Cast-In Band Heaters

Wire Braided Hose Flexible Teflon® Wire Braided Hose provides an excellent means of connecting Cast-In Heaters to the extruder plumbing system. This style of hose meets the demands of medium to tight bending radius requirements. The stainless steel braid protects the Teflon® hose from any harsh mechanical conditions that may be present. A variety of brass male and female threaded fittings can be incorporated onto the hose, making it a practical choice for use in conjunction with Tempco’s Style RC Non-Exposed Fittings and other available fittings. Rigid brass adapter fittings as listed below are used to mate the base hose assembly to your existing installation. This allows for the installation of the rigid NPT coupling into the plumbing system and then attaching the swivel fitting on the hose, making assembly relatively easy. Remember to use Teflon® tape or equivalent. Standard Hose: Size 8 (1/2″) .405″ I.D., .549″ O.D. Operating Pressure: 2000 PSI Burst Pressure: 8000 PSI Installation Accessories Additional Options Aluminum (standard) Bolt Clamp Brass Bronze Cast Materials Clamping Options Cooling Methods Cooling Tube Fittings Customer Specified Finish Electrical Terminations Explosion Resistant Flexible Hose Lead Wire (w/ & w/out protection) Liquid Lugs Moisture Resistant NEMA Rated None Pins Quick Disconnect Right Angle Screw Terminals Sheet Metal Special Design Special Features Standard Finish Straight Straps Termination Protection Type TS: Teflon® Sleeving over Lead Wire Contamination seal shrink-down Teflon® sleeving over the heater and lead wire splice. Provides a good moisture resistant seal. Maximum operating temperature 500°F (260°C). Available for .260″, .315″ and .430″ and diameter heaters. Specify lead length. Air Fittings Type T7: Ceramic Insulator Ceramic insulator is the same diameter as the heating element. .260″ diameter heater has 6-32 screw terminals. .315″ diameter heater has 8-32 screw terminals. .430″ diameter heater has 10-32 screw terminals Type T: Mica Insulator Mica insulator is the same diameter as the heating element. .260″ diameter heater has 6-32 screw terminals. .315″ diameter heater has 8-32 screw terminals. .430″ diameter heater has 10-32 screw terminals. Type SF and SF9: Quick Disconnect Spade Tabs Quick-disconnect spade tabs spot welded to pin. Available for .260″, .315″ and .430″ diameter heaters. Type SF represents straight. Type SF9 represents 90° to pin. Specify tab orientation. Type S: Heavy Duty Ceramic Insulators (Standard) Standard unless otherwise specified. .315″ diameter heater has 8-32 screw terminals. .430″ diameter heater has 10-32 screw terminals. Type RT: Cast Brass 90° Threaded Elbow 90° threaded elbow is brazed to the cooling tube extension, providing an easy and quick method for connecting cooling lines. Recommended to be factory installed to assure good braze seals. Available for 3/8″ and 1/2″ NPT internal threads. If required, specify. Cooling/Flow Tube Fittings Type RA: 90° Copper Elbow 90° copper elbow is brazed to the Cast-In Heater cooling tube extension with additional tube extension for connecting cooling lines with compression and/or flared fittings. Available for 3/8″ and 1/2″ diameter tubing. If required, specify. Type R3: Straight Threaded Copper Fitting Straight threaded fitting is brazed to the cooling tube extensions, providing an easy and quick method for connecting cooling lines. Recommended to be factory installed to assure good braze seals. Available for 3/8″ and 1/2″ diameter tubing with internal threads. If required, specify. Type R1A: Stainless Steel Wire Overbraid Stainless Steel Wire Overbraid provides flexibility and excellent protection to lead wires against abrasion. Available for .260″, .315″ and .430″ diameter heaters. Specify stainless steel wire overbraid length and lead length. Style may vary from depiction depending on heater diameter and braid diameter used. Type R2: Mica Washers with Lead Wire Connection Mica washers with blockhead and through hole for lead wire connection. Eliminates the use of ring terminals. Available for .315″ and .430″ diameter heaters. Accepts 6-14 gauge wire. Type R1: Flexible Armor Cable Flexible Armor Cable provides excellent protection to lead wires against abrasion and contaminants. Available for .260″, .315″ and .430″ diameter heaters. Specify cable length and lead length. Style may vary from depiction depending on heater diameter and cable diameter used. Type R: Mica Washers Mica washers with 90° blockhead screw terminal with 10-32 screw threads. Available for .315″ and .430″ diameter heaters. Type P2: Quick Disconnect Plug Assembly with Box Quick-Disconnect Cup assemblies provide the simplest and safest means for applying power to any type of Cast-In Heater installation. The box extends over the screw terminals on both Cast-In Band Heater halves. The combination of prewired cup and box assembly, along with factory prewired high temperature lead wire protected with armor cable, eliminates live exposed heater terminals and electrical wiring, protecting employees from electrical shock and the possibility of electrical shorts due to exposed wiring. If prewired plugs are required, specify length of lead wire and cable. Rated 250V maximum, 15 Amp maximum Terminal Box Size varies with dimensions of casting. Type P1: Quick Disconnect Plug Quick-disconnect plug, either mounted directly on casting or on elements ends offset a specified distance from casting. Rating: 16A-250VAC. Type P: Plain Pin Plain terminal pin. Specify Length “L.” Standard 1/2″ (12.7 mm) pin length. Type MR1: Moisture Resistant Box with Shield This design incorporates the MPR housing style along with a perforated tube shielding unheated extensions of the tubular heating elements. This feature provides mechanical strength to the element extension and prevents overheating of the terminals, reducing possible premature failure from corrosion and oxidation. Type MR: Strain Relief and Lead Wire – Moisture Resistant Moisture resistant shrink strain relief and lead wire with or without stainless steel overbraid. Available for .260″, .315″ and .430″ diameter heaters. Specify lead wire and overbraid length. Maximum operating temperature is 350°F (177°C). Type MPR: Moisture Resistant Box This design has a moisture resistant die cast aluminum box with a non-removable polyurethane gasket in the lid. Lid is secured with captive stainless steel screws. Body and lid are painted in basic industrial gray; interior contains copper ground screw. Box is mounted to a plate that is brazed to the element. Available in a wide variety of sizes. Type L and L9: Terminal Lug and Pin Terminal lug spot welded to pin with 10-32 binding head screw. Available for .260″, .315″ and .430″ diameter heaters. Type L represents straight; Type L9 represents 90° to pin. Specify lug orientation. Type HS: Hi-Seal Fittings Hi-seal brass fittings are highly dependable under the most adverse conditions. For reliable and trouble-free service with ease of installation, we strongly recommend hi-seal fittings. Available for 3/8″ and 1/2″ diameter tubing. Male thread is 1/2″ NPT for 1/2″ tube and 3/8″ tube. Type FF: Flared Seal Fittings Brass flared seal fittings are well adapted for low to medium pressure and resistant to mechanical pullout. Available for 3/8″ and 1/2″ diameter tubing with SAE 45° flare. Type F: Flexible Lead Flexible lead: insulated stranded wire crimped to cold pin. Crimp connection is insulated with fiberglass sleeving. Available for .260″, .315″ and .430″ diameter heaters. Wire insulation rated to 250°C, 450°C optional. Specify lead length. Type EP: Explosion & Moisture Resistant Box Cast iron explosion and moisture resistant boxes should be used in areas where the surrounding air may become contaminated with combustible gases or a high humidity level may exist. Installation requires one box per Cast-In Heater half and they are brazed to the tubular heater. The standard box has one 1/2″ NPT hub. Optional: Two hubs per box available. Cast-In Heater fitted with boxes can be factory prewired with high temperature lead wire, protected with special armor cable. If either of these options is required, please specify the following: Number of hubs Cable type Lead wire length Cable length Type E: Right-Angle Lug Right-angle lug welded to pin with mica washer insulators and 10-32 binding head screw. Available for .260″, .315″ and .430″ diameter heaters. Type CB: Cast Aluminum Box A Cast Aluminum Box is used to protect and secure lead wire terminations on narrower designs. Type C7: Terminal Box attached to Clamping Straps Type C7 terminal boxes are made from rust-resistant sheet metal. The C7 base is fixed to the clamping straps. The box has two 7/8″ diameter knockouts opposite each other for standard 1/2″ BX connectors. The cover is removable, providing easy access to the screw terminals for electrical wiring. To simplify installation, Cast-In Heaters fitted with boxes can be factory pre-wired with high temperature lead wire, protected with armor cable. If either one of these options is required, specify terminal box type, lead wire and cable length. Satisfies NEMA 1 requirements. C7 Terminal Box Size varies with dimensions of casting. Type C4: Heavy Duty Ceramic Insulator with Terminal Cover Heavy duty ceramic insulator with terminal cover. .315″ diameter heater has 10-32 screw terminals. .430″ diameter heater has 10-32 screw terminals. Type C2: Standard Terminal Box (on flat pad) Type C2 is an individual terminal box for protecting the terminals on each Cast-In Band Heater half and on many other Cast-In Heater designs with one set of heater terminals. The C2 box design requires a flat pad on half-round castings or a flat surface on other casting designs for mounting. It is made from heavy gauge, rust-resistant sheet metal. The cover is removable for easy access to terminals. The box has two 7/8″ diameter knockouts opposite each other for standard 1/2″ BX connectors. To simplify installation, Cast-In Heaters fitted with boxes can be factory pre-wired with high temperature lead wire that can be protected with armor cable. If one of these options is required, specify terminal box type, lead wire and cable length. Satisfies NEMA 1 requirements. Standard C2 box size: L = 4″ W = 2-1/2″ H = 2-1/8″ Strap Clamping Strap clamping is used to secure the heater to the extruder barrel with 3/4″ or 1-1/4″ wide low expansion stainless steel clamping straps with 1/4″-20 socket head cap screws and barrel nuts. Electroless Nickel-Plated — A plating technique (without using an electric current) used to deposit a coating of nickel on a substrate to prevent corrosion, wear and also as a protective coating. Teflon Coating — Teflon is non-reactive so it is often used in containers and pipework for reactive and corrosive chemicals. Hard coat anodizing — Anodizing increases resistance to corrosion and wear. Magnaplate — Strong wear and corrosion resistance non-stick coating that withstands high temperatures. This cast-in does not need a cooling feature. This cast-in will not have an electrical termination. It is for cooling only. This Cast-In will not have Terminal Protection. Liquid Cooled Band with Recessed NPT Fittings The recessed cooling tube design incorporates 3/8″ or 1/2″ diameter tubing formed into a serpentine or any other suitable shape with specially designed stainless steel NPT fittings that are welded to the tube ends and cast below the surface of the Cast-In Heater, thus eliminating the troublesome, commonly used tube extensions as they exit the casting for connection to the coolant lines. Non-exposed fittings will drastically increase the operating life of a Cast-In Heater with liquid cool function, as this feature eliminates broken and/or damaged cooling tube extensions which are a major factor in premature heater failure. Type RC fittings are available in two female NPT thread sizes, 3/8″-18 and 1/2″-14. Standard clamping styles for Cast-In Band Heater sets are low thermal expansion alloy straps or bolt clamping. Specify fitting thread size and clamping style when ordering. If not otherwise specified, supplied with Type S electrical screw termination and straps for clamping. For fittings with special thread size, consult Tempco with your requirements. Liquid Cooled Band – Single Set of Cooling Tubes The single set cooling tube design features 1/4″, 3/8″ or 1/2″ diameter tubing precisely formed into a serpentine or any other suitable shape and cast into the body of the Cast-In Heater. This is the most widely used method for providing a means of cooling in liquid-cooled Cast-In Heaters. From this basic design, the user can choose to factory equip the cooling tubes with any of the cooling tube termination options. Liquid Cooled Band – Dual Set of Cooling Tubes The Dual cooling tube design incorporates two sets of 3/8″ or 1/2″ diameter tubing formed into a serpentine or any other suitable shape within the same Cast-In Heater. Dual cooling tubes will actually double the operating life of a Cast-In Heater with liquid-cool function, since cooling tube failures usually occur before heating element failures There are two main causes for failure on liquid- cooled Cast-In Heaters: Stress corrosion cracking at the exiting point of the tube extensions and clogged lines due to scale build-up that reduces flow, decreasing cooling capacity and finally completely blocking the tube. Once the first set of cooling tubes has failed, reconnect to the spare set and you are back in operation, thus eliminating costly downtime and additional labor for heater replacement. Dual cooling tubes are also used when additional cooling capacity is required. Finned without Side Flanges The standard mounting method for these designs is bolt clamping. An alternative mounting method is to use stainless steel straps. Type “T” screw terminals are the standard termination. These cast-in band heaters are normally made to be used in conjunction with the Cool to-the Touch and Multi-Versal Shroud Systems. They can also be used as stand alone replacements for other heating and cooling extrusion systems. Finned with Side Flanges The standard mounting method for these designs is bolt clamping. An alternative mounting method is to use stainless steel straps. Type “E” screw terminals are the standard termination. These cast-in band heaters are normally made to be used in conjunction with the Arctic Cast Shroud System. They can also be used as stand alone replacements for other heating and air cooling extrusion systems. Please specify a finish. Material: Bronze Maximum Surface Temperature: 1350°F (732°C) Density (lb/in3): 0.272 Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 9 @ 68° – 572°F Thermal Conductivity (BTU-in/hr-ft2-°F): 437 Material: Yellow Brass Maximum Surface Temperature: 1200°F (649°C) Density (lb/in3): 0.304 Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 12.2 @68° – 500°F Thermal Conductivity (BTU-in/hr-ft2-°F): 582 Strap clamping is used to secure the heater to the barrel by bolts clamping the two halves together around the barrel. A variety of bolt clamping designs and hardware is available. Aluminum Material: Standard Aluminum 319 (Optional Aluminum 356 in Learn More) Maximum Surface Temperature: 700°F (371°C) Density (lb/in3): 0.101 Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 12.7 @ 68° – 572°F Thermal Conductivity (BTU-in/hr-ft2-°F): 754 Material: Optional Aluminum 356 Maximum Surface Temperature: 750°F (399°C) Density (lb/in3): 0.0968 Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 12.9 @ 68° – 572°F Thermal Conductivity (BTU-in/hr-ft2-°F): 1160 Adaptor Fittings Rigid brass adapter fittings are used to mate the base hose assembly to your existing installation. 125 RMS Standard RMS Surface Finish as defined in ASME B46.1 — RMS is the root mean square of the profile height deviations from the mean line, recorded within the evaluation length. The standard surface finish for the machined surface of Tempco cast-in heaters is 125 RMS. Consult Tempco if a different surface finish is required.