When a tank heater fails, it is almost never the wire — it is scale, chloride or a watt density too high for the water. We size the sheath material and surface loading against your water chemistry, then test leakage current after the humidity cycle.
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Ranges we hold every day. Anything outside them is possible — it just needs a conversation before the drawing.
| Power | 3 – 36 kW · 230 V single phase or 400 V 3-phase (star / delta) |
|---|---|
| Flange | DN50 / DN80 / DN100, 1.5" – 4" ANSI, custom square flange |
| Sheath material | SS316L (low chloride), Incoloy 800 / 840 (high temp, hard water), titanium (sea water, brine) |
| Element diameter | Ø8 / 10 / 12.5 / 16 mm, 3 / 6 / 9 elements per flange |
| Watt density | Water 6–12 W/cm² · Soft water 8 W/cm² · Hard water 4–6 W/cm² · Oil 3–6 W/cm² · Alkaline cleaning 5–8 W/cm² |
| Immersion length | 200 – 2000 mm below flange |
| Thermostat | Built-in rod or capillary thermostat 0–90 °C / 0–120 °C, or Pt100 pocket |
| Safety | Manual reset over-temperature cut-out, earth stud, low-level cut-out wiring option |
| Terminal housing | IP54 steel or polycarbonate box, IP65 on request |
| Insulation resistance | ≥ 100 MΩ at 500 V DC after humidity test |
| Leakage current | < 0.5 mA at 1.06 × rated voltage, measured wet |
| Standards | IEC 60335-1, IEC 60335-2-6 (ranges), CE / RoHS; PED on request |
Four things we control in the process, and four reasons elements fail in the field.
NiCr coil, 3-phase resistance matched
MgO compacted, terminal end potted
Elements welded to flange, leak tested
Thermostat, cut-out, housing, earth
Hipot, IR, wet leak current, pressure
200 pcs repeat size · 500 pcs new tooling · samples from 1 pc
After drawing confirmation, including test data
Engineering-backed quote with the wall thickness and watt density stated
Acid descaling reaches the MgO at the terminal end where the seal has aged. Moisture enters, insulation resistance drops, and the unit trips on leakage current. Our terminal end is potted and sealed for this cycle — and we test leakage current wet, not dry.
4–6 W/cm². Above 6 W/cm² in water over 20 °dH, scale builds fast enough that the sheath overheats between service intervals.
Yes, Ø8–16 mm titanium sheaths for sea water, brine and chloride above 500 mg/L. Lead time is about 20 days.
Standard builds include a rod thermostat with a manual-reset over-temperature cut-out and an earth stud. Pt100 pocket and IP65 housing are options.
CE declaration, RoHS statement, and a test sheet per unit with hipot, insulation resistance, resistance value and wet leakage current. PED documentation is available for pressure-boundary flanges.
Send a drawing, a sample photo or just the application — we will tell you what watt density and sheath you need before quoting.