HM — HMT108 Ceramic Mat Heater Repair Kit

60V / 80V Compatible | 80/20 Nickel-Chrome Heating Wire | Nickel 212 TIG-Welded Cold Tails | 2× Male 60 Amp Camlocks (Twistlocks)SKU: HMT108

Overview

The HM HMT108 is a professional-grade ceramic mat heater repair kit designed to restore damaged or failed flexible ceramic mat (pad) heaters to full operational condition — extending the service life of existing heaters and avoiding the cost and lead time of full heater replacement. Built to the same exacting material standards as new OEM ceramic mat heaters, the HMT108 kit provides everything needed to repair the heating element and connection tails of a 60V or 80V ceramic mat heater used in post-weld heat treatment (PWHT) and preheat applications.

At the heart of the kit is a length of 80/20 Nickel-Chrome (NiCr) 19 multi-strand heating wire — the same wire alloy and construction used in the manufacture of premium flexible ceramic mat heaters worldwide. The cold tail connections are made from Nickel 212 pure nickel wire, TIG-welded to the hot zone heating element to ensure a metallurgically sound, low-resistance joint that keeps the full heat of the circuit concentrated in the ceramic-beaded heating zone and away from the camlock connectors. Two complete male 60-amp camlock (twistlock) connectors are included — ready to install and connect directly to the power console output camlocks.

What's Included

Box Dimensions & Shipping Weight (Estimated)

80/20 Nickel-Chrome Heating Wire — The Industry Standard

The 80/20 Nickel-Chrome (NiCr80/20) alloy is the universal heating element material for flexible ceramic mat heaters in PWHT and preheat applications — and for good reason. Its properties make it uniquely suited for continuous, high-temperature resistance heating duty:

• High resistivity — generates efficient, consistent heat output at the low voltages (60V and 80V) used by field heat treatment power consoles
• Excellent oxidation resistance — maintains electrical and mechanical properties at temperatures up to 1,050°C (1,922°F) without significant oxidation or degradation
• Stable resistance — resistance value remains consistent across the full operating temperature range, ensuring predictable and controllable heat output throughout the heat treatment cycle
• High ductility — the 19 multi-strand wire construction maintains flexibility even after repeated thermal cycling, preventing wire breakage from bending fatigue during heater handling, positioning, and repeated use
• Compatible with 60V and 80V systems — the same alloy and wire construction serves both voltage ratings, making this a single versatile repair kit for mixed-voltage heat treatment fleets

Nickel 212 Cold Tail Wire — TIG Welded for Maximum Reliability

The cold tail wires are the critical transition zone between the high-temperature NiCr heating element and the camlock connectors. Correctly engineered cold tails perform two essential functions:

• Electrical transition — carry full circuit current from the heating zone to the camlock connectors with minimal resistance, preventing heat buildup in the tail region that would otherwise damage the camlock connectors and the insulating bead string
• Thermal gradient management — the longer the cold tail, the greater the temperature drop between the hot zone and the connector. The Nickel 212 pure nickel wire has a lower resistivity than the NiCr heating element — so it generates significantly less heat per unit length than the active heating zone, keeping the camlocks at a safe operating temperature even during extended heat treatment cycles at maximum temperature

The TIG-welding process used to join the Nickel 212 cold tail to the NiCr heating wire produces a superior metallurgical bond compared to mechanical crimping or brazing:

• Full fusion joint — complete metallurgical continuity across the joint with no gaps, voids, or partially bonded areas that could create local resistance hot spots
• High joint strength — the TIG-welded joint is stronger than the parent wire in tension, preventing joint failure from the mechanical stresses of heater handling and thermal cycling
• Low contact resistance — the clean, oxide-free fusion interface minimizes joint resistance, ensuring consistent electrical performance and preventing joint overheating

60 Amp Male Camlock Connectors — Ready to Install

The two included male 60-amp camlock connectors (twistlocks) are the industry-standard connection interface between ceramic mat heaters and heat treatment power console output circuits. Key features:

• 60-amp current rating — matched to the standard 60A circuit capacity of 60V (2.7 kW) and 80V (3.6 kW) ceramic mat heaters
• Twistlock design — a quarter-turn locking action provides fast, secure, and positive connection to female panel-mount camlock receptacles on the power console — no tools required
• Male configuration — correct polarity for connection into female camlock sockets on the power console output panel
• Complete assemblies — supplied ready to install; no additional hardware or assembly required
• Standard compatibility — compatible with all standard 60-amp camlock (twistlock) systems used by Hotfoil-EHS, EHS, and other major heat treatment power console manufacturers

Why Repair Rather Than Replace?

Ceramic mat heaters represent a significant investment — particularly larger heater configurations used for pressure vessel and structural PWHT operations. The most common failure modes of ceramic mat heaters are not failures of the ceramic bead structure itself, but localized failures of the heating wire, cold tails, or camlock connectors — all of which are fully addressable with the HMT108 repair kit:

• Broken or burned-out heating wire — repaired by splicing in new NiCr wire using the appropriate ceramic bead section
• Failed or corroded cold tail wires — replaced with new Nickel 212 wire, TIG-welded to the existing or new heating element
• Damaged or seized camlock connectors — replaced with the included new male 60-amp camlocks
• Combined cold tail and connector failure — the most common repair scenario, fully addressed by the complete HMT108 kit

A heater repaired with the HMT108 kit using the correct materials and welding technique will perform identically to a new heater — at a fraction of the replacement cost.

Ideal Applications

• Repair of damaged 60V and 80V flexible ceramic mat (pad) heaters for PWHT and preheat operations
• Replacement of failed or corroded cold tail assemblies on existing ceramic mat heaters
• Replacement of damaged, seized, or worn 60-amp camlock connectors
• Field repair of ceramic mat heaters on active construction, fabrication, or maintenance sites
• Workshop refurbishment of used or returned ceramic mat heater stock
• Maintenance stock for heat treatment contractors operating large ceramic mat heater fleets

Compatible With

• All standard 60V and 80V flexible ceramic mat heaters using 80/20 NiCr heating wire
• Hotfoil-EHS power consoles with 60-amp camlock outputs
• EHS, Maritime Stress, and all other manufacturers' 60-amp twistlock-equipped ceramic mat heaters and power console systems