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Special Mica 11/28/00 2:53 PM Page 47

W A T L O W

Band Heaters
Special Mica
Barrel and Nozzle

For over 75 years, Watlow has been


solving complex and unique
application problems with standard
mica barrel and nozzle heaters.
Watlow is continuously improving
design and application knowledge
through engineering expertise and
experience with numerous OEM and
end-user applications.

Band Heaters
This has resulted in the development
of many specialty variations in
construction resulting in the best
heat solutions. This catalog contains
a sampling of what can be done.
Please contact a local Watlow sales
engineer for custom applications.
Performance Capabilities
• Sheath temperatures to 900°F
(480°C)
• Watt densities to 55 W/in2
(8.5 W/cm2)
Features and Benefits
• UL® component recognition
available for applications up to
900°F (480°C) sheath
temperature.
• Patented clamping strap assures
efficient heat transfer.
• Low mass design allows fast
heat-up and quick response.
SST. Strap
• Design variations provide user
convenience and heater
protection.
Applications
• Extruders
Resistance Ribbon
• Blown film dies
• Injection molding machines Mica Insulation
• Other cylinder heating
applications
Zinc Steel

Post Terminals

UL® is a registered trademark of


Underwriter’s Laboratories, Inc.
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Special Mica 11/28/00 2:53 PM Page 48

Band Heaters
Special Mica
Barrel and Nozzle
Applications and No-Heat Area for Special Mica Band (Post Terminals)
Technical Data Heater Size No-Heat Area
Operating Factors Heater Diameter Width at Terminals
Use as a low watt density rating as the Type in (mm) in (mm) in (mm)
application permits. A close match of Less than 2 (50.8) Up to 6 (152.4) 1 (25.4) x width
the heat supplied to the actual require- One Piece Up to 3 (76.2) 11⁄2 (38.1) x width
ments will reduce temperature over- 2 (50.8) or more
More than 3 (76.2) 1 (25.4) x width
shoot, reduce cycling and increase the
life of any band heater used. Up to 3 (76.2) 3 (76.2) x width
Two Piece 3 (76.2) or more
More than 3 (76.2) 2 (50.8) x width
Calculate the safe maximum wattage
for the heater using:
Heated Area x Maximum
Watt Density
Calculate the heated area of the band Maximum Allowable Watt Density
heater by subtracting the no-heat area Watt Density—W/cm2
from the total area in contact with the 2 4 6 8
cylinder (3.14 x I.D. x width). Subtract 1100
the no-heat area at the terminals
(from table) and any additional 1000
no-heat area caused by holes, slots 500
or oversize gaps. 900

Cylinder Temperature—°C
Cylinder Temperature—°F

Determine the maximum watt density


of the heater from the graph on this 800
page. The curves are based on 400
narrow heaters mounted on a smooth, 700
steel cylinder. Apply the necessary
correction factors: 600
300
• For heaters 21⁄4 inches (57 mm) to
1/
1 2"

five inches wide (127 mm), multiply


10"

500
3" (

(38

watt density by 0.8.


(
254

.1
6.2

400
• For high expansion cylinders
mm

200
mm

mm

(aluminum or brass), reduce the


)D

300
)D

watt density by 3 W/in2 (0.46 W/cm2).


ia.
) Di
ia.

• For heaters 21⁄4 inches to 5 inches


a.

100
200
wide installed on a high expansion 10 20 30 40 50 60
cylinder, reduce watt density by a
Watt Density—W/in2
total of 3 W/in2 (0.46 W/cm2) only.
• For regular cylinder surfaces other
than smooth, machined finish,
reduce watt density by 3 W/in2
(0.46 W/cm2).
• For heaters that will be insulated
or enclosed, contact Watlow for
specific watt densities.

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Special Mica 11/28/00 2:53 PM Page 49

W A T L O W

Band Heaters
Special Mica Physical Limitations of Variations
Barrel and Nozzle Diameter Width
Physical Limitations of Heater Type Min. Max. Min. Max.
inch (mm) inch (mm) inch (mm) inch (mm)
Variations
1 pc. 15⁄16 (33.3) 22 (559) 5
⁄8 (15.8) 15 (381)
Check the table to be certain the 2 pc. 3 (76.2) 44 (1117) 5
⁄8 (15.8) 15 (381)
variations and lead arrangements Expandable:
Narrow 13⁄4 (44.4) — — 1 (25.4) 3 (76.2)
being ordered are available on the Wide 13⁄4 (44.4) — — 2 (50.8) 6 (152.4)
heater size required. If you need to O.D. heater
exceed any limitations please contact 1 pc. 3 (76.2) 22 (559) 1 (25.4) 6 (76.2)
a Watlow representative. 2 pc. 3 (76.2) 44 (1117) 1 (25.4) 6 (76.2)
Type K leads 3
⁄4 (19.05) — — 5
⁄8 (15.8) 15 (381)
Type L leads 3
⁄4 (19.05) — — 3
⁄4 (19.05) 15 (381)

Band Heaters
Type E leads 11⁄2 (38.1) 22 (559) 3
⁄4 (19.05) 15 (381)
Type F leads 11⁄2 (38.1) 22 (559) 3
⁄4 (19.05) 15 (381)
Type H leads 11⁄2 (38.1) 22 (559) 3
⁄4 (19.05) 15 (381)
Type B leads 11⁄2 (38.1) 22 (559) 3
⁄4 (19.05) 15 (381)
Post terminals 15⁄16 (33.3) — — 1 (25.4) 15 (381)
Type A leads 3
⁄4 (19) — — 3
⁄4 (19) 15 (381)
Type C leads 15⁄16 (33.3) — — 1 (25.4) 15 (381)
Terminal box 31⁄2 (88.9) — — 13⁄8 (34.9) 15 (381)
Plug w/bracket 3 (76.2) — — 31⁄2 (88.9) 15 (381)
3-phase — — — — 3 (76.2) 15 (381)
European plug
1 pc. vertical 15⁄16 (33.3) 22 (559) 1 (25.4) 15 (381)
1 pc. horizontal 3 (76.2) 22 (559) 2 (50.8) 15 (381)
2 pc. vertical 3 (76.2) 44 (1117) 1 (25.4) 15 (381)
2 pc. horizontal 3 (76.2) 44 (1117) 2 (50.8) 15 (381)
HV Wedge-Lok 1 (2.5.4) 3 (76.2) 1 (25.4) 6 (76.2)
Clamping tabs 2 (50.8) — — 1 (25.4) 15 (381)
Welded barrel nuts
1 pc. 2 (50.8) 22 (559) 1 (25.4) 15 (381)
2 pc. 4 (101.6) 44 (1117) 1 (25.4) 15 (381)

Note: Some combinations of maximum and minimums cannot


occur on the same heater.
Standard gap is 1⁄4 inch (6.35 mm)

Variations
Different Widths

The 11⁄2 inch (38 mm) wide heater is (16 mm) to 15 inches (381 mm).
the most efficient due to maximum Multiple clamping straps are provided
clamping action. Heaters are for heaters more than three inches
available in widths from 5⁄8 inch (76 mm) wide.

Expandable Heaters

Heaters three inches (76 mm) wide shipped open and should not be
or less are constructed with a closed and reopened more than
notched sheath. Heaters wider than twice. To order, specify
three inches are constructed with an expandable.
expansion seam. These heaters are

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Special Mica 11/28/00 2:53 PM Page 50

Band Heaters
Special Mica
Barrel and Nozzle Holes and Notches
Variations
Continued ;;
;;
;;
;;
An economical way to provide may be provided in nearly any
;;
;; access for instrumentation is to location as long as there is at least
;;
;; specify an oversize gap between one inch (25 mm) between the hole
the heater ends. Holes and notches and one side of the heater. Standard
in the sheath should be specified hole sizes up to two inches (51 mm)
only when all the cylinder surface diameter. For proper hole and/or
adjacent to the hole or notch must notch location, a dimensional
be heated. When required holes drawing is required.

Two Piece Band Heaters

Two-piece construction is available which the heater will be wired. For


on heaters three inches (76 mm) or example, a two-piece band that is
greater in diameter. Heaters three 240VÅ(ac) per half may be wired in
inches wide or less with post series to a 480VÅ(ac) power supply.
terminals have one terminal on each In this case the band heater lead wire
end. Heaters over three inches wide insulation must be rated for
with post terminals have the two 480VÅ(ac). To order, specify two
terminals side by side on one end. piece band heater, with volts and
On two-piece units with leads, also watts per half and power supply
specify the power supply voltage. The voltage.
power supply voltage is the voltage to

Outside Diameter

This variation is specially designed Consult Watlow for available sizes


and constructed to heat the inside and terminations. Option available
diameter of cylinders, i.e., large as standard mica construction only.
diameter blown film dies. All the To order, specify outside diameter
terminations and mounting hardware heater.
0.625" are located on the I.D. of the heater.
(16 mm)

Metallic Terminal Box


31/2"for 31/2-515/16" I.D.
4" for 6-3915/16" I.D. 17/16"
(37 mm) Terminal boxes are attached to the ends of the box. Terminal box is
heater to cover the terminals for an available on two piece heaters.
113/16" added safety feature. Conduit may When ordering, specify terminal
(46 mm)
be attached to the box through 7⁄8 box.
inch (22 mm) diameter holes in the

See page 49 for


minimum/maximum
50 dimensional requirements.

thinband terminal box


Special Mica 11/28/00 2:53 PM Page 51

W A T L O W

Band Heaters
Special Mica
Barrel and Nozzle High Temperature “Quick Disconnect” European Style Plugs
Variations
Continued These plugs provide the simplest and electrical wiring that can be a
25/16" 21/16"
(59 mm) (52 mm) and safest way to apply power to potential hazard to employees or
13/4" band heaters. The combination of machine. Maximum amps 15 at
113/16" (44 mm) high temperature male and female 240VÅ(ac), maximum volts 240. To
(46 mm)
quick disconnect plug assemblies order, specify vertical or horizontal
21/4"
eliminates all live exposed terminals European plug.
(57 mm)

15/16"

Band Heaters
(33 mm)

Vertical Horizontal

High Temperature “Quick Disconnect” European Style Female Adaptors

Available as an accessory item that disconnect” European style plugs.


must be used in conjunction with Specify code number N6027AF049
high temperature “quick or N6027ZZ028 and quantity.
Right Angle Straight
Code # N6027AF049 Code # N6027ZZ028

Ceramic Terminal Covers


Stock Option A convenient and economic way to
insulate post terminals. Sized for
standard length posts. 10-24 screw
thread size. These are supplied as
an accessory item and shipped
separately. Specify Z-4918 and
quantity.
Code # Z-4918

Special Construction Square, Rectangular and Hex Bands


Variations
Square and rectangular heaters are hex shaped portion of the nozzle
made in either one or two-piece injection molding machines. Hex-
construction. These units are ideal shaped heaters are made to exact
for heating dies on plastic customer specifications. To order,
extruders, or the barrels of twin specify square or rectangular
screw extruders. Hex-shaped heaters. A dimensional drawing is
heaters are commonly used on the required.

See page 49 for


minimum/maximum
dimensional requirements.
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Special Mica 11/28/00 2:53 PM Page 52

Band Heaters
Special Mica Square, Rectangular and Hex Bands (continued)
Barrel and Nozzle
Clamping Styles Figure 2 shows bent-up flanges or
Special Construction The preferred clamping style is built-in strapping bracket at the
Variations illustrated in Figure 1 showing bent- side.
Continued up flange clamping. This clamping The least preferred clamping style is
style applies a uniform clamping shown in Figure 3. The one-piece
force at the corners. heater does not apply an uniform
clamping force.

"B" "B" "B"

"A" "A" "A"

Figure 1 Figure 2 Figure 3

Hinged Two-Piece Band

The hinged, two-piece band heater


is connected with a reinforced
hinge. It can be opened and closed
as often as necessary resulting in
easy installation and removal.
To order, specify hinged two-piece
band and watts and volts per each
half.

Thermocouple Coupling
The thermocouple coupling Standard bushing sizes available
simplifies the installation of an are:
external thermocouple with a
NPT Size Depth Height
threaded fitting. The standard
location for the coupling is 90 1
⁄2 - 27 9
⁄16" 5
⁄8"
degrees from the gap. 1
⁄4 - 20 3
⁄4" ⁄16"
11

3
⁄8 - 18 7
⁄8" 5
⁄8"

To order, specify thermocouple


coupling.

Bayonet Adaptor

The bayonet adaptor simplifies the


installation of an external
thermocouple with a bayonet
adaptor. The standard location for
the adaptor is 90 degrees from the
gap. To order, specify bayonet
adaptor.
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Special Mica 11/28/00 2:53 PM Page 53

W A T L O W

Band Heaters
Special Mica Cone Shapes
Barrel and Nozzle
Special Construction Cone shaped heaters are ideal for
Variations applications where heat is required
for hoppers or funnels. The Top ID
Continued
preferred method of attachment is
with bent-up flange clamping. Cone Height
shaped heaters are made to exact
customer specifications.
Bottom ID
To order, specify cone shape
adapter. A dimensional drawing is
required.

Band Heaters
Clamping Variations HV Wedge-Lok
Designed to provide excellent from stock. To order, specify
clamping where mounting space is HV Wedge-Lok.
limited. Available with Type A and L
leads only. Clearance from I.D. Less than 2" wide:
5/16" (8 mm)
of the heater to the outside edge of
More than 2" wide:
the Wedge-Lok is 5⁄16 inch (8 mm) 11/32" (9 mm)

nominal. Available on certain sizes

1" to 3"
Diameter

Standard and Low-Profile


Clamping Strap
The standard clamping strap depends on the screw length and
requires 9⁄16 inch (14 mm) clearance the diameter of the heater. The low-
above the heated surface, at the profile clamping strap is standard on
/16" (14 mm)
9

barrel nuts. When clearance is units less than 13⁄8 inches (45 mm)
limited, smaller barrel nuts can be wide and utilizes a 1⁄2 inch (13 mm)
used which require only 3⁄8 inch wide strap. Consult Watlow for more
(9 mm) clearance. The clearance information. To order, specify low-
required by the clamping screw profile clamping strap.

Welded Barrel Nuts


An ideal way to provide access instrumentation device,
for instrumentation is to specify an welded barrel nuts are recommended.
oversized gap between the heater Maximum gap is one inch (25 mm)
0.563" ends. If the clamp strap interferes Specify welded barrel nuts and
(14 mm)
with the positioning of the gap dimension when ordering.
Spot Welded

See page 49 for


minimum/maximum
dimensional requirements.
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Special Mica 11/28/00 2:53 PM Page 54

Band Heaters
Special Mica Clamping Tabs
Barrel and Nozzle Tabs—or lock-up flanges—are
Clamping Variations available. However, the special mica
band heater and strap design
Continued
provides superior clamping and
improved heat transfer and should
Non-Stock Option
be used whenever possible. To
order, specify clamping tabs.

Clamping Pads

Clamping pads have a hole to allow Clamping Pad

easy fastening to machine barrel.


Clamping pads are used when an
obstruction hinders a standard As required
clamping strap from fitting com-
pletely around the machine barrel.
To order, specify clamping pads
and degrees coverage.

Termination Variations Post Terminal Options

Standard post terminals have a


threaded length of 7⁄16 inch (11 mm) (11 mm) 7/16" 3/4" (19 mm)
and require 3⁄4 inch (19 mm)
Standard
clearance from the cylinder.
Terminals with 11⁄16 inch (17 mm)
threaded lengths are available that
(17 mm) 11/16"
require one inch of clearance. Button 1" (25 mm)

terminals require only 7⁄16 inch (11 mm) Long


clearance. Maximum amperage for
post terminals is 35 amps. To order,
specify standard, long or button 7/16" (11 mm)

terminals. Button

Three Terminal Construction

A third terminal can be added to of the heater centered on the width.


provide dual voltage or three-heat On heaters three inches wide or
operation. Or, it can be connected wider, the terminals are located
to the sheath for easy grounding. side-by-side on one end. Special
Standard terminal location on terminal locations are available. To
heaters three inches (76 mm) wide order, specify dual voltage or
or less is one terminal at each end three-heat operation.

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W A T L O W

Band Heaters
Special Mica Type B Type C
Barrel and Nozzle
;;
Termination Variations ;;
;;
;; ;;
;;
Continued

Heaters rated at less than 250 volts


;;
;;
;; ;;
;;
use UL® approved lead
insulation for operations to 482˚F
(250˚C) as standard. Lead Two fiberglass-insulated lead wires Two fiberglass lead wires exit a
insulation UL® rated for operation to exit in a single metal braid for good single tightly woven metal braid for
850˚F (450˚C) may be required in abrasion protection, lead flexibility good abrasion protection, lead

Band Heaters
high temperature applications and wiring convenience. Leads are flexibility and wiring convenience.
where the leads are shrouded or two inches (51 mm) longer than Leads are two inches (51 mm)
enclosed with the heater. All heaters braid. To order, specify Type B. longer than the braid. To order,
rated at more than 250VÅ(ac) use specify Type C and length.
this wire.

Type E Type F

;;
;;
.30"

;;
(8 mm)

;;
;;
Loose metal braid encloses two Loose fiberglass sleeving encloses
fiberglass leads for good abrasion two fiberglass leads for additional
protection, lead flexibility and wiring insulation protection where high
convenience. Leads are two inches temperature or minor abrasion is
(51 mm) longer than the braid. To present. Leads are two inches
order, specify Type E and length. (51 mm) longer than the sleeving. To
order, specify Type F and length.

Type H Type K

.38"

A stainless steel, flexible conduit Flexible lead wires exit vertically


encloses the leads for superior from the heater. These leads can be
mechanical protection where lead bent adjacent to the heater for a
abrasion is a particular problem. quick and easy connection. To
Leads are two inches (51 mm) order, specify Type K and length.
longer than the conduit. To order,
specify Type H and length.
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Special Mica 11/28/00 2:53 PM Page 56

Band Heaters
Special Mica
Barrel and Nozzle
Termination Variations Right Angle Armor Cable
Continued
Armor cable provides superior leads. Right angle armor cable is
11/4"
(32 mm) protection to lead wires where available on any clamping or
abrasion can cause damage. The construction variation.
standard leads are 12 inches To order, specify right angle armor
1 1 /4 "
(32 mm) (304.8 mm) of armor cable over cable.
14 inches (355.6 mm) of flexible

Removable Armor Cable

Removable armor cable is accept the standard armor cable


1 /2 " N.P.T. recommended on applications connector. The standard flexible
where removable armor is required. leads are 14 inches (355.6 mm).
It is available on any clamping or To order, specify removable armor
1 5 /8 " construction variation. The fitting will cable.
(41 mm)

Installation Procedures clamp screw. Each screw should Note: This retightening must be
have an ultimate torque value as done when the heaters are cold. If
in below chart. the heater becomes loose due to
1.Install heaters over a clean 4.When installing terminal lugs, normal operating and cycling the
surface. torque the top nut to 12 in-lbs. strap can be retightened,
The bottom nut should be held although frequent adjustments are
2.Install clamp straps, tightening
by a wrench when tightening the not advisable. It is advisable to
until screw cannot be tightened
top nut. check bands for tightness every
additionally. On heaters with
three to four months.
multiple straps, alternately tighten 5.After the machine has been run
each strap until no additional for its initial heat up, it is
tightening occurs. advisable to retighten the
3.To insure that the heater is clamping bands.
properly seated on the barrel, it is
advisable to tap around the Clamp Strap Torque Specifications
circumference of heater with a soft
mallet. This will result in a final Strap Width Strap Allen Pan Head
inch (mm) Screw Type Type
conforming of the heater to the
cylinder. Generally after this is 7
⁄8 (22.2) 10 - 24 60 - 75 lb/in 30 - 35 lb/in
done, operators can get an 5
⁄8 (15.8) 10 - 24 30 - 35 lb/in 30 - 35 lb/in
additional turn or two on the 1
⁄2 (12.7) 8 - 32 25 lb/in 25 lb/in

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