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Multicell Heaters
Multicell Heaters
The advanced design of the multicell insertion heater from Watlow offers three major advantages: extreme process temperature capability, independent zone control for precise temperature uniformity, and loose fit design for easy insertion and removal. Performance Capabilities • Has been engineered to achieve process temperatures above 2200°F (1204°C) • Up to eight independently controllable zones

Features and Benefits • Multiple, independently controllable zones allow process temperature uniformity not possible with any other single sheathed heater. • The heater’s radiant design allows for loose insertion in boiling holes, and piping holes. Since it will not bind or seize in the hole, the heater is easily removed and replaced with minimal down time. • The oxidized sheath provides high emissivity and improves the heater’s performance as oxidation increases. • Individually metal-sheathed coils are swaged into a larger, high temperature alloy outer sheath for maximum protection against element burnout through the outer sheath.

High Grade MgO Insulation Zone 1 High Temperature Alloy for Outer Sheath

Multicell Heaters

Resistance Wire

Cross Section Zone 3 Independently Controllable Heated Zones Zone 2

• Satisfies long heater needs (40 foot plus) providing reduced wiring. • Quick disconnect plug and jack permit fast replacement of individual elements while the press stays at operating temperature.

• Special bending capabilities solve unusual machinery needs and keep leads away from heated zones. • Flexible leads up to 986°F (530°C).

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Multicell Heaters
Multicell Heaters
Applications • Hot gas generators • Hot isothermal forming • Radiant heating processes • Glass tempering • Soil remediation • Hot forging dies • Long heater needs (40 foot plus) • Heated platens • Aluminum processing • Fluidized bed processes • Glass bending, forming, treating • Hazardous waste treatment systems • Super plastic forming • Heated platens (single and multiple zones) • Heat treating processes • Super plastic forming with diffusion bonding

Terminations

Applications and Technical Data
Definition of Terms Cold Toe: A physical minimum requirement of 1.6 ± 5⁄16 Independent Zone: Up to three, separately controlled zones which can be of varying lengths and wattages Heated Length: The combined sum of all independent zones Wattage: Ratings are the combined sum of all independent zones
Lead Wire Length

Sheath Length Heated Length ±2% No-Heat Section Independently Controlled Zone Independently Controlled Zone Independently Controlled Zone

1.6 ± /16
5

Cold Toe

Note: For heated toe see page 201.

Maximum Allowable Watt Densities Single Zone ➀
Platen Or Oven Temperature In Air—°C
200 70 400 600 800 1000 10

Maximum Allowable Watt Densities Multi Zone ➀
Platen Or Oven Temperature In Air—°C
200 70 400 600 800 1000 10

A B C
8

A B

60

60

C
W/cm 2 On Heater Element
50

W/in 2 On Heater Element

W/in 2 On Heater Element

D
50

D

8

40

6

40

6

30 4 20 2 10

30 4 20 2 10

0

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20

0

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20

Process Temperature—°F X 100

Process Temperature—°F X 100

Note: Shaded area is standard, Non-shaded area consult factory. A = 0.935 inch diameter, 240VÅ(ac), 3-phase B = 0.685 inch diameter, 240VÅ(ac), 3-phase C = 0.935 inch diameter, 480VÅ(ac), 3-phase D = 0.685 inch diameter, 480VÅ(ac), 3-phase

Note: Shaded area is standard, Non-shaded area consult factory. A = 0.935 inch diameter, 240VÅ(ac), 3-phase B = 0.685 inch diameter, 240VÅ(ac), 3-phase C = 0.935 inch diameter, 480VÅ(ac), 3-phase D = 0.685 inch diameter, 480VÅ(ac), 3-phase

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Multicell Heaters
Multicell Heaters
Applications and Technical Data
Continued Physical Design Parameters All bending of a multicell heater is restricted to the cold area of the heater. All bend radii points must be one inch (25 mm) from the hot/ cold junction.
E

“L”
90° No-Heat

Angle

R

Straight Length Heated Length

No-Heat Cold

Straight Length Heated Length

l
1" (25 mm) Minimum

1" (25 mm) Minimum

l

Droop
Straight Length Cold No-Heat
X

Crank
r X

Heated Length


R

Straight Length Heated Length

R E r

Y

L E
No-Heat Cold

1" (25 mm) Minimum

l

Straight
l
Straight Length Heated Length

2" (51 mm) Minimum Cold

Multicell Heaters

Special high-temperature R&D project with replaceable external thermocouple capability.

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Multicell Heaters
Multicell Heaters
Applications and Technical Data
Physical Design Parameters Continued
Diameter inches Bending Style Sheath Length Min./Max. inches (mm) 8 180 (203) (4572) Minimum No-Heat Length inches (mm) 2 7 1⁄2 9 3⁄4 17 12 2 (51) (191) (248) (432) (305) (51) Total Heated Length Min./Max. inches (mm) 6 160 6 172 1⁄2 6 170 1⁄4 6 163 6 168 10 64 (152) (4064) (152) (4382) (152) (4324) (152) (4140) (152) (4267) (254) (1626)

0.935 0.935 0.935

Straight Angle L Crank Droop Straight

(343) 13 1⁄2 180 (4572) 15 3⁄4 (400) 180 (4572) 23 180 18 180 12 66 (584) (4572) (457) (4572) (305) (1676)

Weldments to the Multicell Heater Element
1" (25 mm) 1" Min. (25 mm)
Min. All Weldments Must Be 1 inch (25 mm) Minimum From The Hot/Cold Junction Into The Cold Section

0.935 0.935 0.935 HOT-TOE

Cold Section No-Heat

Hot Cold Junction Hot Cold Junction

HTD Section HTD Section

Symbol Min. Length inches (mm)

E 4 (102)

r 2 1⁄2 (38)

X 1 1⁄2 (38)

R 2 1⁄2 (38)

Y 1 (25)

l 12 (305)

Tabs, rings and brackets are used to hold the heater in place and keep it from creeping.

Zones Min. Heated inches (mm)

1 6 (152)

2 6 (152)

3 6 (152)

N

. 1" Min ) (25 mm o-Heat

Diameter inches

Bending Style

Sheath Length Min./Max. inches (mm) 8 180 12 1⁄2 180 14 180 18 180 15 1⁄2 180 (203) (4572) (318) (4572) (356) (4572) (457) (4572) (394) (4572)

Minimum No-Heat Length inches (mm) 2 6 1⁄2 8 12 9 1⁄2 (51) (165) (203) (305) (241)

Total Heated Length Min./Max. inches (mm) 6 178 6 173 1⁄2 6 172 6 168 6 170 1⁄2 (152) (4521) (152) (4407) (152) (4369) (152) (4267) (152) (4331)

0.685 0.685 0.685
. 1" Min ) (25 mm o-Heat

Straight Angle L Crank Droop

0.685 0.685

N

Symbol
. 1" Min 5 mm) (2 o-Heat

E 4 (102)

r 2 1⁄2 (38)

X 1 1⁄2 (38)

R 2 1⁄2 (38)

Y 1 (25)

l 12 (305)

Min. Length inches (mm)

N

Zones Min. Heated inches (mm)

1 6 (152)

2 6 (152)

3 6 (152)

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Multicell Heaters
Multicell Heaters
Termination Standards
Potting Sleeves
B Heater O.D. inches 0.685 0.935 0.935 ➀ 3 wire only Dimension A inches (mm)
3

Dimension B inches (mm) 1 1⁄2 1 1⁄2 1 1⁄2 (38) (38) (38)

Zone 1 1 1

Phase 1 1 3➀

Type No. 61L 91L 91L

A

⁄4 1 1

(19) (25) (25)

Potting Cups
B

Heater O.D. inches 0.685 0.685 0.685 0.685 0.935 0.935 0.935 0.935

Dimension A inches (mm) 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 (35) (35) (35) (35) (35) (35) (35) (35)

Dimension B inches (mm) 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 1 3⁄8 (35) (35) (35) (35) (35) (35) (35) (35)

Zone 2 3 1 2 2 3 1 2

Phase 1 1 3 3 1 1 3 3

Type No. 62L 62L 62L 62L 92L 92L 92L 92L

A

Ceramic Wedge with 10-32 Threaded Terminals
B

Heater O.D. inches 0.685 0.935

Dimension A inches (mm) 1 1⁄4 1 5⁄8 (32) (41)

Dimension B inches (mm) 1 1⁄4 1 5⁄8 (32) (41)

Zone 1 1

Phase 1 1

Type No. 61T 91T

A

Potting Cup with 10-32 Threaded Terminals
C B

Multicell Heaters

Heater O.D. inches 0.685 0.935

Dimension A inches (mm) 1 3⁄8 1 3⁄8 (35) (35)

Dimension B inches (mm) 1 3⁄8 1 3⁄8 (35) (35)

Dimension C inches (mm)
5 5

Zone 1 1

Phase 3 3

Type No. 62T 92T

⁄8 ⁄8

(16) (16)

Note: All threaded terminals are supplied with mating nuts and washers.
A

Potting Cup for Right Angle Exit
B

Heater O.D. inches 0.685 0.935

Dimension A inches (mm)
3

Dimension B inches (mm) 1 1⁄2 1 1⁄2 (38) (38)

Zone 1 1

Phase 1 or 3 1 or 3

Type No. RAE1 RAE2

⁄4 1

(19) (25)

A Lead wires

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Multicell Heaters
Multicell Heaters
Termination Assemblies
All termination assemblies are available with potting sleeves or cups, with or without armorflex lead wire protection. Please specify potting vessel and lead cover option when ordering.

Omitted Connectors

Ring Spade Connector Connector

Female Faston

Male Faston

Twist-Lock® Plug

Plug and Socket Connector

Termination illustrations shown with armorflex covering.

Options
Plug and Socket and Twist-Lock® Plug Variations Two zone heaters requiring a quick disconnect plug will typically be supplied with a four contact plug and socket while three zone heaters will be supplied with a six contact plug and socket. Twist-Lock® plug variations are typically supplied with single zone multicell heaters. When ordering a Twist-Lock® plug, please specify the NEMA type as shown below. For any other plug variations, please contact the factory. Note: Mating connectors are also available for plug terminations listed. Contact factory.

Male Plug P404-CCT P406-CCT 4570C 4720C 5266C 5666C 7102C 7545C 7567C

Zones 2 3 1 1 1 1 1 1 1

Type 4 Wire 6 Wire 3 Wire 3 Wire 3 Wire 3 Wire 2 Wire 2 Wire 3 Wire

Voltage 600 600 250 125 125 250 250 250 125

Amperage 30 30 15 15 15 15 20 15 10

Blade Type Straight Straight Twist-Lock® Twist-Lock® Straight Straight Twist-Lock® Twist-Lock® Twist-Lock®

Plug and Socket

1" (25 mm)

1.44" (37 mm)

1" (25 mm)

6 Contacts

4 Contacts

Twist-Lock®
X W Y

Straight

W G F W W W

Twist-Lock® is a registered trademark of Hubbell Incorporated.

4720C

4570C

7567C

7102C

7545C

5266C

5666C

F.O.B.: Hannibal, Missouri

How to Order To order multicell insertion heaters, please specify: • Sheath diameter • Heater length • Configuration • Potting vessel 200

• • • • • •

Connector Lead cover Flexleads Watts Volts Lead wire length (12-inch standard)

• NEMA type for Twist-Lock®/straight plugs, if required • Process temperature • Control system • Ground voltage Availability Made-to-Order: Consult Watlow

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Multicell Heaters
Multicell Heaters
HOT-TOE Multicell Heaters
Watlow’s new HOT-TOE multicell heater eliminates the unheated section typically found at the end of standard multicell constructions. Benefits of the HOT-TOE multicell are threefold: • heat to the full length of the assembly • optimum heat distribution for extended heater life • double wall ground fault isolation Multicell heaters have always offered many advantages including extreme process temperature capabilities, independent zone control and a loose fit design for easy insertion and removal. Now Watlow’s multicell heater line includes another valuable heater characteristic with the addition of the HOT-TOE multicell. This HOT-TOE feature allows for optimum heat distribution with a lowered watt density for shorter length designs. By heating the full section of the unit, temperatures for internal wires are lower, therefore improving heater life. Due to the design of the HOT-TOE multicell, ground fault isolation over the heated portion can also provide improved heater safety. Watlow’s HOT-TOE multicell heaters can be engineered to achieve process temperatures to 1900°F (1037°C) and can satisfy 240 volt, single-phase power requirements for the process industry. Designed to handle applications that demand high voltages and wattages, these multicell heaters have a rugged construction that permits the heaters to survive in conditions that would normally be lethal to many other heater types. U.S. Patent Pending Performance Capabilities • Sheath temperatures to 1900°F (1038°C) • Heated toe section Features and Benefits • Inconel® 600, Incoloy® 800 or equivalent sheath material and a special internal construction assures high temperature performance and corrosion protection in static air applications. • Available in 0.935 inch (23.7 mm) diameter it is configurable to existing tubular designs that may be experiencing short life. • Single-phase, single zone, 240 volts individual metal-sheathed coils swaged into hightemperature outer sheath and solves unusual machinery requirements. • Single-ended termination lead wires can be installed into flanges and screw plugs similar to standard product configurations. • Bendable in standard multicell configurations makes it easy to apply in a wide variety of applications. Applications • SPF single zone platens • Radiant heating • Drying • Environmental—VOC abatement • Process air heating: duct heaters, circulation heaters • Vacuum • Flue gas cleaning (desulfurization) • Fluidized beds • Light metals extrusion

Multicell Heaters

Inconel® and Incoloy® are registered trademarks of Special Metals Corporation.

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Multicell Heaters
Multicell Heaters
HOT-TOE Multicell Heaters
Maximum W/in 2 On Heater Element
70
A = HOT-TOE, 0.935" diameter, 240VÅ(ac), 1-phase

Platen Or Oven Temperature In Air (°C )
200 400 600 800 1000 10

60 8

Single Zone HOT-TOE Heater* This chart should be used to verify the correct watt density for a platen or oven application assuming no air flow. To use this chart, select platen or oven temperature from X axis. Find the intersection with curve A. Determine maximum watt density by reading left or right to the intersection with Y axis.

50

40

6

30 4 20 2 10

0

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20

Platen or Oven Temperature In Air (°F X 100)

Note: Shaded area is standard. Non-shaded area, consult factory. * Other designs and voltages with higher temperature capabilities are available. Consult factory.

Sheath Temperature Comparisons
1900˚F 1800˚F

HIGH TEMPERATURE TUBULAR

HOT-TOE MULTICELL HEATER

1400˚F

*Assuming normal design practices. F.O.B.: Hannibal, Missouri

How to Order To order, please specify: • Volts • Watts • Heater sheath material • Lead wire temperature rating • Heated length 202

TYPICAL TUBULAR HEATER

Availability Made-to-Order: Five to six weeks • • • • No-heat length—lead end only Overall sheath length Formation—if desired Mounting option, stop bracket, etc. • Process temperature

For Multicell Radiant Heater Specification Data Sheet see FAX REPLY sheet 1470.

Maximum W/cm 2 On Heater Element

A

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