01 · Threaded
Screw-in immersion heaters
One or more hairpins in a brass or stainless threaded nipple that screws into the vessel – for storage heaters, boilers and tanks.
- G ½″ – G 2″ (BSPP, ISO 228-1) or NPT
- M4 / M5 / M6 studs with nuts
Water heating · Liquid heating elements
We start from the water, not from the tank.
Flanged and screw-in immersion heaters for storage water heaters, high-load elements for instantaneous heaters and three-phase industrial immersion heaters. Hardness, chloride content, set-point and duty decide the sheath and the surface load.
A storage-heater element is a mature design: two to four hairpins on a round flange or a threaded nipple, sized for a low surface load to limit scale. Instantaneous heaters are the opposite case – high surface load in fast-flowing water, guarded by a flow switch against dry running.
- Sheath for the water: copper, stainless steel, Incoloy® or nickel-diffusion coated stainless – titanium on request.
- Thermostat pocket designed in, with matching stem thermostats from our own production.
- Joints made in our own plant: hairpins brazed or welded into flanges and nipples, terminal ends sealed.
Immersion & flanged heaters
Applications · where they work
Storage and instant water heaters, boilers, urns and tanks.
Screw-plug and flanged immersion heaters, instantaneous-heater spirals and tea-urn elements – wherever water or another liquid is heated directly, from storage heaters and samovars to electric towel radiators.
Key specifications
Specified for the medium: the water-heating envelope in figures.
Typical values per element across storage, instantaneous and industrial heaters. The water decides where a design sits within each range.
| Parameter | Typical values |
|---|---|
| Sheath diameter | 6.5 – 16 mm; 8.0 – 10 mm storage heaters, 6.5 – 8.5 mm instantaneous heaters, 12 – 16 mm industrial immersion heaters |
| Sheath materials | Copper (tinned or nickel-plated), AISI 304, AISI 316L, Incoloy 800, Incoloy 825, nickel-diffusion coated stainless; titanium on request |
| Power range | 800 – 3000 W storage heaters; 3 – 27 kW instantaneous heaters (multi-element); 3 – 36 kW three-phase industrial |
| Voltage | 230 V single phase; 400 V three-phase star or delta; 120 / 240 V North America |
| Watt density on the heated sheath | 6 – 12 W/cm² storage heaters (lower in hard water); 12 – 25 W/cm² instantaneous heaters; 8 – 15 W/cm² industrial immersion |
| Terminal types | M4 / M5 / M6 studs with nuts; 6.3 mm flat tabs; terminal box with cable gland for industrial |
| Sealing options | Epoxy resin, silicone resin, STF seal for high-humidity installations |
| Mounting | Round flanges Ø 48 – Ø 180 mm (steel, enamelled, stainless) with gasket; brass or stainless threaded nipples G ½″ – G 2″ (BSPP, ISO 228-1) or NPT; thermostat pocket tube |
| Typical appliance standards & marks | VDE to EN 60335-1 for approved element families; appliance to 2-21 (storage), 2-35 (instantaneous); drinking-water material approvals (e.g. WRAS, DVGW, ACS) per project; RoHS, REACH; CE marking of the finished appliance |
| Typical forms | Flanged 2–4 hairpin immersion heaters, screw-in nipple heaters, tube-in-tube instantaneous heater cartridges, bare flow-heater coils, three-phase flange heaters with terminal box |
Standards and marks are those the finished appliance typically has to meet. BALÇIK TORMEC’s own approvals are listed on the Certificates page; further marks are obtained per project. All values typical – final values confirmed by our engineers.
Typical forms · immersion heaters
Five forms – the surface load follows the water.
From a compact screw-in heater to a 36 kW three-phase flange heater, every form is sized for its medium: a low load where scale grows, a high load only where water flows fast.
02 · Flanged
Flanged storage-heater elements
Two to four hairpins brazed or welded into a round flange, with a pocket tube for the thermostat and safety cut-out.
- Round flanges Ø 48 – Ø 180 mm
- 800 – 3000 W storage heaters
03 · Instantaneous
Instantaneous heater elements
Compact multi-element blocks and tube-in-tube cartridges that heat water as it flows – laid out so that no part of the sheath sees stagnant water.
- 3 – 27 kW instantaneous heaters (multi-element)
- 12 – 25 W/cm² instantaneous heaters
Also in series
Three-phase industrial heaters
Several hairpins on one flange, connected in star or delta, with a terminal box and cable gland.
- 3 – 36 kW three-phase industrial
- 12 – 16 mm industrial immersion heaters
Dry heaters
The element sits in a pocket inside the tank, without contact with the water – no scale on the sheath, and it can be replaced without draining.
- For storage water heaters
Technical drawing · anatomy
Flange, hairpins, pocket: one sealed assembly.
Hairpins and the thermostat pocket are brazed or welded into the flange, and the stem thermostat senses the water through the pocket. Joint and terminal seal have to stay tight through thousands of pressure and temperature cycles.
Sheath for the water
Copper and AISI 304 for soft water; AISI 316L where chlorides are high; nickel-diffusion coated stainless for hard or aggressive water; Incoloy® 825 where chlorides and high temperatures combine. Titanium on request.
Watt density on the heated sheath
6 – 12 W/cm² for storage heaters, lower in hard water, so scale grows slowly and the sheath stays well below its limit even under a scale layer. 12 – 25 W/cm² only where the water flows fast.
Joints and sealing
Brazed or welded tube-to-flange joints; terminal ends sealed with epoxy or silicone resin, or STF in high-humidity installations. In enamelled tanks, isolation from the anode circuit is part of the flange design.
Safety and appliance standards
Thermostat and cut-out pockets, cold-zone length and dry-run behaviour belong to the safety design. Appliances are typically approved to EN 60335-1 with part 2-21 (storage) or 2-35 (instantaneous); drinking-water approvals such as WRAS, DVGW or ACS per project.
Joints and validation
Joined, sealed and tested in our plant.
Tube-to-flange joints are brazed or welded in our own plant and terminal ends are sealed before every element passes a 100 % electrical test – traceable back to the raw-material lot.
Samples are validated in our laboratory before series release: quality and validation laboratory.
- Insulation resistance, dielectric strength and leakage current, measured cold and at operating temperature.
- Corrosion and salt spray on heads, flanges and terminals; humidity storage for the terminal seal.
- Life test at rated power in the target medium.
- Flange pressing and cold-zone verification on assembled heaters.
- Material composition (XRF) and coating thickness on plated and coated sheaths.
Video · on YouTube
How our tubular heating elements are made.
A short film from our YouTube channel: BALÇIK TORMEC tubular heating elements from raw material to the 100 % tested series part – made in Kahramankazan since 1959.
Online catalogue
66 water-heating designs in our online catalogue.
Flange, screw-in, instantaneous and three-phase elements in copper and stainless. Start from the closest design – sheath, surface load and joint follow your water.
Related
Controls, coatings and tools for water heating.
BALÇIK TORMEC stem thermostatsRegulating contact and safety cut-out for the pocket
Nickel diffusion coatingAgainst scale and aggressive water
STF terminal sealingFor high-humidity installations
Engineering calculatorsCheck watt density against the medium
Professional kitchen & laundryBoilers, steam generators and beverage machines
Balçık BrazingFurnace brazing and nickel diffusion coating
Tell us the water. We design the element.
Hardness, chloride content, set-point and duty are enough to start. Add the vessel interface and we propose sheath, surface load and joint – with a target price.
