Heating system and terminal assembly for heating system

Abstract

A terminal assembly for a heater system includes a plurality of resistive heating elements arranged in a plurality of power supply phases, the terminal assembly including a plurality of power supply busbars, a neutral busbar, a phase barrier disposed between each of the plurality of power supply busbars, and a plurality of interchangeable couplings. Each power supply bus corresponds to one of the plurality of power supply phases and is configured to connect a power lead from the one of the plurality of power supply phases and a first end of the plurality of resistive heating elements. The resistive heating element is in electrical communication with the power lead. The neutral bus bar is longitudinally offset from the power supply bus bar and is configured to receive the second end of the resistive heating element. The interchangeable coupler is configured to connect at least a subset of the resistive heating elements to at least one supply bus or at least one neutral bus.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Patent Application No. 17 / 719,841, filed on April 13, 2022. The disclosure of the above application is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to heating systems and, more particularly, to heat exchangers or electric circulation heaters having resistive heating elements and configurations of electrical terminals for connecting the resistive heating elements to a power source. Background Art

[0004] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0005] Industrial electric heaters typically utilize resistive heating elements that convert electrical energy into heat to heat materials such as solids, liquids, or gases. In some applications, the resistive heating elements are immersed in the liquid or gas, or the liquid or gas flows between the resistive heating elements. In some applications, a large amount of power is used to bring the material to the desired temperature. For example, some applications require power greater than 1 megawatt, and some applications are in the range of 5 megawatts or more. Typical low-voltage electric heaters operate at around 700 volts, but may require high current (e.g., over 7,000 amperes) to achieve the required power. High current may require large and expensive electrical components, cables, and grounding strategies. In addition, some industrial power supplies require step-down transformers to provide the low voltage.

[0006] The present disclosure addresses issues associated with connecting and disconnecting resistive heating elements to a power source in these industrial applications, including medium pressure heating systems, as well as other challenges of fluid heating vessels. Utility Model Content

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0008] As used herein, the term "medium voltage" should be interpreted to mean approximately 2,000 V to 20,000 V. However, it should be understood that the teachings of the present disclosure are not limited to medium voltage heaters or heater systems.

[0009] In one form, the present disclosure provides a terminal assembly for a heater system having a plurality of resistive heating elements arranged in a plurality of power phases. The terminal assembly includes a plurality of power busbars, a neutral busbar, a phase barrier, and a plurality of interchangeable connectors. Each power busbar corresponds to one of the plurality of power phases. Each power busbar is configured to connect a power lead from one of the plurality of power phases to a first end of a plurality of resistive heating elements such that the plurality of resistive heating elements are electrically connected to the power lead. The neutral busbar is longitudinally offset from the plurality of power busbars and is configured to receive a second end of the plurality of resistive heating elements. The phase barrier is disposed between each of the plurality of power busbars. The plurality of interchangeable connectors are configured to connect at least a subset of the plurality of resistive heating elements to at least one power busbar or at least one neutral busbar.

[0010] In a variation of this terminal assembly, it can be implemented individually or in any combination: the terminal assembly includes a plurality of shunt busbars, each shunt busbar corresponds to one of the plurality of power phases, and each shunt busbar is configured to connect one or more of the plurality of resistive heating elements in series; the plurality of shunt busbars are longitudinally offset between the plurality of power busbars and the neutral busbar; the plurality of power phases include three power phases; the terminal assembly further includes a substrate, which is longitudinally offset from the neutral busbar; the terminal assembly further includes a plurality of mounting posts, which are arranged between the substrate and the neutral busbar and at least one of the plurality of power busbars; each power busbar connects the power lead from one of the plurality of power phases on one side and the first end of the plurality of resistive heating elements on the opposite side; each of the plurality of power busbars and the neutral busbar includes a plurality of through holes, and the plurality of interchangeable connectors are installed in the through holes; at least one interchangeable connector includes at least one contact arm, and the At least one of the through holes defines at least one slot, and the at least one contact arm of the at least one interchangeable connector is configured to be inserted through the at least one slot and rotated to abut against opposite sides of the at least one power bus or the at least one neutral bus; the at least one interchangeable connector includes opposing contact arms, and the at least one through hole defines opposing slots, and the opposing contact arms are configured to be inserted through the opposing slots and rotated to abut against the opposite sides of the at least one power bus or the at least one neutral bus; at least one interchangeable connector includes a threaded inner hole, and the terminal assembly further includes a fastener disposed in the threaded inner hole to secure the at least one interchangeable connector to the at least one power bus or the at least one neutral bus; the plurality of interchangeable connectors are conductive to provide active electrical connection to the corresponding resistive heating elements, or are non-conductive to provide passive electrical connection to the corresponding resistive heating elements; the phase barrier includes a central axis and a plurality of blades extending radially away from the central axis.

[0011] In another form of the present disclosure, a heating system includes a terminal assembly as described above and a plurality of resistive heating elements coupled to the terminal assembly. In variations of this heating system, which may be implemented individually or in any combination, the first and second ends of the plurality of resistive heating elements are positioned within the terminal assembly, and at least one of the first and second ends is decoupled from a plurality of power busbars and / or neutral busbars via a non-conductive, interchangeable coupling; at least one of the resistive heating elements includes a terminal extension disposed within one of the interchangeable couplings; and the heating system further includes insulating material surrounding the terminal extension.

[0012] In yet another form of the present disclosure, a terminal assembly for a heater system having a plurality of resistive heating elements arranged in a plurality of power phases includes a plurality of supply busbars, a neutral busbar, a plurality of shunt busbars, a phase barrier, and a plurality of interchangeable resistive heating elements. Each supply busbar corresponds to one of the plurality of power phases, and each supply busbar is configured to connect a supply lead from one of the plurality of power phases to first ends of the plurality of resistive heating elements, such that the plurality of resistive heating elements are in electrical communication with the supply leads. The neutral busbar is longitudinally offset from the plurality of supply busbars and is configured to receive second ends of the plurality of resistive heating elements. Each shunt busbar corresponds to one of the plurality of power phases and one of the plurality of supply busbars, and each shunt busbar is configured to connect at least two of the plurality of resistive heating elements in series between the corresponding supply busbar and the neutral busbar. A phase barrier is disposed between each supply phase of the plurality of supply busbars and the plurality of shunt busbars. A plurality of interchangeable connectors are configured to connect at least a subset of the plurality of resistive heating elements to at least one supply busbar or at least one neutral busbar.

[0013] In a variation of this terminal assembly, it can be achieved individually or in any combination: the multiple shunt busbars are longitudinally offset between the multiple power supply busbars and the neutral busbar; each of the multiple power supply busbars, each of the multiple shunt busbars and the neutral busbar are spaced apart from each other; the multiple power supply phases include three power supply phases; the terminal assembly further includes a substrate longitudinally offset from the neutral busbar; and the terminal assembly further includes a plurality of mounting posts, which are arranged between the substrate and the neutral busbar and between the substrate and the multiple shunt busbars.

[0014] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order that the present disclosure may be better understood, various forms thereof, shown by way of example, will now be described with reference to the accompanying drawings, in which:

[0016] Figure 1 is a perspective view of a power supply portion and a resistive heating element of a heater system for a circulation heater or heat exchanger according to the teachings of the present disclosure;

[0017] Figure 2 According to the teachings of this disclosure Figure 1 An enlarged fragmentary perspective view of an end portion of a heater system;

[0018] Figure 3is an enlarged fragmentary perspective view of a resistive heating element according to the teachings of the present disclosure with the end cap removed to expose Figure 2 The U-shaped bend return in the end;

[0019] Figure 4a is constructed according to the teachings of this disclosure Figure 1 A perspective view of a terminal assembly of a heater system;

[0020] Figure 4b is constructed according to the teachings of this disclosure Figure 4a An enlarged perspective view of an exemplary through hole of a power supply busbar of a terminal assembly;

[0021] Figure 5a yes Figure 4a Exploded perspective view of the supply busbar, optional shunt busbar, and neutral busbar of the terminal assembly;

[0022] Figure 5b yes Figure 5a A three-dimensional diagram of the power supply bus;

[0023] Figure 5c yes Figure 5a Exploded three-dimensional diagram of the shunt busbar;

[0024] Figure 6a is a perspective view of an interchangeable coupling constructed in accordance with the teachings of the present disclosure;

[0025] Figure 6b yes Figure 6a a bottom perspective view of the interchangeable coupling shown;

[0026] Figure 7 is installed through a through hole in one of the busbars according to the teachings of the present disclosure Figure 6a A perspective cross-sectional view of an interchangeable coupling (without its mechanical fasteners installed);

[0027] Figure 8 According to the teachings of this disclosure Figure 7 a perspective cross-sectional view of an interchangeable coupling (with its mechanical fasteners installed);

[0028] Figure 9 is a perspective view of another form of a power bus and a neutral bus having a square phase barrier configuration constructed in accordance with the teachings of the present disclosure;

[0029] Figure 10 According to the teachings of this disclosure Figure 9 An enlarged stereogram of the busbar and phase barrier;

[0030] Figure 11 is a front view of another form of power supply busbar in a three-phase configuration constructed according to the teachings of the present disclosure;

[0031] Figure 12 is a busbar having a busbar not shown according to the teachings of the present disclosure Figure 11 A front view of the power supply bus;

[0032] Figure 13 According to the teachings of this disclosure Figure 11 A side view of the power supply bus; and

[0033] Figure 14 According to the teachings of this disclosure Figure 11 Electrical schematic diagram of the three-phase power provided by the power supply bus. DETAILED DESCRIPTION

[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0035] refer to Figures 1 to 2 By way of example, a heating system for an electric circulation heater is shown and generally designated by reference numeral 10 , the heating system 10 including a heating portion 12 , a distal portion 14 , and a power supply portion 16 , the heating portion 12 including a plurality of resistive heating elements 18 extending parallel to a longitudinal axis “L” of the heating system 10 between the power supply portion 16 and the distal portion 14 .

[0036] Also refer to Figures 2 to 3 At the distal portion 14, each resistive heating element 18 extends from the power supply portion 16 and is bent into a curve at the distal portion 14 (eg Figure 3 1 and 2. As shown in FIG. 1 , the resistive heating element 18 extends back into the power supply portion 16 and into the power supply portion 16. In one form, each resistive heating element 18 comprises at least one resistive wire 19 with an electrical wiring end (e.g., a power pin, further described below with reference to the power supply portion 16), an insulating material 21, and an outer sheath 23. Typically, the insulating material 21 wraps around the resistive wire 19, and a portion of the electrical wiring end. The outer sheath 23 houses the resistive wire 19, the insulating material 21, and a portion of the electrical wiring end. This structure is often referred to as a "tubular" heater, however, the teachings herein should not be construed as being limited to this particular heater structure. For example, the teachings herein may be applied to systems having a cartridge heater or a cable heater, etc., while remaining within the scope of the present disclosure.

[0037] Return Reference Figure 1 The power supply section 16 includes an enclosure 20, connections for a multi-phase power source 22, and a terminal assembly 100. The enclosure 20 is generally a housing designed to separate the three-phase power source 22 and the terminal assembly 100 from the resistive heating element 18 and to protect the terminal assembly 100 from the external environment.

[0038] Now refer to Figure 4a and Figure 4b , showing the terminal assembly 100 in more detail. The terminal assembly 100 includes a plurality of longitudinally arranged conductive busbars, and more specifically, a supply busbar 102, a neutral busbar 104, and an optional shunt busbar 106. In this form, a total of three (3) supply busbars 102, a single neutral busbar 104, and three (3) shunt busbars 106 are configured for a three-phase power configuration. However, it should be understood that any number of busbars may be employed to support a different number of power phases while remaining within the scope of the present disclosure. These conductive busbars are generally used as electrical bus elements to connect the resistive heating elements 18 to each other and to the appropriate power connections (i.e., power, return, ground). Therefore, the name "busbar" should not be interpreted as limiting these elements to any particular shape or geometric configuration.

[0039] In one form, an electrical circuit (not shown) is optionally embedded in at least one of the plurality of longitudinally arranged conductive plates. This configuration is shown in co-pending U.S. application Ser. No. 17 / 558,956, entitled "ENCAPSUED BUS CIRCUIT FOR FLUIDHEATING SYSTEMS," which is commonly owned with the present application and the contents of which are incorporated herein by reference in their entirety. The electrical circuit is similar to a printed circuit board structure, wherein the circuit provides the necessary electrical connections and controls for the electric heater during operation. However, it should be understood that the circuit can alternatively be applied (e.g., deposited, bonded) to the distal end face of the conductive busbar, rather than being embedded, while remaining within the scope of the present disclosure.

[0040] The power bus 102 is configured to connect the power source 22 to the resistive heating element 18. Figure 4a Combined with Figure 1 Each power bus 102 includes a terminal 108 to connect a power lead 109 from the power source 22 to a first end (near the power supply portion 16) of a plurality of resistive heating elements 18, so that the power bus 102 is used to provide bus power to different groups of resistive heating elements 18.

[0041] The neutral bus 104 serves as a power return and is longitudinally offset from the power bus 102 as shown. The neutral bus 102c serves as a power return and is configured to receive the second ends (proximate the power supply section 16) of the plurality of resistive heating elements 18. In one form, the neutral bus 104 is annular and is a single piece as shown. However, it should be understood that the configuration of the neutral bus 104 can be any shape and / or number and still be within the scope of the present disclosure. The neutral bus 110 includes a neutral connection post (not shown) that is configured to connect to the neutral lead ( Figure 1 , element 111), so that one end of the resistance heating element 18 is connected to the neutral lead 111.

[0042] The shunt busbars 106 are optional and are configured as shunts to provide additional resistance to achieve a desired power density. More specifically, each shunt busbar 106 corresponds to one of a plurality of supply phases and is configured to connect one or more of a plurality of resistive heating elements 18 in series. The shunt busbars 106 are also longitudinally offset from the supply busbars 102 and the neutral busbar 104, which provides sufficient dielectric isolation for operation at medium voltage. Both the supply busbars 102 and the optional shunt busbars 106 are spaced apart or separated from each other to dielectrically separate the different supply phases and suppress arcing, as described in more detail below. It should be understood that the configuration of the plurality of shunt busbars 106 may also be of any geometry or number and still be within the scope of the present disclosure.

[0043] Now refer to Figure 4b and Figures 5a to 5c , each of the power bus 102, the neutral bus 104, and the optional shunt bus 106 includes a plurality of through-holes 105 configured to receive electrical terminal portions of a plurality of resistive heating elements 18. In one form shown, the plurality of through-holes 105 are slotted in shape. More specifically, each through-hole 105 defines a central portion 105a and a set of opposing slots or notches 105b. In the example shown, the central portion 105a has a generally circular shape, and the opposing slots 105b have a generally rectangular shape. It should be understood that the shape of the plurality of through-holes 105 can accommodate any geometric shape without departing from the scope of the present disclosure.

[0044] Now refer to Figure 4a and Figures 6 to Figure 8 , provides an innovative interchangeable coupler 114 that is configured to connect one end of the electric heating element 18 to at least one of the busbars 102, 104, 106 described above. Each interchangeable coupler 114 is configured to be installed within a corresponding through hole 105 of the busbars 102, 104, 106. More specifically, each interchangeable coupler 114 includes a body 116. The body 116 includes an upper end 118, a lower end 200, and an inner cavity 202 extending from the upper end 118 to the lower end 200. In one form, the inner cavity 202 is as shown in FIG. Figure 8 The bottom 200 of the body 116 also includes a plurality of elastically flexible (or elastically deformable) gripping members or flexible fingers 204 separated by slots 205. The inner cavity 202 also includes a lower hole 203 ( Figure 6b), whose diameter is slightly smaller than the outer diameter of the end legs 207 of the resistive heating element 18, so that when the connecting legs 207 of the corresponding heating element 18 are inserted into the lower hole 203, the flexible claws 204 are configured to deflect outward. As a result, the flexible fingers 204 contact the corresponding heating element 18 and secure it in place. In one form shown, a total of four (4) flexible fingers 204 are used, however, it should be understood that any number of flexible fingers 204 can be used while remaining within the scope of the present disclosure.

[0045] As further shown, the body 116 also includes at least one contact arm 206 extending outwardly from the body at the upper end portion 118 of the body 116. The contact arm 206 of each interchangeable connector 114 is configured to be inserted through a corresponding slot 105b (at Figure 4b and is rotated so that its upper surface abuts the opposite side of one of the busbars 102, 104, 106 (at Figure 7 and 8 105b) is best shown in FIG. In one form, each interchangeable connector 114 includes two diametrically opposed contact arms 206, as shown. The diametrically opposed contact arms 206 are similarly configured to be inserted through opposing slots 105b and rotated to abut opposing sides of the respective busbars 102, 104, 106. In one form, the contact arms 206 rotate approximately 90 degrees to lock the interchangeable connector 114 in place. It should be understood that each interchangeable connector 114 may include any number of contact arms 206, and that each of the plurality of through-holes 105 defines a minimum number of slots to at least equal the number of contact arms 206 provided on the respective interchangeable connector 114.

[0046] As further shown, each interchangeable coupler 114 includes a fastener 208 configured to be secured within a threaded portion of the inner bore 202 to secure the corresponding interchangeable coupler 114 to at least one of the busbars 102, 104, 106. A washer 209, which in one form is a Belleville washer, is provided below the head of the fastener 208 and is optional to prevent the fastener 208 from loosening and to distribute torsional loads.

[0047] In one form, the interchangeable coupling 114, and more specifically the body 116, is electrically conductive to provide an active electrical connection of the respective resistive heating elements 18 to the respective busbars 102, 104, 106. However, in another form, the body 116 of the interchangeable coupling 114 is non-conductive to provide a passive electrical connection of the respective resistive heating elements 18, with the non-conductive interchangeable coupling being used when any of the resistive heating elements 18 is not active or "out of circuit." When it is desired to electrically connect the resistive heating elements 18, the non-conductive interchangeable coupling is removed and a conductive interchangeable coupling is inserted in its place.

[0048] Return to reference Figure 4a , the terminal assembly 100 further includes a base plate 210 that is longitudinally offset from the neutral busbar 104. In one form, the base plate 210 is a generally disc-shaped body that encloses and seals one end of a tube (not shown) that encloses the heating element 18, it being understood that the base plate 210 may be shaped in any manner and still be within the scope of the present disclosure. The base plate 210 includes a plurality of through-holes 212 that are generally configured to receive the resistive heating element 18. In addition, the terminal assembly 100 includes a plurality of mounting posts 214 to establish the appropriate offset between the busbars 102, 104, 106.

[0049] Continue to refer to Figure 4a In one form, the terminal assembly 100 includes a phase barrier 222 disposed between a central portion of the substrate 210 and between the plurality of busbars 102, 104, 106. The phase barrier 222 includes an electrically insulating material such that the phase barrier 222 provides dielectric isolation between each powered phase of the busbars 102, 104, 106. As shown, in one form, the phase barrier 222 includes a central spindle 224 and a plurality of blades 226. The plurality of blades 226 are securely coupled to the central spindle 224 and extend radially outward from the central spindle 224 between the busbars 102, 104, 106. In one form, the blades 226 are mechanically secured to the central spindle 224, however, the central spindle 224 and the blades 226 may be formed as a single, integral piece.

[0050] Now refer to Figure 9 and Figure 10, an alternative form of phase barrier having a square pattern is shown and is generally designated by the reference numeral 300. In this form, a total of nine (9) conductive busbars 310 (power busbars) and 320 (neutral busbars) are employed, and each conductive busbar is individually separated by a phase barrier 300. Thus, as shown, one end of each resistive heating element 18 is electrically connected to the power busbar 310, while the other end of the resistive heating element 18 is electrically connected to the neutral busbar 320. The interchangeable couplers 114 shown and described above are used with this variation of the present disclosure to secure the resistive heating elements 18 to the busbars 300 / 310, but are not shown for clarity. It should be understood that these and other configurations of phase barriers and busbars (including the shunt busbars shown and described above) should be construed as falling within the scope of the present disclosure.

[0051] Reference Figures 11 to 14 , shows an exemplary structure of a three-phase power supply having power supply busbars 400, 410, and 420 in a triangular configuration. The resistive heating element 18 is connected to each busbar at a smaller through-hole 500 as shown, while a larger through-hole 510 is provided to pass through to connect the resistive heating element 18 from busbar 400 to busbar 420. ( Figure 12 ) It should be understood that this configuration of busbars, resistive heating element connections, and three-phase power is merely exemplary and is provided to illustrate various configurations that may be used with the innovative terminal assemblies and interchangeable connectors according to the teachings herein.

[0052] Unless otherwise expressly indicated herein, when describing the scope of the present disclosure, all numerical values ​​expressing mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics should be understood as modified by the word "about" or "approximately." Such modifications are required for various reasons, including industrial practice, materials, manufacturing and assembly tolerances, and testing capabilities.

[0053] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0054] The apparatus and methods described in this application may be implemented in part or in whole by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions contained in a computer program. The above-described functional blocks, flow chart components, and other elements serve as software specifications, which can be converted into a computer program by routine work of a skilled technician or programmer.

[0055] The description of the present disclosure is merely exemplary in nature and, thus, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

Claims

1. A terminal assembly for a heater system having a plurality of resistive heating elements arranged in a plurality of power phases, the terminal assembly comprising: a plurality of power busses, each power bus corresponding to one of the plurality of power phases, and each power bus being configured to connect a power lead from one of the plurality of power phases to first ends of a plurality of resistive heating elements such that the plurality of resistive heating elements are in electrical communication with the power lead; a neutral busbar longitudinally offset from the plurality of power busbars and configured to receive second ends of the plurality of resistive heating elements; a phase barrier disposed between each of the plurality of power supply buses; as well as A plurality of interchangeable couplings are configured to connect at least a subset of the plurality of resistive heating elements to at least one power bus or at least one neutral bus.

2. The terminal assembly of claim 1 , further comprising a plurality of shunt busbars, each shunt busbar corresponding to one of the plurality of power phases, and each shunt busbar being configured to connect one or more of the plurality of resistive heating elements in series.

3. The terminal assembly according to claim 2, wherein: The plurality of shunt busbars are longitudinally offset between the plurality of power busbars and the neutral busbar.

4. The terminal assembly according to claim 1, wherein The plurality of power supply phases includes three power supply phases.

5. The terminal assembly of claim 1, further comprising a base plate longitudinally offset from the neutral busbar. 6 . The terminal assembly of claim 5 , further comprising a plurality of mounting posts disposed between the base plate and at least one of the neutral busbar and the plurality of power busbars.

7. The terminal assembly according to claim 1, wherein Each power busbar is connected on one side to a power lead from one of the plurality of power phases and on an opposite side to first ends of a plurality of resistive heating elements.

8. The terminal assembly according to claim 1, wherein Each of the plurality of power busbars and the neutral busbar includes a plurality of through-holes, and the plurality of interchangeable couplers are mounted within the through-holes.

9. The terminal assembly according to claim 8, wherein: At least one interchangeable connector includes at least one contact arm, and at least one of the through-holes defines at least one slot, wherein the at least one contact arm of the at least one interchangeable connector is configured to be inserted through the at least one slot and rotated to abut an opposite side of the at least one power bus or the at least one neutral bus.

10. The terminal assembly according to claim 9, wherein The at least one interchangeable connector includes opposing contact arms, and the at least one through-hole defines opposing slots, wherein the opposing contact arms are configured to be inserted through the opposing slots and rotated to abut the opposing sides of the at least one power bus or the at least one neutral bus.

11. The terminal assembly of claim 1 , wherein at least one interchangeable connector comprises a threaded inner hole, and the terminal assembly further comprises a fastener disposed in the threaded inner hole to secure the at least one interchangeable connector to the at least one power bus or the at least one neutral bus.

12. The terminal assembly according to claim 1, wherein The plurality of interchangeable couplers are either electrically conductive to provide active electrical connection of the corresponding resistive heating elements or non-conductive to provide passive electrical connection of the corresponding resistive heating elements.

13. The terminal assembly according to claim 1, wherein The phase barrier includes a central spindle and a plurality of blades extending radially away from the central spindle.

14. A heating system comprising: The terminal assembly according to claim 1; as well as The plurality of resistive heating elements are coupled to the terminal assembly.

15. The heating system of claim 14, wherein: The first and second ends of the plurality of resistive heating elements are positioned within the terminal assembly, and At least one of the first and second ends is decoupled from the plurality of power busbars and / or neutral busbars via a non-conductive interchangeable coupling.

16. The heating system according to claim 15, wherein At least one resistive heating element includes a terminal extension disposed within one of the interchangeable couplings.

17. The heating system of claim 16, further comprising insulating material surrounding the terminal extension.

18. A terminal assembly for a heater system having a plurality of resistive heating elements arranged in a plurality of power phases, the terminal assembly comprising: a plurality of power busses, each power bus corresponding to one of the plurality of power phases, and each power bus being configured to connect a power lead from one of the plurality of power phases to first ends of a plurality of resistive heating elements such that the plurality of resistive heating elements are in electrical communication with the power lead; a neutral busbar longitudinally offset from the plurality of power busbars and configured to receive second ends of the plurality of resistive heating elements; a plurality of shunt busbars, each shunt busbar corresponding to one of the plurality of power phases and one of the plurality of power busbars, and each shunt busbar being configured to connect at least two of the plurality of resistance heating elements in series with each other between the corresponding power busbar and the neutral busbar; a phase barrier disposed between the plurality of power supply buses and each power supply phase of the plurality of shunt buses; as well as A plurality of interchangeable couplings are configured to connect at least a subset of the plurality of resistive heating elements to at least one power bus or at least one neutral bus.

19. The terminal assembly according to claim 18, wherein The plurality of shunt busbars are longitudinally offset between the plurality of power busbars and the neutral busbar.

20. The terminal assembly according to claim 18, wherein Each of the plurality of power bus bars, each of the plurality of shunt bus bars, and the neutral bus bar are spaced apart from one another.

21. The terminal assembly according to claim 19, wherein The plurality of power supply phases includes three power supply phases.

22. The terminal assembly of claim 19, further comprising a base plate longitudinally offset from the neutral busbar.

23. The terminal assembly of claim 22, further comprising a plurality of mounting posts disposed between the base plate and the neutral bus bar and between the base plate and the plurality of shunt bus bars.

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