Overview of the JPC Y3 types enclosures for general uses

The design of Ultimheat connection boxes for immersion heaters was oriented on the multiplicity of applications and therefore every possible machining.
Two lines of aluminum boxes of similar sizes (whose design is registered) exist:
– A “Universal” range which can cover all applications, and allows the mounting of all variants of accessories, including small series.
– A “Simplified” range, designed for specific applications, invariable, and large production series, for which the cost prevails on performance.
The complementary range of plastic enclosures has been designed to be used when aluminum is not convenient.

1. Technical features comparison of “Universal” and “simplified” types

1: M5 lid screw

2: Galvanic corrosion protection washer

3: Unlosable secrew retaining washer

4: Lid wall

5: Lid gasket

6: Bottom wall

7: Crimped nut

8: Nylon on nut

9: Epoxy

10: M4 studs on cover

11: M4 studs on bottom

12: Hole/ thread for cable gland

13: Hole/ thread for immersion heater fitting

14: M4 ground screws

15: Identification label recessed place

1.1 wallsand threads

Universal

– 3mm thick body , (and sometimes 4mm for the bottom) allows to make threads without the need for inside nut, for example, cable glands, plugs for internal adjustment of thermostats and immersion heaters fittings

Simplified

– Walls of 1.7 to 2 mm thick which does not allow tapping.
– Mounting accessories (heater fitting, cable gland) shall be made using an internal nut.

1.2 internal accessories mounting

Universal

– Studs on internal lid for mounting thermostat brackets and waterproof shaft outlet
– Studs on internal lower part of the housing for mounting terminals blocks or other accessories not linked with the lid

Simplified

– No studs for accessories internal mounting,
– Thermostats can be mounted only with holes on cover for shaft and mounting screws

1.3 examples of internal accessories mountings

Universal

Outside adjustment thermostat, waterproof shaft outlet

1: Knob

2: Thermostat shaft

3: Waterproof shaft outlet gasket

4: Lid

5: Bracket

6: Bracket mounting screws

7: Thermostat mounting scews

8: Thermostat

Simplified

Inside adjustment thermostat with inside printed dial

 

1: Cable gland cap

2: Gasket

3: Thermostat shaft (short)

4: Arrow clips

5: Bracket

6: Bracket mounting screws

7: Thermostat mounting screws

8: Printed adhesive dial

Universal

Inside access manual reset thermostat

1: Cable gland cap

2: Gasket

3: Lid

4: Bracket mounting screws

5: Bracket

6: M10 x1 nut

7: Manual reset thermostat

Simplified

Outside access manual reset thermostat

1: Silicone cap

2: Lid

3: Bracket mounting screws

4: Bracket

5: M10 x1 nut

6:Manual reset thermostat

Universal

Inside access 3 pole manual reset, bottom mounted

1: Cable gland cap

2: Gasket

3: Lid

4: Bracket mounting screws

5: Bracket

6: Manual reset shaft

7: 3 Pole manual reset thermostat

8: Thermostat mounting screws

9: Backside thermostat bracket (x2)

10: Backside bracket screws

11: Box bottom

Simplified

Outside access 3 pole manual reset, bottom mounted

1: Silicone cap

2: Lid

3: Bracket mounting screws

4: Bracket

5: Manual reset shaft

6: 3 Pole manual reset thermostat

7: Thermostat mounting screws

8: Backside thermostat bracket (x2)

9: Backside bracket screws

10: Box bottom

1.4 machining

Universal

– Drilling holes and thread tapping are possible on every side upon customer drawings

Simplified

– The hole diameters for immersion heater fittings are defined in the tool and are therefore invariant.
– The diameter and position of the holes for cable glands are defined in the tool and are therefore invariant
– Thread tapping is not possible.

1.5 screws

Universal

– Nyloc nuts: prevent loosening by vibration
– Stainless steel screws and stainless steel nuts to prevent galvanic corrosion between nuts and screws
– Crimped and epoxy sealed nuts to avoid galvanic corrosion between nut and aluminum
– Plastic washer under the screw head : prevents corrosion between the screw head and the lid
– Lid captive screws, A2 stainless steel, with double style recessed head (slot and Pozidriv)
– 2 x M4 Internal threads for grounding, with stainless steel screws and washers. Biggest models have also external grounding screws

Simplified

– Threads for lid screws are tapped directly on aluminum
– No protection against galvanic corrosion
– The lid screws are standard plated steel hex head. Stainless steel captive screws are available as an option.
– No internal grounding screw, but two holes can be threaded for M4 screws.

1.6 accessories

Universal

– Recessed label place to prevent voluntary or involuntary removal
– Holes for hammer drive screw mounting of metal identification plate (On large size models)
– Lid silicone foam gasket: withstand 200 °C and provides good compensation of surface irregularities in the sealing surfaces
– Wide range of internal accessories for mounting thermostats, control or manual reset with waterproof external access or adjustment

Simplified

NBR 70 shore gasket

1.7 surface finish (Aluminium housings options)

Universal

– As cast surface,deburred (last character of reference= 0)
– As cast, vibration polished and deburred (last character of reference = 7)
– Sand blasted finish to provide the best bonding with epoxy paint (last character of reference= 1)
– RAL 7035 grey epoxy paint: last character of reference = G (other colours are available on request).

Simplified

– As cast surface, deburred (last character of reference= 0)
– As cast, vibration polished and deburred (last character of reference = 7)

Cast surface

Vibration polished

Sand blasted

“Orange skin” epoxy painting

1.8 minimum ordering quantities

Universal

– 1 piece (MOQ apply for epoxy painting)

Simplified

– 1000 pieces for products already tooled
– 5000 pieces box with holes or specific dimensions not already tooled