Starwound Cable Heaters

Cable heaters are drawn, elongated, compacted heating elements with the electrical conductor protected inside a metallic sheath with magnesium oxide electrical insulation. Cable heaters are formed straight from round or square tubular stock. Once drawn and compacted, they are used as straight cable in some applications or assembled into various shapes, including star wound or spiral wound patterns. These configurations provide increased surface area, optimal heat transfer, compactness, and a fast heat up and cool down because of their small mass. Alloy 316 stainless steel cable heaters are commonly used in clean environments and where moisture or contaminants are present.

Starwound cable heaters provide optimal heat transfer of fluids (air, gases, liquids), yielding optimal heat distribution. The heater's flexibility allows for winding patterns that distribute power (wattage) precisely as required and generate high temperatures in tight areas. Starwound cable heaters placed inside pipes and ducts create a turbulent flow path, enhancing heat transfer and efficiency.

• Small diameter, low mass heater allows for fast heat up/cool down.
• Starwound element creates turbulent flow, resulting in more efficient heating.
• Sheathed stainless steel element for safely heating clean or impure gas, air, or liquid streams.
• Broad heater configuration is adaptable to any application.

BCE

510-274-1990

https://bcemfg.com

Custom Coiled Cable Immersion Heater with Thermocouple and Thermal Cutout

BCE Custom Coiled Immersion Heater
with thermocouple and thermal cutout.

A major US Aerospace company approached BCE in need of a custom heating solution.  

Their existing heating element failed to evenly distribute heat inside a water reservoir, leading to thermal stratification and hotspots. 

Additionally, while the customer's existing thermal system included temperature limiting devices, the new heater design required it's own thermal cut-out to ensure over-temperature protection and remove any possibility of a runaway condition.

The coiled immersion heater needed to satisfy the following:

• Temperature uniformity throughout the heated section (± 3 C)
• Hermetic seal 
• Over-temperature heater failure
• Thermocouple for additional temperature measurement
• 275 Watt, 115 Volt

OUTCOME

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BCE designed a highly effective coiled heater with exceptional heat uniformity.  An additional
thermocouple was welded to the sheath of the heater to ensure accurate temperature measurement. A thermal cutout was placed into the NPT bushing and potted with thermally conductive epoxy to allow for heater failure if all other safety systems fail. 

BCE was able to design, create 3D models/ drawings, and provide the custom heating elements within a 3 week timeframe.

Contact BCE:
510-274-1990

https://bcemfg.com