Heatmax offers a diverse range of heaters designed to meet various heating needs across industrial and commercial applications, including tubular, over-the-side, and L-shaped heaters. Explore our products to learn more about our tailored heating solutions.
All of our products are designed, manufactured, and shipped from our facility in Mentor, Ohio.
If you already have an idea of what you’re looking for, input your specifications into the Heatmax Calculator for customized recommendations.
Alternatively, if you provide your tank dimensions (including insulation and lid details), solution chemistry, starting temperature, ambient temperature, target temperature, and target heat-up time to the Heatmax team, we can determine the wattage needed to meet your specifications. Feel free to fill out our “Request a Quote” form, email sales@heatmaxheaters.com, or call us today to discuss your project.
Different applications require various element watt densities for industrial immersion heaters due to a variety of factors, each influencing how effectively and safely the heater operates within a specific environment. Here are some key reasons:
1. Viscosity of fluids: Fluids with higher viscosity (thicker fluids) transfer heat away from the heating element more slowly than those with lower viscosity (thinner fluids such as water). Thicker fluids require lower watt densities to prevent overheating and degradation of both the fluid and the heater.
Our standard electric immersion heaters are tailored to heat a range of non-flammable aqueous solutions, primarily water-based process chemistries. These thinner fluids can tolerate a typical watt density of about 35 Watts per square inch.
For thicker fluids, such as concentrated sodium hydroxide, phosphates, glycols, and oil, we advise using "derated" heaters, which have a watt density less than 20 Watts per square inch. For some chemistries such as wax or paraffin, or crude oil, we still recommend lower watt densities.
2. Chemical compatibility or corrosion resistance: The construction material of the heating element and the medium being heated must be compatible to prevent corrosion or deterioration of the heater. Some materials can withstand higher temperatures and watt densities better than others.
Our PTFE-covered heaters, with a standard watt density of 10 watts per square inch, are already considered derated and suitable for challenging applications as well as more corrosive solutions.
3. Flow rate: In applications with high flow rates, the fluid (or air/gas) constantly moving past the heater allows for more efficient heat transfer away from the element. This can permit higher watt densities. Conversely, in static or low-flow applications, lower watt densities are preferable to avoid overheating localized areas.
Air applications also vary in their appropriate watt density. For heating dry-wells with static air, we recommend using heaters derated to 10 watts per square inch. For duct heaters with air flow, 20 or 30 watts per square inch are standard, but higher watt densities are possible if the flow rate is high enough.
4. Element lifespan considerations: Lower watt densities generally reduce the stress on the heating element and the medium being heated, leading to longer heater element lifespan. This is particularly crucial in critical applications where equipment failure can lead to significant downtime.
Please consult our sales experts for the right watt density for your specific application.
Different applications require varying element alloys in industrial immersion heaters due to a variety of factors related to the operational environment, material properties, and performance requirements. Here are some of the main reasons:
Due to these factors, it is crucial to select the right alloy for each application to ensure that the industrial immersion heater operates effectively, safely, and has a long service life. Reach out to our sales experts to discuss the best alloy for your specific application.
The Amp draw of a heater will be included in the label of the heater. The calculation for amperage is relatively straightforward.
We recommend referring to the latest NEC code book, as guidelines can change with new editions. Local codes and amendments also can affect how the NEC is applied, so it is crucial to consult with a local electrical inspector or a qualified electrician. However, here are some general principles and steps typically followed:
These guidelines provide a general framework, but for specific applications, it is essential to consult the NEC directly or work with professionals who are knowledgeable in electrical safety and code requirements.
The typical lead time can vary depending on the complexity of customization, the volume of the order, and the availability of materials. For a precise estimate of lead time based on your specific customization requirements, reach out to our team.
We recommend cleaning your heaters often enough to avoid buildup, although frequency will vary depending on application, solution, frequency of use, etc. Contact your chemical supplier for specific cleaning instructions.
Heatmax’s heating products are designed with several safety features to ensure secure and reliable operation within industrial and commercial settings, including:
Heaters vary in complexity and include specific instructions accordingly. For screwplug heaters requiring connection to element threaded terminals, a wiring diagram accompanies the product. If this diagram is missing, contact your sales representative for an electronic copy suited to your heater's part number.
Heaters employing lead wires or terminal blocks are equipped with terminals labeled L1 and L2 for single-phase connections, or L1, L2, and L3 for three-phase connections, indicating the connection points for each phase. For heaters with multiple three-phase circuits, each circuit will possess its distinct L1, L2, and L3 terminals. Additionally, all heaters come with a green ground wire.
Heaters featuring advanced options like thermal protectors, pilot-duty thermostats, or thermocouples will have appropriately labeled lead wire connections. For accurate installation and safety, we strongly recommend consulting a professional.
Heatmax's TCD controls feature a manual reset button specifically designed for resettable thermal protectors. This manual reset is necessary due to the operational nature of the thermal protectors.
Essentially functioning as an overtemperature switch, the thermal protector opens the circuit and discontinues power to the heater upon detecting temperatures above a set limit. Once the temperature decreases below this limit, the circuit would typically close and re-energize the heater automatically. However, the manual reset button maintains the open circuit state, requiring manual intervention to restart the heater.
This precaution prevents the heater from cyclically shutting off and re-energizing in scenarios such as low liquid levels causing overheating. Thus, it is mandatory for heaters equipped with resettable thermal protectors to be paired with controls that include a manual reset button, ensuring the heater doesn't reactivate until it is safe and the operator is prepared.
Heatmax heaters are designed with a focus on efficiency, but their energy efficiency compared to other options in the market can vary based on the specific model, heating technology, and the application for which they are used. Our heaters are engineered to maximize heat transfer efficiency by optimizing the conversion of energy into usable heat.
We provide comprehensive installation manuals, guidelines, and instructions with our products. These detailed documents outline proper installation procedures, safety precautions, electrical connections, mounting instructions, and other relevant information necessary for proper setup.
Typically, heaters are equipped with clearly marked lead wires, and the accompanying controls (TCD or LLC) include a wiring diagram detailing the appropriate connections. You can usually find this diagram inside the control enclosure. If it is absent, reach out to your sales representative with the control part number to obtain an electronic version of the wiring schematic.
If you have any questions or concerns, consulting a professional or qualified electrician is the safest approach.
We offer certain models specifically designed to meet the requirements for use in hazardous or corrosive environments. For hazardous environments with the presence of flammable gasses, vapors, or combustible dust, Heatmax provides heaters designed to meet specific safety standards and certifications, such as explosion-proof or flameproof heaters.
For precise information regarding the suitability of Heatmax heaters for hazardous or corrosive environments, we recommend reaching out to our team directly. Our specialists can provide detailed guidance and recommend the most suitable heaters that comply with the required safety standards for your specific industrial setting.
The overtemperature switch, or "thermal protector," serves as an essential safety mechanism. Its function is to monitor and respond if the heater sheath surpasses a specific temperature threshold by tripping. It’s imperative that this protector is wired to ensure that if it trips, it will cease the operation of all heaters in that tank.
Yes, all of our heating solutions include customizable features to meet specific power requirements and voltages. Get in touch with our team if you have any questions about specific models.
In-line wired thermostats are integrated directly into the heater's circuitry, enabling them to autonomously switch the heater on and off. This setup offers simplicity and direct control, eliminating the need for external relays or contactors. However, in-line thermostats are subject to amperage load limitations, making them less suitable for high-power applications.
On the other hand, pilot-duty thermostats don't connect directly to the heater. Instead, they control secondary devices like relays or contactors. These devices then manage the heater's power load. This method is typically employed in larger heating systems where the power requirements exceed the direct control capacity of a thermostat.
Choosing between in-line and pilot-duty thermostats depends on the specifics of your heating system, including power demands and operational complexity. Our sales team can provide expert advice on the best configuration for your needs, ensuring efficient, safe, and appropriate temperature control for your industrial heater.
At Heatmax, our commitment to enhancing our products is ongoing. In recent years, we've focused on increasing the durability and flexibility of our offerings. This has led us to phase out Plastisol-coated enclosures due to their low heat tolerance and, more recently, to introduce enclosures made of flame-retardant, vapor, and corrosion-resistant polypropylene.
As we innovate and evolve our product line, older components are discontinued to make way for advancements. This means the new heater you purchase may appear different from its predecessor. However, our dedicated sales team will ensure that it matches the essential specifications of the previous model, including immersion length, wattage, and voltage.
According to National Electric Code , Section 425.22, “equipment rated more than 48 Amperes and employing such elements have the heating elements subdivided, and each subdivided load shall not exceed 48 amperes.”
For some heater styles, it is possible to do multiple circuits (particularly in flange and duct heaters) where space allows.
The Heatmax liquid level controller is engineered to function alongside Heatmax's remote mount double-probe assembly and a TCD controller. This probe assembly facilitates the flow of current between the probes when submerged in a conductive solution.
If the level of the solution falls beneath the probes, their inability to conduct will effectively break the circuit. By integrating the LLC in series with the heater's thermal protector and connecting it to the TCD, any disruption in this circuit—like a drop in liquid level below the probes—will de-energize the heater.
The heater remains off until the liquid level is restored to a point where both probes are submerged again.
The lifespan of an industrial immersion heater can vary based on several factors, including the type of heater, the quality of the materials used, the operational environment, maintenance practices, and the frequency of use.
Generally, a well-maintained immersion heater used in optimal conditions can last from 5 to 10 years. However, harsher environments, corrosive solutions, higher watt densities, and more intensive use can shorten the lifespan considerably.
We recommend using a power washer or a mild cleaning solution. For mineral deposits, a mild acid like vinegar or a commercial descaling agent can be used. For oily residues, a degreaser may be necessary.
If you’re scrubbing your heating elements, use non-abrasive tools to avoid damaging the elements. Avoid using a hammer to loosen thick layers of sediment build-up, as this can cause dents.
The surface of an electric immersion heater reaches temperatures significantly higher than the surrounding liquid, unlike the tank walls, which generally match the temperature of the contained liquid.
This variance is critical because many chemicals become more reactive or corrosive at higher temperatures. Consequently, the heater may be prone to chemical damage, even when the tank walls remain unaffected. To improve the heater’s lifespan, we may recommend a more robust element alloy, such as 316 Stainless Steel, Incoloy, or Titanium.
Yes, we can cross-reference most other manufacturers' part numbers. Feel free to provide us with the part numbers you're interested in, and we'll do our best to find a compatible option. If we don't have sufficient information to cross-reference a competitor's part, we’ll inform you accordingly.
If you’re operating multiple heaters in a single tank, it is essential that you connect multiple heaters’ thermal protectors together in series. Instructions on how this should be done are available on the Thermal Protector Data Sheet available here. Please also see the below diagram.
First, make sure you’re establishing a good point of comparison. We recommend holding a thermometer at the same location as the TCD’s probe and keeping it there for 15 minutes before comparing readings.
It’s important to locate the thermometer in the same location as the probe as the temperature can be different in different parts of the tank. Heat rises, so the bottom of the tank will be the coolest.
Once you’ve established how many degrees the TCD is off by, you can program an “Offset” in the control to adjust the temperature reading. For example if the TCD temperature reading is 5°F too low, an offset will be programmed to add 5°F to the temperature reading so it will operate the heater at the appropriate temperature.
Please ask your sales representative (sales@heatmaxheaters.com) for instructions on how to program an offset for your control.
With the certainty provided by Ohm's Law, you can accurately determine the wattage (heat output) of a heater by simply measuring the voltage and resistance (Ohms). To use Ohm's Law for checking if a heater is operating properly, follow these steps. However, it is crucial to note that any work involving electrical appliances should be done with a thorough understanding of safety procedures and preferably by a qualified professional.
1. Understand Ohm's Law: Ohm's Law states that Voltage (V) = Current (I) * Resistance (R). From this relationship, you can calculate any one of the three values if you know the other two.
2. Ensure safety: Before conducting any tests, ensure the heater is disconnected from power source before removing the terminal enclosure lid or any other barriers to the heating element safely, ensuring you're not at risk of touching live electrical components.
3. Measure resistance:
a. Use a multimeter set to the resistance (Ω) setting.
b. Disconnect the heating element from its power source completely to isolate it for an accurate measurement.
c. Place the multimeter probes on the heater element terminals. If lead wires are provided, use the multimeter probe on two lead wires.
d. A typical healthy heating element will have a certain resistance value. If the element is in good working order, the multimeter should show a resistance value close to this number. A reading far off from the expected value or an infinite resistance (open circuit) indicates a faulty element. To determine if the resistance reading (Ω) reading is within scope, please send your reading to the sales team (sales@heatmaxheaters.com). From there, they’ll determine what the resistance (Ω) range should be for your particular heater.
4. Measure Voltage: It’s also important to check the voltage being supplied to the heater. The heater is designed to work with a specific voltage and departing from this will change resistance and amperage readings.
a. When checking voltage, the heater typically needs to be connected to power, and extreme caution should be taken to avoid electric shock.
b. Set the multimeter to measure voltage appropriate for your heater (AC voltage).
c. With the heater turned on, measure the voltage across the input terminals of the heater. This should match the rated voltage of the heater.
5. Analyze results:
a. Correct voltage and resistance: If the voltage matches the rated voltage and the resistance is as expected, the heater is likely functioning properly. Your sales representative will be able to advise on the correct resistance range. The voltage that should be connected to the heater is labeled on the heater.
b. Correct voltage but wrong resistance: If the voltage is correct but the resistance is too high or too low, the element might be damaged, and the heater will need to be replaced.
c. No voltage: If there's no voltage across the heater's terminals when it is supposed to be on, there may be an issue with the power supply or the controls.
d. No resistance (infinite): This usually means there's a break in the element, and it is not functioning at all. This is most likely caused by a short and the heater will need to be replaced.
Remember, safety is paramount when working with electrical devices. Always ensure that you have isolated the device from power before conducting resistance checks, and understand the proper use of your testing equipment. If you're ever in doubt, it is best to consult a professional.
An industrial immersion heater is considered a non-durable product to be replaced once an element fails rather than repaired. The reasons for this are as follows:
To place an order with your quote, please email your written purchase order (PO) to orders@heatmaxheaters.com. From there, our order entry team will process your order and, once entered, they will contact you to confirm credit card details. If your company has established terms with us, confirming credit card details will not be necessary.
To get in touch with our team, fill out the contact form here.
