MICA-type

Cylinder- / Band Heater Ceramic

General information

Cylinder- / band heating elements are primarily used to heat metal cylinders, particularly in injection moulding machines, blow moulding heads and extrusion cylinders. A mandrel heater design is also available.

As standard, we use hot-dip aluminized sheet steel, which offers high heat reflectivity and good resistance to corrosion and oxidation. We also use V2A stainless steel (material no. 1.4301), known for its good resistance to acids and chlorine, weldability and ease of processing.

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Specifications

	HRHK
Operating temperature max. in °C	550
Thermal load max. in W/cm²	7
Wall thickness in mm	Ca. 13
Operating voltage in V	Up to 500
Power tolerance	+ 5% / -10%
Integrated temperature sensor available	Yes
Dmin in mm	50
Dmax in mm	3000
Bmin in mm	ca. 18
Bmax (one-piece) in mm	500

In general, following consultation and clarification of all technical details, we can accommodate individual customer requirements, for example regarding materials, dimensions, electrical parameters, drill holes and cut-outs, etc.
If dimensions smaller than Dmin or Bmin are required, nozzle band heaters from the BDK series (ceramic) may be considered.

Power calculation

When estimating the power output of ceramic cylinder- / band heaters (HRHK), a maximum permissible power density (power density on the inner surface of the ring heater) of 7 W/cm² may be used. The maximum permissible power can be calculated approximately as follows.

\begin{matrix} P = 7 \frac{W}{{cm}^{2}} \cdot \frac{D_{inner} \cdot B}{100} \cdot π \\ D_{inner} : Inner diameter of cylinder- / band heater in mm \\ B : Width of cylinder- / band heater in mm \end{matrix}

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 HRHK series ceramic ring heaters (power ratings in W) – with diameters of 60 mm – 450 mm and widths of 36 mm – 300 mm

D/W in mm	W36	W51	W66	W81	W96	W111	W126	W141	W156	W171	W186	W201	W216	W231	W246	W261	W276	W298
D60	475	675	870	1070	1265	1465	1665	1860	2060	2255	2455	2650	2850	3035	3245	3445	3640	3930
D80	635	895	1160	1425	1690	1955	2215	2480	2745	3010	3270	3535	3800	4045	4330	4590	4855	5245
D100	790	1120	1450	1780	2110	2440	2770	3100	3430	3760	4090	4420	4750	5060	5410	5740	6070	6555
D120	950	1345	1740	2140	2535	2930	3325	3720	4115	4515	4910	5305	5700	6070	6490	6890	7285	7865
D140	1110	1570	2030	2495	2955	3415	3880	4340	4805	5265	5725	6190	6650	7080	7575	8035	8495	9175
D160	1265	1795	2320	2850	3380	3905	4435	4960	5490	6015	6545	7070	7600	8095	8655	9185	9710	10485
D180	1425	2020	2615	3205	3800	4395	4990	5580	6175	6770	7365	7955	8550	9105	9740	10330	10925	11795
D200	1585	2245	2905	3565	4220	4880	5540	6200	6860	7520	8180	8840	9500	10115	10820	11480	12140	13105
D220	1740	2465	3195	3920	4645	5370	6095	6820	7545	8275	9000	9725	10450	11130	11900	12625	13355	14415
D240	1900	2690	3485	4275	5065	5860	6650	7440	8235	9025	9815	10610	11400	12140	12985	13775	14565	15730
D260	2060	2915	3775	4630	5490	6345	7205	8060	8920	9775	10635	11495	12350	13150	14065	14925	15780	17040
D280	2215	3140	4065	4990	5910	6835	7760	8680	9605	10530	11455	12375	13300	14160	15150	16070	16995	18350
D300	2375	3365	4355	5345	6335	7325	8315	9300	10290	11280	12270	13260	14250	15175	16230	17220	18210	19660
D325	2575	3645	4715	5790	6860	7935	9005	10075	11150	12220	13295	14365	15440	16440	17580	18655	19725	21300
D350	2770	3925	5080	6235	7390	8545	9700	10855	12005	13160	14315	15470	16625	17705	18935	20090	21245	22935
D375	2970	4205	5445	6680	7915	9155	10390	11630	12865	14100	15340	16575	17815	18965	20285	21525	22760	24575
D400	3165	4485	5805	7125	8445	9765	11085	12405	13720	15040	16360	17680	19000	20230	21640	22960	24280	26215
D450	3565	5045	6530	8015	9500	10985	12470	13955	15440	16920	18405	19890	21375	22760	24345	25830	27315	29490

At high power levels and the resulting currents, the cylinder- / band heaters are divided into several segments. The exact segmentation is determined based on the customer’s specific requirements.

A detailed calculation for each individual case by the Gebr. Bach GmbH is always required! For large dimensions or high power ratings, it is advisable – and in some cases essential – to divide the system into circular segments or partial shells, or to use multiple cylindrical heating elements. Design notes (for illustrative purposes):

500 mm < D < 1000 mm -> 2 half-shells
D ≥ 1000 mm -> 4 segments

The operating temperature for the HRHK heater type is up to 550 °C. If the continuous load is below 3 W/cm² or the operating temperature is 300 °C or less, a Mikanite ring heater may be considered.

Where possible, a spring-loaded clamp should be selected as the fastening. As this involves radiant heat transfer, the tension spring ensures optimum clamping force on the cylinder.

As general advice, the spring should have 2/3 of its free length when pre-tensioned.

Further details (please click on)

Installation and commissioning

Installation

During installation, care must be taken to avoid deformation or 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 heating element must be clamped onto the cylinder to be heated with a form-fitting manner. Care must be taken to avoid damaging or even destroying the ceramic elements inside the heating element. A torque is recommended which ensures that the ceramic elements of the heating element are in optimum contact with the cylinder.

A visual inspection should confirm this. When using compression springs, ensure the spring is pre-tensioned (approx. 2/3 of the spring tension) to ensure its travel in both directions. 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, retighten the clamping screws to 3 to 3.5 Nm.

Storage

The heating element must be stored in a dry, dust-free environment. If stored in too humid conditions, the insulation material may absorb moisture, posing 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.

Electrical installation

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

Ensure that the operating voltage of the heater matches the supply voltage. All connections must be made using heat-resistant cable (see operating conditions and safety instructions). These must be routed such 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.

Operating conditions and safety instructions

The maximum operating temperature of HRHK ring heaters is 550 °C. Please note that the relevant fire safety regulations must be observed and appropriate safety precautions must be taken. No critical conditions must occur either on the cylinder-ring heater or in the material to be heated (such as fire, explosion, smoke or gas development, etc.).

Due to the high temperatures, only suitable temperature-resistant connection cables must be used. Care must also be taken to ensure adequate protection against contact, dust and moisture.

The maximum surface load on the heating elements of the HRHK series should not exceed 7 W/cm². Incorrect installation and the wrong choice of control system can lead to faults and accidents. Any use for purposes other than those intended or under different operating conditions requires the manufacturer’s written approval; otherwise, no warranty or liability will be accepted.

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!

You’ve come to the right place when it comes to your electric heating systems. We offer bespoke solutions tailored to your specific requirements. Please describe your requirements to us. If necessary, feel free to include a supplementary PDF file, photos, a DXF drawing or a STEP file, which you can upload here.

Contact details

We look forward to work with you to solve your electric heating challenges!

Office hours: Monday to Friday, 8.00 am to 3.00 pm

mail@etb-bach.com +49 (0) 3624 / 3073 0 +49 (0) 3624 / 3073 200

Hamburger Straße 4b,
DE-99885 Ohrdruf