Nozzle Band Heaters MICA-type

      General information

      Nozzle band heaters are primarily used to heat the nozzle area of injection moulding machines, hot-runner moulds, film welding machines and hand-held welding equipment. In addition, they can also be used to heat all metal cylinders in industrial applications. The nozzle bands are impervious to plastics and are generally manufactured with a brass sheath (BDS). For special applications, or for PVC processing, the sheath can be made of stainless steel (BDSE). In both cases, versions with integrated thermocouples as well as with surface sensors are available.

      Specifications

       

      BDS

      BDSE

      Sheath material

      Brass

      Stainless steel (1.4301)

      Operating temperature max. in °C

      350

      350

      Thermal load max. in W/cm²

      5.5

      5.5

      Wall thickness in mm

      Ca. 3 - 4

      Ca. 5 - 6

      Operating voltage in V

      Up to 500

      Up to 500

      Power tolerance

      + 5% / -10%

      + 5% / -10%

      Integrated temperature sensor available

      Yes

      Yes

      Dmin in mm

      25

      25

      Dmax in mm

      160

      160

      Bmin in mm

      16

      18

      Bmax in mm

      80

      48

      • In general, individual customer requirements regarding materials, dimensions and electrical parameters can be accommodated following consultation and clarification of all technical details.

      • If dimensions larger than Dmax or Bmax are required, cylinder heaters from the RHK series (MICA-type) or the HRHK series (ceramic) may be considered.

      Power calculation

      For the power estimation, a maximum permissible surface load (thermal load on the inner surface of the nozzle band heater) of 5.5 W/cm² may be used for nozzle band heaters of the BDS series. The maximum permissible power can be calculated approximately as follows.

      P = 5.5 W cm 2 D inner B 100 π D inner : Inner diameter of nozzle band heater in mm B : Width of nozzle band heater in mm P=5.5 {{W} over {cm^{2}}} cdot {{D_{innen} cdot B} over {100}} cdot π newline newline alignl D_{inner}:" Inner diameter of nozzle band heater in mm" newline alignl B:" Width of nozzle band heater in mm"

      This results in the power ratings in watt for the respective diameters and widths, as shown in the table below. The usable surface area for power generation – and thus the electrical output – may be reduced due to sensor holes, necessary cut-outs, etc. The table is intended solely to provide an estimation of possible power ratings for potential future orders.

      Power Table for BDS series nozzle band heaters (Power ratings in W) – with diameters of 30 mm – 160 mm and widths of 16 mm – 80 mm

      D/W in mm

      W16

      W20

      W22

      W25

      W30

      W34

      W40

      W44

      W50

      W55

      W60

      W70

      W80

      D30

      80

      100

      110

      130

      155

      175

      205

      225

      255

      285

      310

      D35

      95

      120

      130

      150

      180

      205

      240

      265

      300

      330

      360

      420

      D40

      110

      135

      150

      170

      205

      235

      275

      300

      345

      380

      415

      480

      550

      D45

      120

      155

      170

      190

      230

      260

      310

      340

      385

      425

      465

      540

      620

      D50

      135

      170

      190

      210

      255

      290

      345

      380

      430

      475

      515

      605

      690

      D55

      150

      190

      205

      235

      285

      320

      380

      415

      475

      520

      570

      665

      760

      D60

      165

      205

      225

      255

      310

      350

      415

      455

      515

      570

      620

      725

      825

      D65

      180

      225

      245

      280

      335

      380

      445

      490

      560

      615

      670

      785

      895

      D68

      185

      235

      255

      290

      350

      395

      470

      515

      585

      645

      705

      820

      940

      D70

      190

      240

      265

      300

      360

      410

      480

      530

      605

      665

      725

      845

      965

      D75

      205

      255

      285

      320

      385

      440

      515

      570

      645

      710

      775

      905

      1035

      D80

      220

      275

      300

      345

      415

      470

      550

      605

      690

      760

      825

      965

      1105

      D85

      235

      290

      320

      365

      440

      495

      585

      645

      730

      805

      880

      1025

      1175

      D90

      245

      310

      340

      385

      465

      525

      620

      680

      775

      855

      930

      1085

      1240

      D100

      275

      345

      380

      430

      515

      585

      690

      760

      860

      950

      1035

      1210

      1380

      D110

      300

      380

      415

      475

      570

      645

      760

      835

      950

      1045

      1140

      1330

      1520

      D120

      330

      415

      455

      515

      620

      705

      825

      910

      1035

      1140

      1240

      1450

      1655

      D125

      345

      430

      475

      540

      645

      730

      860

      950

      1080

      1185

      1295

      1510

      1725

      D160

      440

      550

      605

      690

      825

      940

      1105

      1275

      1380

      1520

      1655

      1935

      2210

      Power Table for BDSE series nozzle band heaters (Power ratings in W) – with diameters of 30 mm – 160 mm and widths of 18 mm – 48 mm

      D/W in mm

      W18

      W21

      W24

      W27

      W30

      W34

      W39

      W45

      W48

      D30

      95

      110

      125

      140

      155

      175

      200

      D35

      110

      125

      145

      165

      180

      205

      235

      270

      290

      D40

      125

      145

      165

      185

      205

      235

      270

      310

      330

      D45

      140

      165

      185

      210

      235

      265

      305

      350

      375

      D50

      155

      180

      205

      235

      260

      295

      335

      390

      415

      D55

      170

      200

      230

      255

      285

      325

      370

      430

      455

      D60

      185

      220

      250

      280

      310

      350

      405

      465

      500

      D65

      200

      235

      270

      305

      335

      380

      440

      505

      540

      D68

      210

      245

      280

      315

      350

      400

      460

      530

      565

      D70

      220

      255

      290

      325

      365

      410

      470

      545

      580

      D75

      235

      270

      310

      350

      390

      440

      505

      585

      620

      D80

      250

      290

      330

      375

      415

      470

      540

      620

      665

      D85

      265

      310

      350

      395

      440

      500

      575

      660

      705

      D90

      280

      325

      375

      420

      465

      530

      605

      700

      745

      D100

      310

      365

      415

      465

      520

      585

      675

      780

      830

      D110

      340

      400

      455

      515

      570

      645

      740

      855

      910

      D120

      375

      435

      500

      560

      620

      705

      810

      935

      995

      D125

      390

      455

      520

      585

      650

      735

      840

      970

      1035

      D160

      500

      580

      665

      745

      830

      940

      1080

      1245

      1325

      A detailed calculation for each individual case by the Gebr. Bach GmbH is always required! The operating temperature for BDS and BDSE series heaters is up to 350 °C. For continuous thermal loads exceeding 5 W/cm² or temperatures above 320 °C, we recommend switching to ceramic nozzle band heaters (BDK) to extend their lifespan.

      Further details (please click on)

      Installation and commissioning

      Installation

      During installation, care must be taken to avoid deformation and excessive spreading of the heating element. Difficult installation conditions should be taken into account at the design stage. The heating elements must only be operated with a suitable temperature control system.

      The following points must be observed:

      • As heat transfer from the heating elements to the body to be heated takes place via contact heat (BDS, BDSE), the entire inner surface of the heating element must be in firm and even contact with the body to be heated.

      • Holes, grooves or similar features beneath the heating element must be avoided.

      • If the connection is not a form-fit connection, the heating element may be destroyed by overheating.

      • If there are several clamping screws, these must be tightened in alternating sequence. The clamping screws must be tightened by hand to a torque of 2 to 3 Nm.

      • In general, care must be taken to ensure that no mechanical damage occurs to the metal parts or the wiring.

      The heating element must not be put into operation until assembly is complete. During initial commissioning, until the operating temperature is reached, the secure fit of the heating element must be checked at regular intervals. If necessary, the clamping screws must be retightened to 2 to 3 Nm.

      Storage

      The heating element must be stored in a dry, dust-free environment. Micanite materials are hygroscopic; therefore, if stored in conditions that are too humid, the insulating material may absorb moisture, resulting in a risk of short-circuiting. It is recommended to heat the element up slowly after prolonged storage or when putting it into service for the first time.

      Electrics

      Electrical connection:

      The nozzle band heaters are provided with a permanently attached connection cable featuring strain relief and kink protection. The connection cable consists of a pure nickel strand with a wire mesh sheath. The standard cable length is 300 mm. Other cable materials and connection lengths are available on request.

      Electrical installation:

      The electrical connection must only be carried out by an authorised electrician or by suitably trained specialist personnel.

      Care must be taken to ensure that the operating voltage matches the supply voltage. All connections must be made using heat-resistant cable (see operating conditions and safety instructions). These must be routed so that they do not come into contact with sharp-edged metal parts or surfaces that radiate heat.

      Note: The user must ensure that the electrical connection is protected against accidental contact.

      VDE regulations

      Where applicable, the product has been manufactured in accordance with the following standards:

      • DIN-EN 60335-1

      • VDE 0700 section 1

      If you have any questions, please contact us!

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      Contact details

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