Wire-Wound Element Construction

Etched Foil Element Construction

Lead Exit A

Lead Exit B

Lead Exit C

Lead Exit D

Lead Exit E

Lead Exit F

Lead Exit G

Lead Exit H

Lead Exit J

Lead Exit K

Lead Exit L

Lead Exit M

Customer Specified

Teflon® Coated Lead Wire

Tempco's standard leads are 10" long, Teflon® insulated, flexible, stranded, plated copper wire. Stripped: 1/4"

• UL1180 rated 300V 200°C
• UL1199 rated 600V 200°C

HPN Cord

HPN Cord and Plug

A two-conductor neoprene cord and plug set can be vulcanized to the heater.
Standard Length: 6 ft. (1.83 M), 7 ft. (2.13M), or custom length as specified.
Supplied with standard straight blade ungrounded plug, or grounded plug. 120Vac only.

• 2-Pole 2 wire non-grounding (NEMA 1-15P)
• 2-Pole 3 wire grounding (NEMA 5-15P)

SJO Cord

SJO Cord and Plug

SJO heavy duty power cord and plug set can be attached to the heaters. Standard Length: 6 ft. (1.83 M), or custom length as specified. Supplied with standard straight blade ungrounded plug, or grounded plug. 120Vac only. (For 240Vac see page 15-15 for optional plugs)

• 2-Pole 2 wire non-grounding (NEMA 1-15P)
• 2-Pole 3 wire grounding (NEMA 5-1

Silicone Rubber Leads

Crimp connectors

Crimp Connectors: insulated or non-insulated

• Ring Terminal
• Spade Terminal
• 1/4" Female Straight Disconnect
• 1/4" Female Right-Angle Disconnect
• Miniature Connectors: example – Molex

Plugs

• Standard 120 or 240 Vac – straight blade
• Twist locking plugs, 120 to 480 Vac
• Specify NEMA or manufacturer's part number

Built-Up Molded Lead Exit

Used to encase lead exit and optional snap action thermostat.

Shown with SJO cord rated -50°C to 105°C.

Sleeving

 Various materials can be put over Teflon® or Silicone Rubber leads to provide mechanical or abrasion protection. The leads exit the heater as a single unit.

• Silicone Rubber/Fiberglass Sleeving (356°F/180°C)
• Heat Shrink Sleeving

PSA (and PSA Plus)

For ease of attachment, specify PSA. Installation is simple: just peel off the protective liner and apply. It will adhere to most clean smooth surfaces. Care must be taken when installing to attain a smooth, consistent, uniform bond to achieve maximum results.
Maximum Temperature: 
 Continuous – 300°F (149°C)
 Intermittent – 500°F (260°C)
Recommended Watt Density:
 Under 5 W/in2 (0.78 W/cm2)

PSA Plus
A layer of aluminum foil is vulcanized to the back of the heater for added
heat dissipation prior to the application of PSA.

Factory Vulcanizing

Flexible heaters can be factory vulcanized to bare or anodized aluminum, Stainless Steel, Marble, or other hard surfaces for permanent attachment and excellent heat transfer.

The uncured silicone rubber heater is placed on the metal part and placed in the vacuum oven where the heater vulcanizes and adheres to the part in one operation. This procedure forms an extremely strong permanent bond with most metals due to the fact that the silicone rubber flows into and fills the micro structure in the surface of the metal. The metal part can be manufactured by Tempco or supplied by the customer. Consult Tempco for other materials including granite.

Magnetic Mounting

Field Applied Adhesive

Products Temporarily Unavailable for Individual Purchase

For a field applied permanent bond, a room temperature and ambient humidity curing silicone rubber adhesive is recommended. Tempco offers two types that will retain physical and electrical properties up to 500°F (260°C).

When using RTV adhesive, cover the heater completely with a thin layer of RTV, position the heater in place, and use a small roller to remove air bubbles, which could cause hot spots and lead to premature failure of the heater.

D-Rings and Straps

Velcro Straps

Boot Hooks and Springs

Boot Hooks and Lacing Cord

Grommets and Lacing Cord

Heavy Duty Spring Clamps

Snaps

Clamping

Outside Diameter Mounting

Tempco has developed the techniques necessary to permanently mount silicone rubber heaters to the outside diameters of pipes and medium size vessels. This technique is particularly useful for heated drums and air or gas heating.

Minimum Diameter: 0.5" (12.7 mm)
Maximum Diameter: 6" (152.4 mm)
Maximum Length: 20" (508.0 mm)

3-D Configurations

Thermocouple

RTD's

Thermistors

No Temperature Sensor

A temperature sensor is not needed for this heater.

Snap Action Thermostat - Automatic Reset

Quick cutout on rise to temperature. The contacts will open on rise when the temperature increases to the snap point of the calibrated bimetal disc.

Setpoint (opens): available from 50 to 450°F in 10°F increments (most thermostats close 20 to 30°F below setpoint)
Electrical Ratings: 125 Vac, 15 Amp, 1875W, 250 Vac, 10 Amp, 2500W
Minimum Heater Width: 1.312"

Adjustable Thermostat

Adjustable thermostats allow the user to dial-in a specific temperature and attain a desired result. The thermostat is enclosed in a molded silicone rubber housing and permanently attached to the heater. The adjustment shaft extends through a pre-formed hole. A high temperature knob is included.
Amps: 12.5A @ 125V, 6.5 A @ 250V
Watts: 1500W @ 120V, 1560W @ 240V
Adjustment Ranges Available:

• 50 to 425°F (10 to 218°C)
• 90 to 140°F (32 to 60°C)
• 100 to 190°F (38 to 88°C)
• 70 to 190°F (21 to 88°C)
• 50 to 160°F (10 to 71°C)
• 70 to 140°F (21 to 60°C)

Snap Action High Limit Thermostat

Creep Action Thermostat

Thermal Fusing

Internal Ground Screen Plane

Some applications may require the heater to be grounded. Due to the fact that the heater sheath is non-conductive, this can only be done artificially. A second layer of insulating material and a conductive grid can be added to the heater. A ground wire is attached to the grid.

A less expensive alternative for setting up a ground wire, especially for the required ground lead of a cordset, is to have a "flying ground lead" (6" long, green) exit the lead patch for attaching to the metal load surface, effectively grounding the process.

Dual Voltage

Due to the flexibility in circuit design for flexible heaters, heating circuits can be designed to accommodate dual voltage.

On dual voltage heaters, three leads, including a common in a different color, are provided for wiring the heater in series for the higher voltage and parallel for the lower voltage. 120/240 Vac or 240/480 Vac can be specified.

Three-Phase Wiring

Heaters can be designed with internal three-phase delta wiring. Three phase WYE wiring is also possible but less preferable in most cases. All 3-phase heaters will have three power leads coming out of the heater. Three phase heaters are typically larger heaters used in high current applications.

Self-Limiting/Self-Regulating

The alloy used for this heater's resistance wire has a high positive temperature coefficient of resistance that allows the heater to reduce power as temperature increases. This self-regulating feature is ideal for many low temperature applications. This feature can also be beneficial when a fast start-up time is required before the heater power levels off to normal
operating temperature.

See Chart for Ratio of Hot to Cold Resistance of the Heater wire at various wire temperatures.

Thermal Sponge Insulation / Thermal Conductive Sponge

To increase heater efficiency, silicone sponge rubber insulation can be bonded to the top side of the heater.
Available thicknesses are 1/16", 1/8", 1/4", 3/8" or 1/2".

Thermal Conductive Sponge can be use to transfer heat evenly to various surfaces. Available in 1/8" thickness.

Foil Backing

Distrubted Wattage

Lead Exit Tab

Multiple Zones

Holes and Cutouts