Electric heating elements have not changed their design for decades and remain in demand in heating equipment. The shape of these devices and construction materials change, but the principle of operation and efficiency remain unchanged.
When choosing heating elements for heating, it is important to know their types and operation scheme, on which the correct functioning of the equipment depends.
- Calculation of device power
Purpose of heating elements
Electric heating elements have gained popularity due to their versatility and high efficiency. All the electricity they consume is used for its intended purpose - heating the surrounding space.
The main heating devices where heating elements are used are:
- Portable and stationary oil electric heaters.
- Water heating radiators.
- Bathroom heated towel rails.
- Electric fireplaces.
- Electric convectors.
- Electric boilers.
The specified equipment can be used as a main or additional heating source. It is inexpensive, easy to install and does not require special skills to operate.
You can connect the heating element to a cast iron central heating radiator after disconnecting the common riser. This device can be used for main and additional heating
Internal structure of electric heaters
It is convenient to consider the internal structure using the example of a tubular model. An electric heater is a ceramic or metal tube filled with a thermal conductor with a spiral located inside.
In the place where the tube is fixed to the flange there are insulating bushings that make it impossible for the conductive spiral to contact the heating element body.
Most TEN models use similar components, but their durability may vary depending on the build quality
The electric heater is mounted primarily with a flange connection, which allows the internal environment of the heating device to be sealed from the external space. The disadvantage of this design is the impossibility of replacing the spiral if it burns out internally.
Marking of heating elements
Example of heating element designation:
- Heating element 120 V 13 / 1.0 T 220
| 120 — expanded length ( L ) in centimeters; | 1,0 — rated power in kilowatts; |
| B - designation of the length of the contact rod in the seal Lk ; | T - designation of the heated medium and shell material; |
| 13 — shell diameter D in millimeters; | 220 — nominal voltage in volts; |
| Symbol and nominal length of the contact rod in the termination | ||||||||
| Length designation | A | IN | WITH | D | E | F | G | H |
| Length, mm | 40 | 65 | 100 | 125 | 160 | 250 | 400 | 630 |
| Designation of the heated medium, maximum watt load, sheath material | ||||
| Symbol | Heated medium | Character of heating | Maximum watt load, W/cm2 | Shell material |
| J | Water, weak acid solution (pH 5 to 7) | Heating, boiling with a maximum temperature on the shell of 100 ° C | 15 | Stainless steel |
| P | Water, weak alkali solution (pH 7 to 9) | Heating, boiling with a maximum temperature on the shell of 100 ° C | 15 | Carbon steel |
| S | Air, gases and mixtures of gases | Heating in a quiet gas environment to a temperature on the heating element shell of 450 °C | 2,2 | Carbon steel |
| T | Air, gases and mixtures of gases | Heating in a quiet gas environment with a temperature on the shell of the heating element above 450 °C | 5,0 | Stainless steel |
| O | Air, gases and mixtures of gases | Heating in an air environment moving at a speed of 6 m/s to a temperature on the heating element shell of 450 °C | 5,5 | Carbon steel |
| K | Air, gases and mixtures of gases | Heating in an air environment moving at a speed of at least 6 m/s with a temperature on the shell of the heating element St. 450 °C | 6,5 | Stainless steel |
| L | Casting molds, compression molds | The heating element is inserted into the groove, there is guaranteed contact with the heated metal, the temperature on the heating element shell is up to 450 ° C | 5,0 | Carbon steel |
| Z | Fats, oils | Heating in bathtubs and other containers, temperature up to 250 °C | 3,0 | Carbon steel |
| W | Low-melting metals and alloys | Heating and melting in baths and other containers with temperatures on the heating element shell up to 450 °C | 3,5 | Carbon steel |
| D | Saltpeter (double shell) | Heating to a temperature of 600 °C | 3,5 | Stainless/black steel |
| N | Saltpeter | Heating to a temperature of 600 °C | 3,5 | Stainless steel |
| Typical forms of heating elements |
Option to complete the heating element with mounting fittings
The fitting (threaded bushing with a thrust flange) is fixed to the electric heater by pressing, soldering or welding (depending on the operating conditions of the heating element in a particular heated environment).
The most commonly used fittings are the sizes given in the table:
| Diameter of the heating element shell, mm | M - thread size | L - length, mm | S—flange thickness, mm | D—flange diameter, mm |
| 8,5 | M 14 x 1.5 | 18 | 3 | 20 |
| 10 | G 1/2″ | 24 | 4 | 30 |
| M 16 x 1.5 | 18 | 3 | 25 | |
| 13 | G 1/2″ | 24 | 4 | 30 |
| M 22 x 1.5 | 22 | 4 | 30 | |
| 16 | M 24 x 1.5 | 22 | 4 | 30 |
| 18,5 | M 27 x 2.0 | 30 | 4 | 36 |
Typical forms of contact terminals
The contact rod is connected inside the heating element to the heating element (spiral), and outside it has a fastening unit for the supply wires (washers and nuts).
Most often, rods with M4 or M5 threads are used.
Heating elements with a shell diameter of less than 8.5 mm are equipped with contact terminals made in the form of petals.
How the device works
The heating element works according to the following principle. When connected to the network, the internal spiral is heated and energy is transferred to the thermal conductor and the outer shell. The heat is then transferred to the surrounding fluid, air or solid material.
When heating a heating element immersed in oil or water, convection currents are created around the tube, which mix the coolant and contribute to its uniform heating.
Electric boilers are known for their reliability and maintainability. They do not have many complex parts, so they are easy to operate and maintain.
In liquid-free heating devices, the heating temperature is usually limited so as not to damage surrounding parts or cause a fire.
To speed up heat transfer, they often use a fan, which circulates air both inside the device and in the room surrounding it.
Types of heating elements for heating devices
The simplicity of manufacturing TENs does not always translate into convenience for users. Many manufacturers produce electric heaters with a specific shape and mounting. If they break, they are quite difficult to buy in a store. Therefore, to make the right choice, it is necessary to study all possible design options.
Tubular models for domestic heating
The tubular design of electric heaters is the most common in household heating equipment.
Heat transfer in them can occur using: convection, infrared radiation or thermal conductivity.
Ready-made heating elements with a regulator and their own power cord can only be purchased if you are sure that the wire length will be sufficient
The shape and length of the tube in such devices can be any and is dictated only by design features. Its most common characteristics are:
- diameter – 5-18 mm;
- length – 200-6000 mm;
- shell material – steel, stainless steel, ceramics, copper;
- power – 0.3-2.5 kW.
Heaters with a power of more than 2.5 kW are not used in household heating devices, because apartment wiring simply cannot withstand the greater load.
Finned version of electric heaters
Finned devices are a modification of a tubular heating element. Their feature is the presence of many thin steel plates located along the entire length of the device.
This design dramatically increases the area of contact with the environment, ensuring a high heating rate.
Finned heating elements are more expensive and require more work space, but provide higher consumer characteristics of heating equipment
Finned models are used mainly in air-type heaters. They provide a quick increase in room temperature, especially with a built-in fan.
Block designs of heating elements
The block version consists of several tubular heaters combined on the basis of a single mounting.
When choosing block heating elements, special attention must be paid to their power and the ability of the boiler with a pump to provide heat removal
This design is used by a combination of two factors:
- The need for increased device power and high heating rate of the working environment.
- The impossibility of rapid transfer of thermal energy from the spiral to the environment due to the small area of the outer shell.
In fact, in a block heater, the load on each heating tube is reduced and the heat transfer rate increases. Such devices are part of household heating boilers and industrial electric heating installations.
The power of block models can be 5-10 kW, so when placing them in an apartment, it is necessary to extend an additional electrical cable into the room.
Cartridge-type devices
Cartridge heating elements have the form of a tube with one free end, which is due to the peculiarity of their installation.
The outer shell is usually made of polished steel to provide maximum contact with the surrounding material. Such tubes are tightly inserted into the corresponding hole in the heating device.
The main disadvantage of cartridge heating elements is the small area of the heat-transferring surface, which requires the use of specific methods for removing thermal energy
Fixation of cartridge models is carried out mainly using a flange connection. They are usually used in industry to heat the working parts of extruders.
There are other structural types of heating elements, but they are used mainly in industrial production and do not affect the topic under consideration.
What heating elements are used in electric boilers and water heaters.
Previously, I wrote a separate article on electric boilers, which I also recommend reading. Well, okay, let's get down to business. Blocks of heating elements are used as heating elements for electric boilers. They consist of several heaters, which are combined together with a nut. To make it clearer, look at the picture below:
The nut is available in the following diameters: 1.25 inches, 2 inches and 2.5 inches. Such a block is sealed using an annular rubber seal (if it is provided structurally) or by winding with thread or FUM tape. As for the tubes, they can be made of carbon or stainless steel. Stainless steel is more expensive, but lasts much longer than black steel. With powers up to 9 kW, units with a supply voltage of 220 V can be installed inside the boilers. With higher power, units with a three-phase voltage of 380 V are installed in the boilers.
Now let's move on to heating elements for water heaters. They can be made on a threaded nut (most often 1.25 inches in diameter) or on a flange that is clamped with bolts. Look at the picture below:
Heating element for a water heater on a flange
There are also “dry” heating elements. They are isolated from water in special flasks and manufacturers claim that they are safer than regular ones. Although all their safety advantages can be negated by installing an RCD that will turn off the power if there is a leakage current greater than 30 mA.
"Dry" heating element
Additional functions of electric heaters
Above we discussed the simplest designs of devices that do not have any built-in adjustment mechanisms.
The thermoregulation unit can have mechanical or electronic automation. The latter is more accurate, but is demanding on the parameters of the home electrical network
But electric heaters can be equipped with simple automation that provides the device with additional functions.
These include:
- Thermoregulation . Heaters with a built-in thermostat for heating have a temperature sensor that is triggered when the working environment is heated to a certain level. The electric heater is adjusted from the outside of the flange.
- Antifreeze . This function is provided by a simplified thermostat, which operates only when the temperature drops to 0-2°C. It prevents water from freezing in heating pipes, consuming a minimum of electricity.
- Turbo heating , which provides forced heating of the working environment during the initial start-up of equipment. It must be remembered that the electrical wiring of the room must withstand a short-term increase in power.
There are not many devices that support additional functions, because the operation of heating devices as a whole is often regulated using a separate automation unit.
How to choose a heating element
When choosing a heating element, you need to pay attention to its power, design, tube length and the availability of additional capabilities. Therefore, before purchasing, you need to find out as much as possible about all its characteristics.
Calculation of device power
The high power of a heating element is not always a positive quality. When choosing, it is important to consider several factors that are related to the level of energy consumption:
- maximum heat transfer power of the heating device as a whole;
- electrical wiring options;
- room volume.
You cannot buy a device with a power that is more than 75% of the maximum heat transfer level of heating equipment.
For example, there is a radiator with 10 sections, each of which releases 150 W of heat to the air, a total of 1.5 kW. When installing an electric heater with a power of 2 kW into it, the surface of the battery will not be able to quickly release all the energy generated.
As a result, the heating element will constantly turn off due to overheating.
The reason for the rapid breakdown of the heating element may be the incorrect choice of device power. As a result of systemic overheating of the coil, it burns out over time.
In apartments with worn-out wiring, the constant load on the outlet should not exceed 1.5-2 kW, otherwise it may catch fire and lead to dire consequences. Therefore, before purchasing a heating element, you need to check the condition of the wiring and, if necessary, replace it.
When the issue with the electrical network and equipment capabilities has been resolved, you can begin to calculate the required power to maintain a comfortable temperature in the room.
In well-insulated houses and apartments, a level of 40 W/m3 will be sufficient. And if there are cracks in the windows, the heating power should be increased to 60-80 W/m3.
You can buy a specific model only after taking into account all the energy factors described above.
Consideration of design features
Most heating elements have an alloy steel shell, which provides strength and resistance to corrosion. Copper devices are used primarily in water heaters, although there are no restrictions on their use in homemade radiators.
In cast iron and steel radiators, the use of heating elements made of non-ferrous metals is undesirable. This can lead to accelerated wear of materials and connections.
Also, when choosing, it is necessary to take into account the direction of the thread of the plug, which can be right or left. Different models of electric heaters also differ in flange diameter. They can range in size from 0.5 to 1.25 inches.
Typically, a heating element from a good manufacturer comes with a brief instruction manual that describes its design parameters. Studying them will help you buy a device that will exactly fit your existing heating equipment.
Heating tube length
The length of the tube is one of the main characteristics that determine the efficiency of the device.
Its large length with equal power leads to an increase in the surface area of the electric heater and acceleration of heat exchange with the working environment. This has a positive effect on the durability of the heating element and the coolant circulation rate.
Heating elements with a long tube are ideal for installation in homemade registers, which are convenient for heating large rooms and outbuildings
It is desirable that the tube runs along the entire length of the working area of the heating device, without reaching the opposite wall by 6-10 cm. This recommendation will allow you to quickly and evenly warm up the coolant.
Availability of additional functionality
It is not always necessary to overpay for the additional capabilities of heating elements. If the heating device is used as an auxiliary device and does not have its own built-in automation, then purchasing a model with a thermostat makes sense.
But if a radiator or electric convector has its own temperature sensors and temperature control mechanisms, additional functions will remain unclaimed.
The electronics built into the heating element plug must have safety mechanisms so that if the control board breaks down, a fire does not occur.
Therefore, it is recommended to purchase expensive electric heaters with built-in automation only if there is a clear need for such equipment.
As for the manufacturers of heating elements, their choice is not important. The main suppliers are companies from Russia, Ukraine, Turkey and Italy. The quality of their products is approximately the same, so there is no point in overpaying for the brand.
Tubular electric heaters (TEH)
Tubular electric heaters (TEH)
Tubular electric heaters (TEH) are designed to heat various media by convection, thermal conductivity and radiation by converting electrical energy into thermal energy and are used as components in industrial installations and household heating devices.
The design of a tubular electric heater with a circular cross-section consists of a heating element located inside a metal shell (a spiral made of a high-resistance alloy) with contact rods. The heating element is insulated from the shell by compressed electrical insulating filler. To protect against moisture from the environment, the ends of the heating elements are sealed. The contact rods are insulated from the shell by dielectric insulators.
D — shell diameter L — expanded length of the heating element Lk — Length of the contact rod in the embedment
An example of a symbol for heating elements according to GOST-13268 :
In terms of configuration, design and purpose, the heating elements offered by our company have a wide range of parameters: - operating voltage from 48 to 380V; — by rated power from tens of watts to tens of kilowatts; - length from a few centimeters to 4 meters; — in configuration , both straight and bent in different planes; — for its intended purpose for heating air, liquids, oil, molds, melting fusible metals, nitrate; - on fastening elements and the shape of contact terminals , both standard and specially required.
Since most tubular electric heaters are individual in their specificity, we accept orders for the manufacture of heating elements according to the customer’s working drawings.
The basic rule when choosing a heating element for a given heated medium is the correct combination of geometric and electrical parameters. The service life and reliability of the heating element depend on how large the surface load is. For different heated media, the permissible specific surface load is different and is a strictly normative value, the excess of which leads to premature failure of the heating element.
An example of a designation when ordering: TEN-100A13/3.15.R.220.F2.R30.Sh.M22x1.5
| 100 | — unfolded length of the heating element shell (cm). |
| A | — length of the contact rod in the seal (A-40 mm, B-65 mm). |
| 13 | — diameter of the heating element shell (7.4; 8; 10; 13). |
| 3,15 | — power consumption (kW). |
| Z | — heated medium (S — calm medium, P — water, O — air moving at a speed of at least 6 m/s, L — molds, Z — oil). |
| 220 | — voltage (V). |
| R30 | — bending radius 30 mm (standard radii 19, 24, 30, 35, 40, 50, 60, 80, 100, mm). |
| Sh | - fitting (M22x1.5 thread) |
The shell material can be stainless steel, copper, brass and black steel. By agreement, heating elements can be manufactured according to drawings with parameters different from those indicated on the website. The heating element can be equipped at the consumer’s request with mounting fittings (fittings).
| Symbol for heated medium | Heated medium | Character of heating | Specific power W cm 2 No more | Shell material |
| X | Water, weak solution of alkalis and acids (pH from 5 to 9) | Heating, boiling with max t = 100C on the shell | 9,0 | Copper and brass (plated) |
| J | Water, weak acid solution (pH 5 to 7) | Heating, boiling with max t = 100C on the shell | 15,0 | Stainless heat resistant steel |
| P | Water, weak alkali solution (pH 7 to 9) | Heating, boiling with max t = 100C on the shell | 15,0 | Carbon steel |
| S | Air and other gases and gas mixtures | Heating in a quiet gas environment to operating temperature t = 450C on the shell | 2,2 | Carbon steel |
| T | Air and other gases and gas mixtures | Heating in a quiet gas environment to operating temperature t = 450C on the shell | 5,0 | Stainless heat resistant steel |
| O | Air and other gases and gas mixtures | Heating in an environment with moving air at a speed of 6 ms with air, with a temperature of 450C on the shell | 5,5 | Carbon steel |
| K | Air and other gases and gas mixtures | Heating in an environment with moving air at a speed of 6 ms with air, with a temperature of 450C on the shell | 6,5 | Stainless heat resistant steel |
| Z | Fats and oils | Heating in bathtubs and other containers | 3,0 | Carbon steel |
| L | Casting molds, compression molds. Tens are inserted into the holes. There is guaranteed contact with the heated metal. | Heating to t = 450C on the shell | 5,0 | Carbon steel |
| Length of rod in embedding, mm | 40 | 65 | 100 | 125 | 160 | 250 | 400 | 630 |
| Symbol | A | B | C | D | E | F | G | H |
Typical forms of heating elements
MAXIMUM POWER OF ELECTRIC TUBULAR HEATERS (TEH), kW
| Expanded length of the heating element shell, cm | Heating element diameter, mm | Heated medium P (water and solutions) | Heated medium S (still air) | ||||||||||||||
| Voltage, V | Voltage, V | ||||||||||||||||
| 36 | 48 | 55 | 60 | 110 | 127 | 220 | 380 | 36 | 48 | 55 | 60 | 110 | 127 | 220 | 380 | ||
| TEN-32 | 8 | 0,32 | 0,5 | 0,5 | 0,63 | 0,63 | 0,63 | — | — | 0,12 | 0,12 | 0,12 | 0,12 | — | — | — | — |
| 10 | 0,63 | 1 | 1 | 1 | 1 | 1 | — | — | 0,16 | 0,16 | 0,16 | 0,16 | — | — | — | — | |
| 13 | 0,63 | 1 | 1 | 1 | 1 | 1 | — | — | 0,2 | 0,2 | 0,2 | 0,2 | — | — | — | — | |
| TEN-45 | 8 | 0,2 | 0,4 | 0,5 | 1 | 1,25 | 1,25 | 0,8 | — | 0,2 | 0,2 | 0,2 | 0,2 | — | — | — | — |
| 10 | 0,63 | 1 | 1 | 1,25 | 1,5 | 1,25 | 1,6 | — | 0,25 | 0,25 | 0,25 | 0,25 | 0,25 | 0,25 | — | — | |
| 13 | 0,63 | 1 | 1 | 1,25 | 1,5 | 1,25 | 1,6 | — | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | — | — | |
| TEN-60 | 8 | 0,16 | 0,32 | 0,4 | 0,5 | 1 | 1,25 | 1,6 | — | 0,16 | 0,25 | 0,25 | 0,25 | 0,25 | 0,25 | — | — |
| 10 | 0,4 | 0,8 | 1 | 1,25 | 2 | 2 | 2 | 2 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | — | |
| 13 | 0,4 | 0,8 | 1 | 1,25 | 2 | 2,5 | 2 | 2 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | — | |
| TEN-80 | 8 | — | 0,2 | 0,25 | 0,32 | 1 | 1,25 | 2 | 2 | — | 0,2 | 0,25 | 0,32 | 0,4 | 0,4 | — | — |
| 10 | 0,32 | 0,5 | 0,63 | 0,8 | 2 | 2,5 | 3 | 3 | 0,32 | 0,5 | 0,5 | 0,5 | 0,5 | 0,5 | 0,5 | — | |
| 13 | 0,32 | 0,5 | 0,8 | 0,8 | 2 | 2,5 | 3 | 3 | 0,32 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | |
| TEN-85 | 8 | — | 0,2 | 0,25 | 0,32 | 1 | 1,25 | 2 | 2 | — | 0,16 | 0,25 | 0,32 | 0,4 | 0,4 | — | — |
| 10 | 0,25 | 0,5 | 0,63 | 0,8 | 2 | 2,5 | 3 | 3,5 | 0,25 | 0,5 | 0,5 | 0,5 | 0,5 | 0,5 | 0,5 | — | |
| 13 | 0,25 | 0,5 | 0,63 | 0,8 | 2 | 2,5 | 3 | 4 | 0,25 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | |
| TEN-100 | 8 | — | 0,16 | 0,2 | 0,25 | 0,8 | 1 | 2 | 3 | — | — | 0,2 | 0,25 | 0,5 | 0,5 | 0,5 | — |
| 10 | 0,25 | 0,4 | 0,5 | 0,63 | 2 | 2,5 | 4 | 4 | 0,25 | 0,4 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | |
| 13 | 0,25 | 0,4 | 0,63 | 0,63 | 2 | 2,5 | 4 | 4 | 0,25 | 0,4 | 0,63 | 0,63 | 0,8 | 0,8 | 0,8 | 0,8 | |
| TEN-125 | 8 | — | — | 0,16 | 0,2 | 0,63 | 0,8 | 2 | 3 | — | — | 0,16 | 0,2 | 0,63 | 0,63 | 0,63 | — |
| 10 | 0,2 | 0,32 | 0,5 | 0,5 | 2 | 2,5 | 4 | 4 | 0,2 | 0,32 | 0,5 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | |
| 13 | 0,2 | 0,32 | 0,5 | 0,5 | 2 | 2,5 | 4 | 4 | 0,2 | 0,32 | 0,5 | 0,5 | 1 | 1 | 1 | 1 | |
| TEN-140 | 8 | — | — | — | 0,16 | 0,63 | 0,5 | 2,5 | 3,5 | — | — | — | 0,16 | 0,63 | 0,63 | 0,63 | 0,63 |
| 10 | 0,16 | 0,32 | 0,4 | 0,5 | 1,6 | 2 | 4 | 5 | 0,16 | 0,32 | 0,4 | 0,5 | 0,8 | 0,8 | 0,8 | 0,8 | |
| 13 | 0,16 | 0,32 | 0,4 | 0,5 | 1,6 | 2 | 4 | 5 | 0,16 | 0,32 | 0,4 | 0,5 | 1 | 1 | 1 | 1 | |
| TEN-170 | 10 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,6 | 4 | 6,3 | — | 0,25 | 0,32 | 0,4 | 1 | 1 | 1 | 1 |
| 13 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,6 | 4 | 8 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,25 | 1,25 | 1,25 | |
| TEN-200 | 10 | — | 0,2 | 0,25 | 0,32 | 1 | 1,6 | 4 | 8 | — | 0,2 | 0,25 | 0,32 | 1 | 1,25 | 1,25 | 1,25 |
| 13 | — | 0,2 | 0,25 | 0,32 | 1 | 1,6 | 4 | 8 | — | 0,2 | 0,25 | 0,32 | 1 | 1,25 | 1,6 | 1,6 | |
| TEN-236 | 13 | — | 0,36 | 0,25 | 0,25 | 1 | 1,25 | 4 | 8 | — | 0,16 | 0,25 | 0,25 | 1 | 1,25 | 2 | 2 |
| TEN-280 | 13 | — | 0,16 | 0,2 | 0,25 | 0,8 | 1 | 3,15 | 8 | — | 0,16 | 0,2 | 0,25 | 0,8 | 1 | 2 | 2 |
| Expanded length of the heating element shell, cm | Heating element diameter, mm | Heated medium Z (oil) | Heated medium O,L (O - moving air, L - molds) | ||||||||||||||
| Voltage, V | Voltage, V | ||||||||||||||||
| 36 | 48 | 55 | 60 | 110 | 127 | 220 | 380 | 36 | 48 | 55 | 60 | 110 | 127 | 220 | 380 | ||
| TEN-32 | 8 | 0,16 | 0,16 | 0,16 | 0,16 | — | — | — | — | 0,25 | 0,32 | 0,32 | 0,32 | 0,32 | — | — | — |
| 10 | 0,2 | 0,2 | 0,2 | 0,2 | 0,2 | — | — | — | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | — | — | |
| 13 | 0,25 | 0,25 | 0,25 | 0,25 | 0,25 | — | — | — | 0,5 | 0,5 | 0,5 | 0,5 | 0,4 | 0,5 | — | — | |
| TEN-45 | 8 | 0,2 | 0,25 | 0,25 | 0,25 | 0,25 | — | — | — | 0,25 | 0,32 | 0,4 | 0,4 | 0,4 | 0,5 | — | — |
| 10 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | 0,32 | — | — | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | — | |
| 13 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | — | — | 0,5 | 0,63 | 0,8 | 0,8 | 0,8 | 0,8 | — | — | |
| TEN-60 | 8 | 0,16 | 0,25 | 0,32 | 0,32 | 0,32 | 0,32 | — | — | 0,16 | 0,25 | 0,4 | 0,4 | 0,63 | 0,63 | 0,63 | — |
| 10 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | 0,4 | — | 0,4 | 0,63 | 0,8 | 0,8 | 0,8 | 0,8 | 0,8 | 0,8 | |
| 13 | 0,4 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | 0,4 | 0,63 | 0,8 | 0,8 | 0,8 | 1 | 1 | 0,8 | |
| TEN-80 | 8 | — | 0,2 | 0,25 | 0,32 | 0,5 | 0,5 | 0,5 | — | 0,12 | 0,2 | 0,25 | 0,32 | 0,8 | 1 | 0,8 | — |
| 10 | 0,32 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | 0,32 | 0,5 | 0,63 | 0,8 | 1 | 1 | 1 | 1 | |
| 13 | 0,32 | 0,5 | 0,63 | 0,63 | 0,8 | 0,8 | 0,8 | — | 0,32 | 0,5 | 0,8 | 1,6 | 1,6 | 1,6 | 1,6 | 1,6 | |
| TEN-85 | 8 | — | 0,2 | 0,25 | 0,32 | 0,5 | 0,5 | 0,5 | — | — | 0,2 | 0,25 | 0,32 | 0,8 | 1 | 1 | — |
| 10 | 0,25 | 0,5 | 0,63 | 0,63 | 0,63 | 0,63 | 0,63 | — | 0,32 | 0,5 | 0,63 | 0,8 | 1,25 | 1,25 | 1,25 | 1,25 | |
| 13 | 0,25 | 0,5 | 0,63 | 0,63 | 0,8 | 0,8 | 0,8 | 0,8 | 0,32 | 0,5 | 0,8 | 0,8 | 1,6 | 1,6 | 1,6 | 1,6 | |
| TEN-100 | 8 | — | 0,16 | 0,2 | 0,25 | 0,63 | 0,63 | 0,63 | — | — | — | 0,2 | 0,25 | 0,8 | 1 | 1,25 | 1 |
| 10 | 0,25 | 0,4 | 0,5 | 0,63 | 0,8 | 0,8 | 0,8 | 0,8 | 0,25 | 0,4 | 0,5 | 0,63 | 1,5 | 1,5 | 1,5 | 1,5 | |
| 13 | 0,25 | 0,4 | 0,63 | 0,63 | 1 | 1 | 1 | 1 | 0,25 | 0,4 | 0,63 | 0,63 | 1,6 | 1,6 | 1,6 | 2 | |
| TEN-125 | 8 | — | — | 0,16 | 0,2 | 0,63 | 0,8 | 0,8 | 0,8 | — | — | 0,16 | 0,2 | 0,63 | 1 | 1,5 | 1,5 |
| 10 | 0,2 | 0,32 | 0,5 | 0,5 | 1 | 1 | 1 | 1 | 0,2 | 0,32 | 0,5 | 0,5 | 1,6 | 1,6 | 1,6 | 1,6 | |
| 13 | 0,2 | 0,32 | 0,5 | 0,5 | 1,25 | 1,25 | 1,25 | 1,25 | 0,2 | 0,32 | 0,5 | 0,5 | 1,6 | 1,6 | 2 | 2,5 | |
| TEN-140 | 8 | 0,16 | — | — | 0,16 | 0,63 | 0,8 | 0,8 | 0,8 | — | — | — | — | 0,63 | 0,8 | 1,6 | 1,6 |
| 10 | 0,16 | 0,32 | 0,4 | 0,5 | 1 | 1 | 1 | 1 | 0,16 | 0,32 | 0,4 | 0,5 | 1,6 | 1,6 | 2 | 2 | |
| 13 | — | 0,32 | 0,4 | 0,5 | 1,25 | 1,5 | 1,25 | 1,5 | 0,16 | 0,32 | 0,4 | 0,5 | 1,6 | 1,6 | 2 | 2,5 | |
| TEN-170 | 10 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,25 | 1,25 | 1,25 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,6 | 2,5 | 2,5 |
| 13 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,5 | 1,5 | 1,6 | — | 0,25 | 0,32 | 0,4 | 1,25 | 1,6 | 3,15 | 3 | |
| TEN-200 | 10 | — | 0,2 | 0,25 | 0,32 | 1 | 1,5 | 1,6 | 1,6 | — | 0,2 | 0,25 | 0,32 | 1 | 1,6 | 3,15 | 3,15 |
| 13 | — | 0,2 | 0,25 | 0,32 | 1 | 1,5 | 2 | 2 | — | 0,2 | 0,25 | 0,32 | 1 | 1,6 | 3,15 | 4 | |
| TEN-236 | 13 | — | 0,16 | 0,25 | 0,25 | 1 | 1,25 | 2,5 | 2,5 | — | 0,16 | 0,25 | 0,25 | 1 | 1,25 | 3,15 | 5 |
| TEN-280 | 13 | — | 0,16 | 0,2 | 0,25 | 0,8 | 1 | 2,5 | 3,15 | — | 0,16 | 0,2 | 0,25 | 0,8 | 1 | 3,15 | 5 |
All manufactured heating elements initially have the ability to work with electrical parameters that differ to one degree or another from the nominal ones indicated on the heating element body or in the accompanying documentation.
The top line shows the rated voltage values for heating elements (markings on heating elements)
The left column shows the actual values of the supply voltages.
At the intersection of the rows and columns there is a power conversion factor of the heating element, by which you need to multiply the rated power of the heating element (see the heating element labeling)
| Heating element power conversion table | ||||||||
| And, volt | 36 | 48 | 55 | 60 | 110 | 127 | 220 | 380 |
| 36 | 1 | 0,56 | 0,43 | 0,36 | 0,11 | 0,08 | 0,03 | 0,01 |
| 48 | 1,78 | 1 | 0,76 | 0,64 | 0,19 | 0,14 | 0,05 | 0,02 |
| 55 | 2,33 | 1,31 | 1 | 0,84 | 0,25 | 0,19 | 0,06 | 0,02 |
| 60 | 2,78 | 1,56 | 1,19 | 1 | 0,30 | 0,22 | 0,07 | 0,03 |
| 110 | 9,09 | 5,25 | 4,00 | 3,36 | 1 | 0,75 | 0,25 | 0,08 |
| 127 | 12,45 | 7,00 | 5,33 | 4,48 | 1,33 | 1 | 0,33 | 0,11 |
| 220 | 37,35 | 21,01 | 16,00 | 13,44 | 4,00 | 3,00 | 1 | 0,34 |
| 380 | 111,42 | 62,67 | 47,74 | 40,11 | 11,93 | 8,95 | 2,98 | 1 |
Example: the heating element marking indicates operating voltage 127V, power: 1 kW. It is necessary to determine the power of such a heating element when it is turned on at 220V.
We select the nominal voltage 127 V in the top line, and the actual voltage 220 V in the left column. At the intersection of the row and column we find the coefficient 3.00. We multiply the rated power of the heating element (1 kW) by the resulting coefficient and get the power at a voltage of 220V - 3 kW.
Attention consumers!
The manufacturer categorically does not recommend using heating elements when the supply voltages differ significantly from the nominal ones, because when the voltage increases, the power of the heating element increases greatly, and when the voltage decreases, the use of the heating element is ineffective. In addition, the design of the heating element, designed for a lower operating voltage, may pose a danger when switched on at a higher voltage. In addition, the manufacturer’s warranty does not cover damage or premature failure of the heating element when operating with power supply parameters different from the nominal ones.
Heating element – double-ended – fastening elements
For reliable fastening of heating elements in the supplied products, electric heaters are equipped with the necessary fastening elements (fittings, bushings, plates...)
Most often, heating elements are attached to the walls of products using fittings.
The fitting (threaded bushing with a thrust flange) is fixed to the electric heater by pressing, soldering or welding, depending on the operating conditions of the heating element in a particular heated environment.
The most commonly used fittings are the dimensions given in the table.
| Diameter of heating element shell (mm) | M – thread size | L – length (mm) | S – flange thickness (mm) | D – flange diameter (mm) |
| 8,5 | M 14 x 1.5 | 18 | 3 | 20 |
| 10 | G 1/2" | 24 | 4 | 30 |
| M 16 x 1.5 | 18 | 3 | 25 | |
| 13 | G 1/2" | 24 | 4 | 30 |
| M 22 x 1.5 | 22 | 4 | 30 |
Of the listed sizes, I would like to highlight, as the most technologically advanced, the version of fittings with G 1/2" (outer thread diameter - 20.96 mm). The use of this standard size of fittings will not require additional costs for counter nuts and sealing gaskets, since size G 1/2" is one of the main sizes of domestic and imported plumbing equipment.
When ordering, you can choose one of the proposed options or specify the required dimensions of the fitting.
Most often, fittings are made of carbon steel. At your request, it is possible to manufacture fittings from stainless steel (for heating elements operating in aggressive environments, in food installations, in medical distillers) and other materials.
All kinds of other fastening elements can be made of various materials and fixed in the required place on the heating element according to your requirements.
