Ceramic Infrared Heaters – Specifications

Ceramic infrared heaters are 96% infrared energy efficient. Uses for electric infrared heat can be found in many industries and applications and can be grouped into four major categories:

a. Curing
b. Drying
c. Heating

Within each of these major categories are literally hundreds of specific applications, and the list keeps growing as technology develops.

Our ceramic infrared heaters (emitters) are manufactured with three basic emitter faces: Concave, Flat and Convex. These emitter face styles will result in the specific radiant emission pattern as shown in our Ceramic Infrared Emitters Technical Manual. The concave surface will emit a “concentrated” radiant pattern which is highly effective when zone heating is desired as well as radiant heating in general. Flat surface emitters will produce a “uniform” pattern for even heating at a close proximity between the emitter and the target being heated. Finally, the convex shaped emitter gives off a “wide area”

pattern which is desirable in comfort heating or other applications that require a dispersed radiant emission pattern.

These heaters are durable, splash-proof and have a non-corrosive finish. Maximum temperature output of up to 1292*F (700*C).

TUBULAR HEATER FOR MANIFOLDS AND HOT PLATES / BLOCKS

Tubular Heaters are generally Formed to specified sizes in Hot Runner Manifolds and Hot Plates. these heaters are mainly used for Hot Runner manifolds and Hot Plates .We offer Tubular Heaters for superior performance and life expectancy to withstand high sheath temperature and provide the best combination of physical strength, high emissivity & good thermal conductivity to heat hot runner manifolds and Hot Plates.For manufacturing manifold tubular heaters it is necessary to provide an accurate dimensional sketch showing all centre distances, bending radius and path.Formed Tubular Heaters is supplied in Chrome Nickel Steel with nominal sheath diameter of 6 mm, 6.5 mm and 8.00mm Standard elements have a threaded terminal post which gives a cold section of approx 40mm minimum.For manufacturing manifold tubular heaters it is necessary to provide an accurate dimensional sketch showing all centre distances, bending radius and path.

How To Order

Please send a detailed dimensional drawing file showing all center distances along with

• Total path length
• Wattage
• Voltage
• Required quantity

TUBULAR HEATERS: FOR MANIFOLDS AND HOT PLATES – APPLICATIONS

TUBULAR HEATERS: FOR MANIFOLDS AND HOT PLATES – TECHNICAL DATA

Length 300 -1550mm 400 – 2100mm
 Maximum Current 12 A 15 A
 Nominal Voltage < 230V < 400V
 Wattage ±10% ±10%
 Dielectric Strength 1.5 HV 1.5 HV
 Insulation MΩ >5Ω >5Ω
 Leakage Current < 0.5 mA < 0.5 mA
 Minimum Unheated 40mm 45mm
 Terminal Pins M3 x .50mm/ Plain M4 x .70mm

LENGTH TOLERANCES – ± 2 %

DIAMETER TOLERENCE – ± 0.10 mm

What is a Cartridge Heater?

A cartridge heater is a device that is usually tubular and is inserted into drilled holes of metal blocks for heating.

Cartridge Heater Selection

The key questions which need to be answered before selecting a cartridge heater are:

  •  How much wattage is required?
  •  What voltage will be used?
  •  What is the heated length required?
  •  How long do the heater leads need to be?
  •  What is the diameter required?
  •  What is maximum temperature?
  •  What is the ambient temperature?

Application Of Cartridge Heaters

The majority of applications do not require maximum watt/in². Use a watt density only as high as needed. Take advantage of the safety margin provided by using ratings less than the maximum allowed. Select space heaters for most even heat pattern rather than the highest possible wattage per heater.

Hi-Density Cartridge Heaters

Hi-Density Heaters provide localized heating in processes requiring close temperature control such as:

  • Dies
  • Molds
  • Hot stamping
  • Packaging equipment
  • Plastic extruders
  • Injection molding mach.
  • Platens
  • Labeling
  • Bag sealing
  • Medical equipment

Maximum Temperature:

932°F (500°C).

Hi-Density Cartridge Heaters Metric Diameters

Standard Sizes and Ratings by Diameter

6.5mm,  8 mm,  10 mm,   11.5mm,  11.8mm,  12.5 mm,  16 mm,  18.5 mm,  19.5 mm,   20 mm

Other Sizes can be also made as per specifications

Temperature Controllers and Sensors for Cartridge Heaters

The sensor for the temperature control is also an important factor and should be placed between the working surface of the part and the heaters. The temperature of the part approximately 1/2″ away from the heaters is used in selecting maximum allowable Watt density from the graph.Control of power is an important consideration in high Watt density applications. On-off control is frequently utilized, but it can cause wide excursions in the temperature of the heater and working parts. Thyristor power controls are valuable in extending the life of high Watt density heaters, since they effectively eliminate on-off cycling.There are a variety of temperature controllers and sensors one can use depending on the application. One of the more popular sensor types for cartride heater applications are the surface mount temperature sensors. Thermocouple, RTD or Thermistors are available with an adhesive backing or the ability to be cemented to the surface being heated. There also bolt on and magnetic surface mount type temperature sensors available. Digital temperature controllers come in many different sizes with many output and input choices. Thermcouple and RTD inputs are the most popular with a dc pulse output. DC pulse ouputs allow the user to go to a larger relay to switch the heater load and use proportional control versus on/off control which can shorten the heater life.

Important Installation Considerations

1. For closest fit and best heat transfer, use reamed holes.
2. When possible, drill holes through the object being heated. This will make heater removal easier.
3. When using an anti-seize coating like Copper Graphite paste, do not apply over lead wires or any other current carrying conductors.
4. When using insulated tape or sleeving, check to make sure they are rated for the temperature of the application. Lower temperature rated materials can contain an adhesive or binder that can carbonize and become electrically conductive.
5. When using heaters near their maximum recommended watt density, it is recommended the temperature sensing probes be approximately 1/2″ from the heater sheath.
6. Lead wires should not be located in the hole containing the cartridge heater during operation. This may cause the lead wires to be exposed to temperatures above their rated temperature.
7. Many applications will subject a heater’s electrical terminations to one or more of the following potentially damaging conditions:

• Moisture
• Flexing
• Oil and other contaminants
• Abrasion
• High temperature

Note: To protect the heater from damage in these harsh environments, Dydac has a wide selection of terminations and options available.

Recommendations for Improving the life of Dydac High Watt Density Cartridge Heaters

Dydac Hi-Density Cartridge Heaters have been widely used in many demanding and diverse applications during the past quarter century. The most common applications are platen, plastic mold and die heating, liquid immersion and air heating. Selection of the wrong termination for the particular application is the major reason for all heater failures. However, failure to consider other important criteria can also have a negative effect on the life of the heater. To get the best performance and assure long life, it is important to carefully evaluate the following factors.

Heater Watt Density and Operating Temperature

Cartridge heater watt density is defined as the wattage dissipated per square inch of the heated sheath surface. For a particular application a heater’s watt density governs internal resistance wire temperature, which determines the outer sheath temperature. It is advisable to use heaters that have watt densities below the maximum recommended watt density for the material being heated to achieve the longest heater life. A Hi-Density cartridge heater designed at the maximum recommended watt density allows the smallest heater to be used to obtain the required wattage with good service life. All things being equal, using a lower watt density heater will typically provide optimized service life.Determining FitWhen heating a platen, mold, die or hot runner probe with Hi-Density Cartridge Heaters inserted into drilled holes, fit is an important factor in determining the life expectancy of the heater.

Temperature Control and Location of Temperature Sensing Device

In order to better control the heater temperature and hence the resistance wire temperature, use of an appropriate temperature control and the proximity of the heater to the sensor is very important.  Higher watt density heaters can generate heat faster than the surrounding area’s ability to dissipate heat. This creates a thermal lag between the heater and the sensor. The closer the sensor to the heater, the better you can control the heater temperature. By keeping the sensor further from the heater, temperature gradients of several hundred degrees can be observed in many applications, especially during initial start-up and heavy thermal cycling. Although the set operating temperature may be low, the heater may be running at a very high temperature. This is a common cause of heater failure. This can be minimized using time proportional and PID functions of the temperature Controllers.

Temperature Control and Location of Temperature Sensing Device

In order to better control the heater temperature and hence the resistance wire temperature, use of an

Power Control

Power control methods affect the life expectancy of heating elements. In general, although economical, on-off controls increase thermal fatigue and oxidation rate on heating elements by causing wide temperature swings of the internal heating element. Silicone controlled rectifiers (SCR’s), and solid state power controls can increase the life expectancy of heating elements by reducing the temperature swings of the internal heating element.

Dydac Coil Heaters for Hot runner systems are manufactured with Premium Materials and under Tight Manufacturing controls. Also known as cable heaters or Hotrunner heaters, these heaters are an advance concept of thermal engineering which has a construction similar to high watt density cartridge heaters. With years of practical experience, Dydac Coil Heaters ensure Highest Quality standards to provide superior performance and better life expectancy at higher temperatures for many diversed applications such as Hot Runner moulds, manifolds & machine nozzles.

ADVANTAGES OF DYDAC COIL HEATER

  • Standard sizes available with various cross section
  • Coil Heaters with Various Watt Density options available
  • Robust Design with Choice of Terminal Exits
  • Coil heaters available with built in Thermocouple
  • Designed for even heat profile
  • Precision fit on Hot Runner
  • Highly Non-corrosive
  • Maximum heat transfer due to more contact area
  • Advanced Thermal Engineering

COIL HEATER APPLICATIONS

  • Hot Runner Nozzles & Bushings
  • Hot runner Injection moulds
  • Injection & Blow Moulding Machine Nozzles
  • PET prefrom & Thin wall container Moulds
  • Hot runner Manifolds

Modern production processes need intelligent heat. And infrared thermal technology is efficient and precise. Today nearly every product that is manufactured comes into contact with infrared radiation during its manufacture. This trend is growing. Consequently, it is even more important that the correct heater is selected for every application. Infrared heaters cover the total spectrum of technologically-available wavelengths; we can help you find the optimal light source to suit your specific process application. Perfectly matched infrared lamps allow heating processes to be carried out at great efficiency with the right amount of energy. Reliable and reproducible manufacturing processes save money.

APPLICATIONS

  • PET perform heating in stretch blow molding machines
  • Printing Ink drying in offset machines
  • Screen-printing curing on T-shirts and textiles
  • Powder coating curing
  • Impregnation plants
  • Rubber coated drying
  • Soldering fusing in PCB industries
  • Sterilizing/mirror coating drying in glass industries
  • Paint baking
  • Paper coating drying
  • All type of lamination
  • Preheating prior to embossing

Various Type of Quartz Infrared Lamps

Some Standard Short Wave Infrared Sizes

Some Standard Short Wave Infrared Sizes with Half Ceramic Coating

OTHER SIZES CAN BE OFFERED ON REQUEST

WITH MODULE

OTHER SIZES CAN BE OFFERED ON REQUEST

Infrared Heating Technology

Technology that harnesses the power of infrared radiation can provide a powerful and efficient process heat source.Infrared heaters with IR technology are well-suited to a wide variety of applications and designed to transmit large amounts of energy quickly and with high efficiency. The particular wavelength of the infrared radiation has a critical effect on the effectiveness of the heating process. Infrared heaters, which are optimally matched to the materials to be heated, can provide energy savings of up to 50% over other technologies. Infrared heaters and infrared heating technology offer significant advantages: heat exactly where it is needed, with the optimum wavelength for the product and in line with the process. Dydac offers a complete range of heaters.We offer and design radiant heating products and equipment for industrial processes using proven infra red technology. This site offers information on our company and our complete product line including radiant heaters and heating equipment for process applications. We offer a full spectrum of high and low intensity heat for industrial processesAs energy costs keep rising, you may consider efficiency measures to save energy and curb energy costs. Process heating accounts for a high percentage of energy use for most industries. Infrared heating technology, a clean and efficient heat transfer measure, is a great solution for your business.

Method of Heat transmission

  • Conduction
  • Convection
  • Radiation

Features:

All of our emitters can be coated with a layer of gold or ceramic as reflectors. The gold/ ceramic coating can concentrate the heat, increasing the effectiveness of the heat output. The emitters with coating are highly economical, converting practically all the consumed electrical power into heatFor the emitters with high watt density or the surface temperature of the tube above 800¢XC , we suggest to use ceramic coating as reflector because the temperature resistance is up to 1000¢XCIn addition to 180¢X (half-tube) coating, we also manufacture 270¢X coating or other customer specified degreesAs energy costs keep rising, you may consider efficiency measures to save energy and curb energy costs. Process heating accounts for a high percentage of energy use for most industries. Infrared heating technology, a clean and efficient heat transfer measure, is a great solution for your business.In general, conduction and convection require heat-transmitting media such as solid, liquid, or gas. However, in the process of heat transmission by conduction and convection , most of heat is wasted. Radiation has higher thermal efficiency by directly transmitting the heat to the object without requiring any media.Infrared radiation, one of the electromagnetic radiations, travels in a straight line at the speed of light from the heat source. In the process of travel, the energy of infrared radiation is not absorbed by air and directly transmits the heat to heated substance from the heat source; therefore infrared radiation is a very efficient source of radiant energy. Infrared radiation can save the process time and reduce the energy costs when applied in the industrial use.

Comparison of Different Heating Source

Hot Air Tubular Metal Heater Medium wave I.R. Quartz Emitter Short Wave I.R. Quartz Emitter
Physical Strength medium high medium medium
Accuracy of Temperature Control Low Medium Medium High
Dust Pollution High Medium Low Low
Radiant Efficiency Low Medium High High
Max. Temperature of element surface 400 ¢XC 700 ¢XC 600 ¢XC 750 ¢XC
Life 2 year 1-2 year 1-2 year 5000 hrs
Heat Up very slow slow fast (1-2 mins) very fast (1-2 secs.)
Infrared Emission Long Wave Long Wave Medium Wave Short Wave