Nozzle Band Heaters Ceramic
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 heaters are impervious to plastics and are also available with integrated thermocouples. Thanks to their ceramic insulation, the nozzle strips in the BDK series have a particularly high power density of 10 W/cm² and can be heated to 650°C.
Specifications
| BDK |
Sheath material | Stainless steel (1.4301) |
Operating temperature max. in °C | 550 (temporarily up to 650) |
Thermal load max. in W/cm² | 10 |
Wall thickness in mm | Ca. 5 - 6 |
Operating voltage in V | Up to 500 |
Power tolerance | + 5% / -10% |
Integrated temperature sensor available | Yes |
Dmin in mm | 25 |
Dmax in mm | 115 |
Bmin in mm | 18 |
Bmax in mm | 90 |
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 HRHK series (ceramic) with a power density of 7 W/cm² may be considered. For power densities below 5 W/cm², nozzle band heaters from the BDS series (MICA-type) may be used.
Power calculation
For the power estimation, a maximum permissible surface load (thermal load on the inner surface of the nozzle band heater) of 10 W/cm² may be used for nozzle band heaters of the BDK series. The maximum permissible power can be calculated approximately as follows.
This results in the power ratings in watt for the respective diameters and widths, as shown in the table below. The table is intended solely to provide an estimation of possible power ratings for potential future orders.
Power table for BDK series nozzle band heaters (power ratings in W) – with diameters of 35 mm – 115 mm and widths of 20 mm – 60 mm
D/W | W20 | W25 | W30 | W35 | W40 | W50 | W60 |
D35 | 215 | 275 | 330 | 385 | 440 |
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D40 | 250 | 310 | 375 | 440 | 500 | 625 |
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D45 | 280 | 350 | 420 | 495 | 565 | 705 | 845 |
D50 | 310 | 390 | 470 | 550 | 625 | 785 | 940 |
D55 | 345 | 430 | 515 | 605 | 690 | 860 | 1035 |
D60 | 375 | 470 | 565 | 660 | 750 | 940 | 1130 |
D65 | 405 | 510 | 610 | 715 | 815 | 1020 | 1225 |
D68 | 435 | 550 | 660 | 770 | 880 | 1100 | 1315 |
D70 |
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D75 |
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D80 |
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D85 |
| Upon Consultation |
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D90 |
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D100 |
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D115 |
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For diameters of 70 mm and above, the power rating is determined in consultation with our team. However, a precise calculation for each individual case by the Gebr. Bach GmbH is always required! The operating temperature for the BDK nozzle band heater type is up to 550 °C. If the continuous thermal load is below 5 W/cm² or below 320 °C, nozzle band heaters from the BDS/BDSE series (MICA-type) should also be considered.
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:
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. If stored in humid conditions, the insulation material may absorb moisture, posing a risk of short-circuiting. It is recommended to heat the element up gradually 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.
At high operating temperatures, such as 550 °C, the leakage current can range from 20 to 40 mA. This should be taken into account when selecting a residual-current device.
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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