Ceramic Band Heaters
Plastic processing requires high operating temperatures and fast production rates. Proheat has designed its ceramic band heaters to meet these demands. These heaters are, in effect, high temperature electric furnaces capable of very efficient heat transfer by radiation, conduction and convection. Built-in insulation minimizes unwanted temperature changes along the barrel.
Other types of band heaters are primarily conductive, requiring an intimate fit with components being heated. Grooves or other surface irregularities form voids under the bands, resulting in hot spots and premature heater failure.
Ceramic bands are recommended here because efficient heat transfer is not affected by irregular surfaces or loose fit. At higher watt densities they can be used in wider increments than other heaters. This means you can reduce the number of bands used and simplify wiring.
Specifications
Temperature Up to 1400 Deg. F
Watt Density Up to 45W/Sq. In.
Voltage Up to 480 V (single or three phase)
Resistance-Tolerance NEMA Standard plus 5%, Minus 10%
Wattage Tolerance NEMA Standard plus 5%, Minus 10%
Maximum Amperage 25/Circuit
Insulation Available in both standard 1/4″ and insulation Plus 1/2″ construction
Sizes 2″ dia. And up; 1-1/2″ width and up (in 1/2″ increments)
Terminals 1/4-20 post terminals standard
Sheath Stainless steel
Lock-up Flange type standard
Maximum ID Consult Proheat
Standard width increments 1/2″
Standard gap when tightened 1/4″
Thickness with 1/4″ insulation 5/8″
Thickness with 1/2″ insulation 7/8″
Lead Protection
Where flexible leads in armor or braid are specified, Proheat recommends the use of post terminal in box with leads off box.
Code
IP. Add if you want the “Insulation Plus”
E. Terminal Connectors on studs – Ring lugs
F. Partial Coverage
G. Thermocouple hole in element area
H. Thermocouple hole in gap area, notched
I. Inner Liner
J. Twist Lock Plug on leads
K. Wider than normal gap, specify
L. Ground stud
M. Dual Voltage – for bands 2-1/2″ or more in width
N. Four wire construction
O. Overlapping shell on gap area
Note: A) Latch and trunion has quick release spring loading, suggested for ceramic band with a 12″ diameter or greater.
B) Terminal boxes and stud terminals are normally located 180 degrees opposite the gap.
WHEN ORDERING PLEASE SPECIFY:
- Quantity
- Inside diameter & width
- Voltage – on 2 piece bands we suggest each piece be rated at half the operating voltage, please specify total voltage
- Wattage – on 2 piece bands please specify total wattage
- Basic construction and options
- Part number (If known or previously ordered)
- Gap (if other than factory minimum)
- Lead length (If other than std. 12″)
| INSULATION PLUS Energy Savings to 30%! INSULATION PLUS -7/8″ thick, 1/2″ thermal insulation, energy savings up to 30% |
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“The Energy Saver”
- Insulation plus employs an additional 1/4-inch of thermal insulation encased in a separate flexible stainless steel shell
- Standard 1/4-inch thick thermal insulation found on all Proheat ceramic band heaters
- Helical nickel-chrome coil for extended service
- Ceramic coil supports
Cooler ambient temperatures around the operating machines.
Comparison of Insulated vs. Non-Insulated Bands in Terms of Wasted Energy
Super Insulation Plus-
1-1/4″ thick, 7/8″ thermal insulation, up to 40 watts/sq. in.
Super Insulation Plus employs an additional 5/8 inch of thermal insulation
encased in a separate flexible stainless steel shell.
“MAXIMUM ENERGY SAVINGS, MINIMUM SHEATH TEMPERATURES”
Ultra Thin –
3/8″ thick, , 3/16″ thermal insulation, up to 65 watts/sq. in.
“HIGH PERFORMANCE FOR CRITICAL HIGH TEMP OPERATIONS”
Proheat’s high performance heater band for processing high temperature engineering resins. “Ultra-Thin” heater bands have the same basic construction as our standard ceramic heaters except they are much thinner and have a high ratio of thermal to electrical insulation. The thin ceramic insulation used results in a lower mass construction, which improves response to control and minimizes temperature lag and overshoot.
The backside thermal insulation is highly efficient and results in minimal heat loss and lower sheath temperature.
The “Ultra-Thin” has averaged 100 deg. F lower sheath temperature when tested against other high temperature heaters at 600 deg. F cylinder temperatures.
The “Ultra-Thin” without thermal insulation and with a perforated sheath is ideally suited for air cooled systems.
“Ultra-Thin” heaters are constructed of all high temperature materials. The heater element itself is computer designed for maximum wire size which results in a long service life. Developed primarily for high temperature, high watt density plastic processing machinery, this premium performance heater can be used in many other applications.
Specifications
Insulation – 3/16″ thick thermal insulation (ceramic fiber)
Sizes – Minimum ID 1-1/2″ (38.1mm) 1″ wide and up
Terminals – Post Terminals Standard ( 10-24 Thread or 1/4″-20 Thread)
Sheath – Stainless Steel
Lock-up – Flange or Barrel Nut Standard
Standard Gap – 1/4″ when tightened
Metric Sizes available
Wall Thickness – 11/32″ (+1/32″, -.00)
Temperature – Up to 1400 Deg. F
Watt Density – Up to 65W/Sq. in. (9.9 W/C2)
Voltage – Up to 480 V (Single or three phase)
Resistance-Tolerance +10%-5%
Wattage Tolerance +5%-10%
Maximum Amperage – 20/Circuit
Options
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A. Armored Cable (BX) B. Braided Over Leads C. Plain Leads D. Right Angle Braid E. Right Angle Braid F. Partial Coverage G. T/C Hole (specify location) H. Inner S.S. Liner I. Ground Stud or Wire J. Dual Voltage K. Latch-Trunion Lock-Up L. Overlap on shell at gap M. Standard Terminal Box N. Low Profile (1″ high) Terminal Box O. Ceramic Terminal Caps P. Quick Disconnect High Temperature Plugs |
Special Note:
These are completely flexible radiant heaters. Heavy clamping
pressures are not required regardless of heater size. No need for
hinged, two piece, or expandable designs associated with mineral insulated (MI), mica or other conduction type heaters.
Air Cooled
Developed especially for air cooled systems
Proheat’s new, super-efficient and economical air cooled ceramic heater bands are designed for use on extrusion machinery or on any heat/cool operation.
Proheat’s new heater bands feature 63% open perforated metal sheath, which assures maximum surface area exposure.
They also provide the user with a more economical operation, via a rapid heat-up and cool-down feature. Their “Black Star” coating further increases efficiency. Advantages of air cooled vs. Liquid cooled operation include: lower cost, replaceable heaters, low maintenance, no leak problems, and close temperature control.
Proheat’s new air cooled ceramic heater bands are available in various sizes to either accommodate new designs or to replace less efficient, more expensive cast aluminum heaters.
Proheat also offers a full line of custom and standard heaters and controls.
Specifications
Temperature – Up to 1400 Deg. F
Watt Density – Up to 45 W/Sq. In.
Voltage – Up to 480 V (single or three phase)
Resistance – Tolerance- NEMA Standard plus 10% Minus 5%
Wattage Tolerance – NEMA Standard plus 5%, Minus 10%
Maximum Amperage – 25/Circuit
Sizes – 2″ dia. And up: 1-1/2″ width and up (in 1/2″ increments)
Terminals – 1/4″-20 post terminals standard
Sheath – Aluminized steel
Lock-up – Flange type steel
Maximum ID – Consult Proheat
Standard width increments -1/2″
Standard gap when tightened – 1/4″
Thickness – 1/2″
Options
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A. Armored Cable (BX) B. Braided Wire C. Lead Wire, No Braid or Armor D. Terminal Connectors on studs – Ring lugs E. Partial Coverage F. Thermocouple hole in element area G. Thermocouple hole in gap area, notched H. Twist Lock Plug on leads I. Wider than normal gap, specify J. Ground stud K. Dual Voltage – for bands 2-1/2″ or more in width |
Note: A) Terminal boxes and stud terminals are normally located 180 degrees opposite the gap.
RADIANT CERAMIC ROLLER HEATERS
1. Post Terminal w/housing
2. Stainless Steel Sheath
3. Sidewall Partial or Full Disk
4. Perfirated Liner
5. “Black Star” Ceramic Heating Surface
6. Mounting Collars
Proheat quality construction in a roller heater design developed especially for the Hot Stamp Industry.
Efficient and long life ceramic heaters provided in standard and custom designs.
Proheat roller heaters feature the quality design practices associated with our ceramic heater bands combined with the innovative design requirements for the heating of rotating rollers.
Proheat roller heaters feature a 63% open perforated metal liner, which assures maximum heating surface exposure while providing the proper support to maintain a positive clearance between the ceramic heating surface and the roller. The addition of a “Black Star” coating provides the optimum design for radiant and convective heat transfer.
Proheat roller heaters are available in a variety of sizes to meet customer specifications. Heaters can be made to meet custom design requirements or will be manufactured to include standard design features as shown above.
Specifications
Temperature – Up to 1200F
Watt Density– Up to 35 watts/square inch
Voltage – Up to 480 volts – Single and three phase
Roller Sizes – 2″ diameter and up. 1-1/2 width and up (in 1/2″ increments)
Terminal – 1/4-20 Post terminals standard
Sheath – Stainless Steel
Mounting Collars – 1/4, 3/8, 1/2, 5/8,
Options
- Terminal locations
- Dual voltage
- Multiple zones
For additional options contact Proheat.
