaters)

Head Diameter
BSP
NPT
ISO
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.
00 - 04 - 0414
Certified Explosion-Proof-Exd
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 212F (100C), 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).
Supply Safety Thermostat

Type
Part No.
Range
Note
Safety
570968671
+52C 3C
Manual reset
Safety
570943160
+85C 3C
Manual reset
Safety
571092931
+90C 4C
Manual reset
Safety
571093491
+123C 4C
Manual reset
Safety
571223670
+150C 4C
Manual reset
Safety
570857302
+0C 200C
Manual reset
Safety
570895640
+20C 3C
Manual reset
Optional Regulation Thermostat

Type
Part No.
Range
Note
Regulation
571064270
-30C+30C
SPDT
Regulation
570142140
+4C+40C
SPDT
Regulation
570977491
+30C+90C
SPDT
Regulation
571275710
+30C+120C
SPDT
Regulation
571086111
+50C+250C
SPDT
Regulation
571086111
+50C+320C
SPDT
Regulation
570898460
+20C+500C
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 - 05 - 0414
SCREWED SELECTION TABLE

FLT / FLT-D RANGE
8 w/ins2 - 1.25 w/cm2
Applications
165
Standard features
rugged industrial construction

stainless steel elements
2 brass screwed plug
1 explosion-proof terminal enclosure with stand-off
Thermostat manual reset cutout
Thermostat for regulation
Thermowell optional
FLT TYPE
165
12
108
12
108
Heavy duty oils, raw crude oils, naphta, aniline etc.
FLT-D TYPE
mm.
Ins.
mm.
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
0120
0200
T4
101200
50250
50300
T3
201350
20500
20500
T2
Fluid TC
Dia.
Elements
100
Maximum
Immersed
Length
No. Elem.
Phase
Voltage
kW
Explosion-proof Exd
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE

X=150
FLT-D 300 TYPE

X=300
0.75
230
995
39
10
0.4
1REBACF28001
1REBACF29001
1REBACR57001
0.75
230
515
20
1B
10
0.4
1REBACF30001
1REBACF31001
1REBACR58001
1.0
230
1295
51
10
0.4
1REBACF28002
1REBACF29002
1REBACR57002
1.0
230
665
26
1B
10
0.4
1REBACF30002
1REBACF31002
1REBACR58002
1.5
230
1905
75
10
0.4
1REBACF28003
1REBACF29003
1REBACR57003
1.5
230
970
38
1B
10
0.4
1REBACF30003
1REBACF31003
1REBACR58003
2.0
230
2525
99
10
0.4
1REBACF28004
1REBACF29004
1REBACR57004
2.0
230
1280
50
1B
10
0.4
1REBACF30004
1REBACF31004
1REBACR58004
2.25
400
995
39
10
0.4
1REBACF32001
1REBACF33001
1REBACR59001
3.0
400
1295
51
10
0.4
1REBACF32002
1REBACF33002
1REBACR59002
4.5
400
1905
75
10
0.4
1REBACF32003
1REBACF33003
1REBACR59003
6.0
400
2525
99
10
0.4
1REBACF32004
1REBACF33004
1REBACR59004
00 - 06 - 0414

FLT / FLT-D RANGE
10.5 w/ins2 - 1.65 w/cm2
Applications
165
Standard features

Explosion-proof terminal enclosure with stand-off
Thermowell optional
FLT TYPE
165
12
108
12
108
Medium viscosity oils, non-flowing heat transfer oil etc.
FLT-D TYPE
mm.
Ins.
mm.
Ins.
Class ATEX
Fluid TC
T3
201350
Class ATEX
Safety TC.
50300
T2
Termostat
TC regulation
50250
Safety TC.
Fluid TC
101200
20500
Class ATEX
T4
FLT-D 150 TYPE

X=150
Termostat
TC regulation
Safety TC.
0200
FLT TYPE
X=0
20500
Termostat
TC regulation
0120
Fluid TC
Dia.
Elements
100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Exd
FLT-D 300 TYPE

X=300
0.5
230
650
26
8.5
0.33
1REBACF34001
1REBABF35001
1REBACR60001
0.5
230
340
13
1B
8.5
0.33
1REBACF36001
1REBACF37001
1REBACR61001
1.0
230
1205
47
8.5
0.33
1REBACF34002
1REBACF35002
1REBACR60002
1.0
230
620
24
1B
8.5
0.33
1REBACF36002
1REBACF37002
1REBACR61002
*1B= 1 Element U bent
00 - 07 - 0414

FLT / FLT-D RANGE
12.5 w/ins2 - 1.95 w/cm2
Applications
165
Standard features

Thermowell optional
FLT TYPE
165
12
108
12
108
Medium viscosity oils, non-flowing heat transfer oil etc.
FLT-D TYPE
0.5
230
mm.
Ins.
485
39
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
0120
0200
T4
101200
50250
50300
T3
201350
20500
20500
T2
Fluid TC
Dia.
Elements
100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Exd
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE

X=150
FLT-D 300 TYPE

X=300
10
0.4
1REBACF28005
1REBACF29005
1REBACR57005
0.67
230
620
24
10
0.4
1REBACF28006
1REBACF29006
1REBACR57006
0.67
230
350
13
1B
10
0.4
1REBACF30006
1REBACF31006
1REBACR58005
0.75
230
680
26
10
0.4
1REBACF28007
1REBACF29007
1REBACR57007
0.75
230
370
14
1B
10
0.4
1REBACF30007
1REBACF31007
1REBACR58006
1.0
230
880
34
10
0.4
1REBACF28008
1REBACF29008
1REBACR57008
1.0
230
460
18
1B
10
0.4
1REBACF30008
1REBACF31008
1REBACR58007
1.5
230
1295
51
10
0.4
1REBACF28009
1REBACF29009
1REBACR57009
1.5
230
665
26
1B
10
0.4
1REBACF30009
1REBACF31009
1REBACR58008
1.5
400
485
19
10
0.4
1REBACF32005
1REBACF33005
1REBACR59005
2.0
230
1670
65
10
0.4
1REBACF28010
1REBACF29010
1REBACR57010
2.0
230
855
33
1B
10
0.4
1REBACF30010
1REBACF31010
1REBACR58009
2.0
400
620
24
10
0.4
1REBACF32006
1REBACF33006
1REBACR59006
2.25
400
680
26
10
0.4
1REBACF32007
1REBACF33007
1REBACR59007
3.0
230
2525
99
10
0.4
1REBACF28011
1REBACF29011
1REBACR57011
3.0
230
1280
50
1B
10
0.4
1REBACF30011
1REBACF31011
1REBACR58010
3.0
400
880
34
10
0.4
1REBACF32008
1REBACF33008
1REBACR59008
6.0
400
1670
65
10
0.4
1REBACF32009
1REBACF33009
1REBACR59009
9.0
400
2525
99
10
0.4
1REBACF32010
1REBACF33010
1REBACR59010

00 - 08 - 0414

FLT / FLT-D RANGE
20.5 w/ins2 - 3.2 w/cm2
Applications
165
Standard features

Thermowell optional
FLT TYPE
165
12
108
12
108
Heat transfert oil, Alkaline solution, Vapour degasing.
FLT-D TYPE
mm.
Ins.
mm.
Class ATEX
Fluid TC
T3
201350
Class ATEX
Safety TC.
50300
T2
Termostat
TC regulation
50250
Safety TC.
Fluid TC
101200
FLT-D 150 TYPE

X=150
20500
Class ATEX
T4
FLT TYPE
X=0
Termostat
TC regulation
Safety TC.
0200
Ins.
20500
Termostat
TC regulation
0120
Fluid TC
Dia.
Elements
100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Exd
FLT-D 300 TYPE

X=300
0.75
230
440
17
10
0.4
1REBACF28013
1REBACF29013
1REBACR57012
1.0
230
565
22
10
0.4
1REBACF28014
1REBACF29014
1REBACR57013
1.5
230
810
32
10
0.4
1REBACF28015
1REBACF29015
1REBACR57014
1.5
230
425
16
1B
10
0.4
1REBACF30015
1REBACF31015
1REBACR58011
1.5
400
340
12
10
0.4
1REBACF32011
1REBACF33011
1REBACR59011
2.0
230
1065
12
10
0.4
1REBACF28016
1REBACF29016
1REBACR57015
2.0
230
545
33
1B
10
0.4
1REBACF30016
1REBACF31016
1REBACR58012
2.25
400
440
17
10
0.4
1REBACF32012
1REBACF33012
1REBACR59012
3.0
230
1540
60
10
0.4
1REBACF28017
1REBACF29017
1REBACR57016
3.0
230
790
31
1B
10
0.4
1REBACF30017
1REBACF31017
1REBACR58013
3.0
400
565
22
10
0.4
1REBACF32013
1REBACF33013
1REBACR59013
4.0
400
2025
79
10
0.4
1REBACF28018
1REBACF29018
1REBACR57017
4.0
400
1030
40
1B
10
0.4
1REBACF30018
1REBACF31018
1REBACR58014
4.5
400
810
32
10
0.4
1REBACF32014
1REBACF33014
1REBACR59014

00 - 09 - 0414

FLT / FLT-D RANGE
20.5 w/ins2 - 3.2 w/cm2
Applications
Heat transfert oil, Alkaline solution, Vapour degasing
Standard features

Thermowell optional
mm.
Ins.
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
Fluid TC
Termostat
TC regulation
Safety TC.
Class ATEX
0120
0200
T4
101200
50250
50300
T3
201350
20500
20500
T2
Fluid TC
Dia.
Elements
100
Maximum
Immersed
Length
No. Elem.
Phase
Voltage
Explosion-proof Exd
kW
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE

X=150
FLT-D 300 TYPE

X=300
400
2525
99
10
0.4
1REBACF28019
1REBACF29019
1REBACR57018
400
1280
50
1B
10
0.4
1REBACF30019
1REBACF31019
1REBACR58015
400
1055
41
10
0.4
1REBACF32015
1REBACF33015
1REBACR59015
400
1540
60
10
0.4
1REBACF32016
1REBACF33016
1REBACR59016
12
400
2025
79
10
0.4
1REBACF32017
1REBACF33017
1REBACR59017
15
400
2525
99
10
0.4
1REBACF32018
1REBACF33018
1REBACR59018
00 - 010 - 0414
SCREWED SELECTION TABLES

FLT / FLT-D RANGE
60 w/ins2 - 9.3 w/cm2
Applications
108
Standard features

Incoloy 800 elements
Thermowell
FLT TYPE
165
12
108
12
165
Industrial water heating
FLT-D TYPE
mm.
Ins.
Class ATEX
T3
Fluid TC
101200
Safety TC.
Class ATEX
T4
50300
Safety TC.
0200
Termostat
TC regulation
Termostat
TC regulation
0120
50250
Fluid TC
Dia.
Elements
100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Exd
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE

X=150
1.0
230
340
13
8.5
0.335
1REBACF38001
1REBACF39001
1.5
230
350
13
8.5
0.335
1REBACF38002
1REBACF39002
2.0
230
450
17
8.5
0.335
1REBACF38003
1REBACF39003
3.0
230
650
25
8.5
0.335
1REBACF38004
1REBACF39004
3.0
230
350
13
1B
8.5
0.335
1REBACF40004
1REBACF41004
00 - 011 - 0414
SCREWED SELECTION TABLES

FLT / FLT-D RANGE
60 w/ins2 - 9.3 w/cm2
Applications
108
Standard features

Incoloy 800 elements
Thermostat regulation
Thermowell optional
FLT TYPE
165
12
108
12
165
Industrial water heating
FLT-D TYPE
mm.
Ins.
Class ATEX
T3
Fluid TC
101200
Safety TC.
Class ATEX
T4
50300
Safety TC.
0200
Termostat
TC regulation
Termostat
TC regulation
0120
50250
Fluid TC
Dia.
Elements
100
No. Elem.
Maximum
Immersed
Length
Phase
Voltage
kW
Explosion-proof Exd
mm.
Ins.
FLT TYPE
X=0
FLT-D 150 TYPE

X=150
1.5
230
340
13
10
0.4
1REBACF42002
1REBACF43002
2.0
230
405
16
10
0.4
1REBACF42003
1REBACF43003
2.5
230
485
19
10
0.4
1REBACF42004
1REBACF43004
3.0
230
565
22
10
0.4
1REBACF42005
1REBACF43005
3.0
230
340
13
1B
10
0.4
1REBACF44005
1REBACF45005
4.0
400
730
28
10
0.4
1REBACF42006
1REBACF43006
4.0
400
385
15
1B
10
0.4
1REBACF44006
1REBACF45006
4.5
400
340
13
10
0.4
1REBACF46002
1REBACF47002
5.0
400
890
35
10
0.4
1REBACF42007
1REBACF43007
5.0
400
465
18
1B
10
0.4
1REBACF44007
1REBACF45007
6.0
400
1055
41
10
0.4
1REBACF42008
1REBACF43008
6.0
400
545
21
1B
10
0.4
1REBACF44008
1REBACF45008
6.0
400
405
16
10
0.4
1REBACF46003
1REBACF47003
7.5
400
485
19
10
0.4
1REBACF46004
1REBACF47004
9.0
400
585
23
10
0.4
1REBACF46005
1REBACF47005
12.0
400
790
31
10
0.4
1REBACF46006
1REBACF47006
15.0
400
950
40
10
0.4
1REBACF46007
1REBACF47007
18.0
400
1110
43
10
0.4
1REBACF46008
1REBACF47008
00 - 012 - 0414
00 - 013 - 0414
INSTRUCTION
USE AND MAINTENANCE
Dangerous Areas Electric Heaters

FLT 80 ; FLT 95
Ex II 2G d IIC T1T4
ATEX 94/9/CE Directive
CEI EN 60079-0 ; CEI EN 60079-1 Standards
12
108
108
165
FLT TYPE
125
12
108
108
165
FLT-D TYPE
125
00 - 014 - 0414
THE FOLLOWING INFORMATION IS THE MINIMUM NECESSARY FOR SAFE

USE. WE CAN SUPPLY MORE INFORMATION AFTER EVALUATION BY OUR
TECHNICAL DEPARTMENT ABOUT DIFFERENT SITUATIONS.
1 Security instructions
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 T4T1, 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
Protection mode
Protection degree
ATEX Code
Max voltage
Max current
Nominal frequency
Ambient temperature
:
:
:
:
:
:
:
Ex d IIC T4T1
IP 65
II2G
750 V
64 A
50/60 Hz
minus 20C, plus 40C (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
xxxx x II 2 G
Xxxx
II
2
G
Ex d IIC
T4T1
See following Table
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
Use cable for operating temperature >
A
C
DO NOT OPEN WHILE ENERGIZED
00 - 015 - 0414
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.
12
108
108
165
FLT TYPE
125
12
108
108
165
FLT-D TYPE
125
00 - 016 - 0414
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

Terminal enclosure
Solution to be heated
Explosion-proof (Ex d)
Concentration and characteristics
Working conditions
Working temperature
Working pressure
Max. immersed length
Vat Heater
Tank dimensions
Minimum liquid level
Internal/external TC
Environmental conditions
Particular requirement if any
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 TC
Particular requirement if any

Other comments if any
00 - 017 - 0414
Hazardous Area Flanged Heaters

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.
FM 11235
9191.IRCR
IT-75.12.6975
UNI EN 15085-2
PRODUCT TRADEMARKS
IT-75.12.6975
UNI EN ISO
3834-3 11/2006
Compliance with the

product must be
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 cant 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:
00 - 018 - 0414
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.
Heater Selection
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.
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 1520 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.
Application
Water & Very

Mild Solution
Corrosive & High

Viscous Solutions
Oil heating
Specialty
Heaters
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
Process Water or
Very Weak Solutions
pH5 to pH9
2-3%
Stainless Steel
45
Weak Solutions
5-6%
Incoloy
45
45
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 - 019 - 0414
CONSTRUCTION
Heating Element
Zoppas Industries Heating Element Technologies (ZIHET) heating elements consists of the 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.
Sheath Material:
Incoloy 800-825
Stainless steel grades 304 and 316
Titanium
Inconel 600 and 625
Mild steel
ZI can offer various options on sheath material to suit application.
To prevent fouling or carbonization, the watt density (w/ins2 or w/cm2) of the element should be limited according to the application. IRCA
standard watts density:
4, 8, 12, 15, 20, 25, 40 and 60 w/ins2 respectively 0.62, 1.24, 1.86, 2.32, 3.10, 3.87, 7.75, 9.30 w/cm2.
Heaters with special watts densities can be made to meet customers individual requirements.
Consult ZIs Technical Department for suggested watts ratings and sheath materials for a wide range of applications.
Element Supports
1. Full diameter plates:
For non-flow conditions, full diameter baffle plates are fitted to the elements to provide rigidity and maintain spacing between the elements.
2. 25% cut segmental baffles:
Used for flow applications, 25% cut segmental cross flow baffles are designed to aid heat transfer as well as support the elements. These
baffles direct the flow across the elements (over the lower and under the upper baffles) and offer very high heat transfer even under low
flow conditions.
3. Longitudinal support plates:
Instead of directing the flow across the element longitudinal, support plates are designed to direct the flow along the elements. Although
less suitable for low flow conditions, the supports are designed to minimize resistance to flow, ensuring that the pressure drop through
the heater is kept to a minimum.
Element Tube Plate/Flange Connection

Welded/brazed:
As standard for general purpose and as an alternative for process applications, the elements are brazed or welded directly to the tube
plate.
Terminal Enclosure
To protect the element/cable connections a terminal enclosure is fitted to the heater.

Certified explosion - proof for hazardous areas.
Standard cabling or conduit can be wired into the terminal enclosure without the need for an intermediate junction box and high
temperature cables. As an optional extra, anti-condensation heaters can be fitted into some of the larger terminal enclosures to keep the
element terminations dry during periods of storage or inactivity. See Table 2 on page XX for the types of enclosures that can accommodate
anti-condensation heaters.
C1 Explosion-proof - Exd
For hazardous areas, explosion-proof flanged immersion heaters can be supplied, independently laboratory tested by the 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 than 158F (70C), 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 a thermostat of which the characteristics are listed on the table below.
Zoppas Industries have to supply a safety thermostat manual reset into the terminal enclosure.
Thermocouples or PT100 can be supplied instead of the thermostats (on request).
00 - 020 - 0414
Supply Safety Thermostat

Type
Part No.
Range
Note
Safety
570968671
+52C 3C
Manual reset
Safety
570943160
+85C 3C
Manual reset
Safety
571092931
+90C 4C
Manual reset
Safety
571093491
+123C 4C
Manual reset
Safety
571223670
+150C 4C
Manual reset
Safety
570857302
+0C 200C
Manual reset
Safety
570895640
+20C 3C
Manual reset
Optional Regulation Thermostat

Type
Part No.
Range
Note
Regulation
571064270
-30C+30C
SPDT
Regulation
570142140
+4C+40C
SPDT
Regulation
570977491
+30C+90C
SPDT
Regulation
571275710
+30C+120C
SPDT
Regulation
571086111
+50C+250C
SPDT
Regulation
571086111
+50C+320C
SPDT
Regulation
570898460
+20C+500C
SPDT
Testing
All ZIHET controls systems and components are fully tested.

In accordance with the proposed EN for industrial electric immersion heaters, all Zoppas Industries Heating Element Technologies flanged
immersion heaters are subjected to pressure, continuity, insulation resistance and dielectric tests.
Test certificates are not supplied as standard, but are available on request.
00 - 021 - 0414
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.
TYPE
VOLUME
SURFACE
POWER
FLGT
dm3 (min-max)
m3 (min-max)
FLGT 50
0.220.45
0.0260.041
---
N.A.
FLGT75
0.71.4
0.0520.081
---
N.A.
FLGT100
0.91.7
0.0360.095
---
N.A.
FLGT125
1.32.5
0.0840.122
---
N.A.
FLGT150
1.63.2
0.0970.139
---
N.A.
FLGT175
2.54.8
0.1260.180
20
---
FLGT200
3.26.2
0.1500.212
20
---
FLGT250
7.512.5
0.2540.331
40
---
FLGT300
10.518
0.3260.417
60
---
FLGT350
1525
0.4300.536
80
---
FLGT400
18.532
0.5190.639
100
---
FLGT450
2440
0.6190754
100
---
00 - 022 - 0414
NOTES

European ATEX Directive 94/9/CE
Electrical and non-electrical equipment and protection system

x
...
Ex
Use of equipment in Type of

Potentially explosive atm protection see
CE Marking following list

Identification number of
Notified body, when appropriate

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 -2040C
For Dust Class put the
maximum surface
temperature after the
T example T100C

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 - 023 - 0414
Worldwide Local Supplier
Headquarters
ZOPPAS INDUSTRIES Partner

Experience Zoppas Industries increasing efficiency using
lean enterprise across all facilities and departments.
Access our state-of-the-art laboratory facilities with over 30 years
design experience.
Manufacturing
facilities
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 customers request.
We at ZOPPAS INDUSTRIES put you in the front seat of globalization - sourcing your local needs globally.
FM 11235
9191.IRCR
00 - 024 - 0414
9196.IRC6
PRODUCT TRADEMARKS
IT-75.12.6975 IT-75.12.6975
UNI EN 15085-2
UNI EN ISO
3834-3 11/2006
Compliance with the

product must be
RICA - Via Podgora, 26 - 31029 Vittorio Veneto (TV) - Italy

Tel. +39 0438 9101 - Fax +39 0438 912272 - 912236
www.zoppasindustries.com - rica@zoppas.com

Immersion Heaters Haz Area UK+USA

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IMMERSION HEATERS

IMMERSION HEATERS HAZ AREA

Hazardous Area Screw Plug Heaters

Compliance with the

How To Use This Catalogue

Water & Very

Corrosive & High

pH6 to pH8 Neutral

IMMERSION HEATERS HAZ AREA

TABLE 1 (Screwed head sizes for immersion heaters)

Supply Safety Thermostat

Optional Regulation Thermostat

IMMERSION HEATERS HAZ AREA

SCREWED SELECTION TABLE

rugged industrial construction

Heavy duty oils, raw crude oils, naphta, aniline etc.

FLT-D 150 TYPE

FLT-D 300 TYPE

SCREWED SELECTION TABLE

rugged industrial construction

Medium viscosity oils, non-flowing heat transfer oil etc.

FLT-D 150 TYPE

FLT-D 300 TYPE

*1B= 1 Element U bent

IMMERSION HEATERS HAZ AREA

SCREWED SELECTION TABLE

rugged industrial construction

Medium viscosity oils, non-flowing heat transfer oil etc.

FLT-D 150 TYPE

FLT-D 300 TYPE

*1B= 1 Element U bent

SCREWED SELECTION TABLE

rugged industrial construction

Heat transfert oil, Alkaline solution, Vapour degasing.

FLT-D 150 TYPE

FLT-D 300 TYPE

*1B= 1 Element U bent

IMMERSION HEATERS HAZ AREA

SCREWED SELECTION TABLE

Heat transfert oil, Alkaline solution, Vapour degasing

rugged industrial construction

FLT-D 150 TYPE

FLT-D 300 TYPE

SCREWED SELECTION TABLES

rugged industrial construction

Industrial water heating

FLT-D 150 TYPE

*1B= 1 Element U bent

IMMERSION HEATERS HAZ AREA

SCREWED SELECTION TABLES

rugged industrial construction

Industrial water heating

FLT-D 150 TYPE

*1B= 1 Element U bent

IMMERSION HEATERS HAZ AREA

Dangerous Areas Electric Heaters

THE FOLLOWING INFORMATION IS THE MINIMUM NECESSARY FOR SAFE

2 Conformity to the directive 94/9/CE

survey organization number ATEX (CESI)

Use cable for operating temperature >

DO NOT OPEN WHILE ENERGIZED

IMMERSION HEATERS HAZ AREA

IMMERSION ELECTRIC HEATERS: DATA SHEET