MATRUSREE ELECTRO HEATS Designs and Manufactures Industrial Electric Band Heaters that set the industry Standard for excellence. Matrusree Band Heater (MBH) is a reliable mica insulated one that can perform at higher operating temperatures [up to 900 F (480 C)] essential to process high temperature resins, providing long, efficient service necessary for today's high productivity of plastic extruders, injection and blow molding machines.|
Band heater is proven for good life efficiency and dependability. It assures maintaining the lowest winding temperatures possible, keeping a low-,ass heating element assembly for fast heat-up and quick thermal response to controls.Mica insulated heaters are widely used on operations involving heating of cylindrical surfaces and are manufactured in a full range of standard construction variations, physical dimensions, electrical ratings, and a complete arrangement of screw terminals and lead terminations.
|FEATURES AND BENEFITS:|
- Maximum watt densities; far in excess of any other type of band.
- Highest application temperatures available
- Best possible clamping and the resulting improved efficiency.
- Longest life available for any application and reduction of equipment downtime.
- High heat transfer rates and the resulting fast response.
|Features & Construction Details:|
|Specially treated rust-resistant steel sheath casing provides the best combination of physical strength, high emissivity and good thermal conductivity to heated cylindrical parts, good for sheath temperatures up to 900°F (480°C). A low thermal expansion alloy sheath casing is available for temperatures up to 1200°F (650°C).|
Specially selected grade and thickness of mica sheet is used to screen the windings, providing outstanding thermal conductivity and dielectric strength.
|Available Dimensions: |
- Minimum Width: 5/8 in. (15.9 mm)
- Width Tolerance: ±1/16 in. (1.59 mm)
- Minimum Inside Diameter: 3/4 in. (19.0 mm)
- Standard Gap: 3/8" (9.5 mm)
- Maximum Voltage: 480 VAC
- Maximum Recommended Voltage w/Leads: 240 VAC
- Maximum Amperage: lead wire termination: 10 amp
- screw terminations: 8-32UNF-20 amp; 10-32UNF-25 amp
- Resistance Tolerance: +10%, -5%
- Wattage Tolerance: +5%, -10%
- Maximum Temperature: Standard Sheath: 900°F(482°C)
- SS Sheath: 1200°F (649°C)
- Nominal Watt Density: 20-45 W/in2 (3-7 W/cm2)
- Maximum Watt Density: Dependent on heater size and
- operating temperature.
- Plastic Injection Molding Machines
- Plastic Extruders
- Oil Reclamation Equipment
- Food and Candy Extruders
- Drum Heating
- Extrusion Dies
- Holding Tanks
- Blow Molding Machines
- Vending Machines
- Barrels & Heads
- Food Service Warming
- Autoclaves & Sterilizers
- Metallurgical Analyzers
- Fluidized Beds
- Hot Runner Molds
- Pulp and Paper Processing Equipment
|Matrusree Band Heater (MBH) s utilize different types of top grade mica. The thickness of each mica layer is carefully selected to balance between the insulating characteristics of Mica and the ease of heat transfer from the resistance ribbon to the machine barrel.The resistance ribbon used in a MBH is not restricted to the capabilities of Nichrome wire. Different alloys are considered for different applications. The internal winding is carefully designed to ensure uniform heat distribution throughout the heater. To maximize the surface-to-surface contact, MBH are carefully rounded and formed to optimize the grip on a machine barrel. The external metallic protective sheath of a MBH is made of a special alloy, which expands less than the barrel when heated. This difference in thermal expansion makes the heater grip the barrel firmly once it is energized, and this improves heat transfer. Poor heat transfer acts like a throttle and makes The resistance element inside the heater function at elevated temperatures, which eventually leads to the premature failure of the heater. MBH s are made in different construction styles, clamping mechanisms, and terminal types. Holes, cutouts, slots, thermocouple or mounting brackets can be accommodated in the design.|
Three of the most commonly used band heaters are:
||The one-piece construction is available on any screw or lead termination and clamping variation. It can be used where band heaters can be slipped over the end.
||The two-piece construction is available on any screw or lead and clamping variation. The Duraband two-piece design provides a built-in hinge making handling and installation easier. It is used on large cylinders or where the heater cannot be slipped over the end of the cylinder. Two-piece band heaters are rated at watts and volts per each half when ordering. Multiple segments like 4-piece design are recommended on larger diameter (typically larger than 15") heaters to improve the clamping force and hence the surface contact between the heater and the barrel for efficient heat transfer.
||The one-piece expandable construction is available on any screw or lead and clamping variation. It can be used where a one-piece band heater would have to be expanded to fit over the barrel during installation rather than slid on the end of the barrel
|Picture Construction: |
|From raw materials through the finished product, MATRUSREE maintains the highest standards in the industry through a series of Quality Control/Assurance checks.|
- Nickel-Chrome - MATRUSREE uses (80%Nickel, 20% Chrome) Nickel-Chrome, the highest grade available for electric heating elements. The gauge of nickel-chrome resistance ribbon wire is selected to achieve the lowest internal element temperatures possible, resulting in maximum heater life. The ribbon wire is wound evenly spaced on a specially selected mica strip providing even heat distribution, thus eliminating hot spotting that can cause premature heater failure.
- Mica insulation- Specially selected grade and thickness of mica sheet is used to insulate the windings, providing excellent thermal conductivity and dielectric strength
|Matrusree Band Heaters Special Custom Designs:|
|Variety and Versatility in MBH:|
|No other heater band has the design and manufacturing suppleness of Mica insulated heaters. Matrusree's custom developed engineering programs with built-in aptitude, and experienced and endowed engineering staff allows us to push the limits on band heater designs|
Throughout our index we show our standard disclaimer and most admired designs. On the other hand, as a custom heating element manufacturer, we make out that many applications require non-standard and unique designs.
At Matrusree, we are constantly challenged by the clients to solve their heating applications. We have the experience, technical knowledge and manufacturing capability to solve all heating problems with unique heater designs.
You should use Matrusree's talent and capabilities to your benefit to solve your specific heating problems in a quick and cost effective manner.
The following are the pictures of the heater designs that we have developed for special applications
|BAND HEATER SELECTION:|
- Prior to selecting a band heater style for an application, there are a number of items that must be taken into consideration. These include type of application, operational temperature, controls and heat required to continually satisfy the application. All band heaters have their own physical and operational characteristics and limitations which should be reviewed prior to making a selection.
- Knowing the maximum watts per square inch of the heater is essential when making your selection and can be calculated by:
||Cold Area to Subtract:
|Two-piece band Holes and cutouts Size
||+ 1?2" width
|LAB TESTED AND FIELD PROVEN CAPABILITIES:|
|To verify total life characteristics of the MBH, a multitude of accelerated life tests have been performed. Under severe operating conditions, including the combination in excess of 800º F (427º C) band temperatures and watt densities in excess of 60 w/in2, the MBH has survived thousands of hours of operation without failure. Field testing of the MBH in typical high temperature plastic molding situations and in applications as extreme as die casting nozzles has further proven the MBH to be the most advanced band heater available.
|Illustrated are the various available styles of clamping for band heaters. When a band is provided the material is of a low coefficient of expansion type. Width of the clamping band or the number used per heater is dictated by the design standards. There are a variety of clamping mechanisms that can be attached to the band or directly to the heater. The most common forms are the strap and strap ends.|
|Factors influencing the type and size of clamping are:|
- Type of band heater
- Diameter and width
- Termination type and location
- Holes or notches in heater
- Preference of the user
|Standard Built-In Strap Clamping:|
|The Built-In Strap is available with any screw or lead termination and construction variation. The Built-In Strap eliminates the use of gauche to- handle separate straps, providing more drawing power than any other type of clamping system. The MBH with Built-In Strap is standard on many designs.|
|The Flange Lock-Up clamping is available with any screw or lead termination and construction variation. The outer sheath is made from a Low Thermal Expansion alloy. The Flange Lock-Up design is considered a standard design on many narrow band heaters. It is not recommended for larger diameter band heaters because it does not provide sufficient drawing power in the larger sizes and may shorten the life of the heater. MBH with Built-In Strap design is used wherever possible because it provides more drawing power than any other type of clamping system.
|The Separate Strap clamping is available with any screw or lead termination and construction dissimilarity.
The Low Profile Strap with Barrel Nuts isavailable with any screw or lead termination and construction variation. It is primarily recommended to alleviate clearance problems on small diameter nozzle bands.
Specially designed for mounting where space is severely limited.
Eliminates the need for straps.
It lends itself mainly to small diameter nozzle heaters.
|Spring Loaded with Built-In Bracket:|
|Spring bolt clamping applies constant tension on the clamping mechanism to compensate for heater elongation once it has been energized. |
The springs provide constant tension, maintaining the heater's inside surface tightly up against the cylinder being heated
|Spring Loaded with Bent-Up Flange:|
|The Heavy Duty Stainless Steel Spring with Flange Lock-Up clamping is available with any screw or lead termination and construction variation. The outer sheath is made from a Low Thermal Expansion alloy. The springs provide constant tension, maintaining the heater's inside surface tightly up against the cylinder being heated. It is not recommended for larger diameter band heaters because it does not provide sufficient drawing power in the larger sizes and may shorten the life of the heater. |
|Terminals are a very convenient way of connecting our band heaters to power; typically, Monel® lugs are used to secure wiring. |
Supplied when heater width is at a minimum or when, in application, a buss bar is used to connect the terminals of adjoining heaters.
|Threaded Terminals [T1]: |
|Threaded Screw Terminals are available on any clamping or construction variation It is considered to be standard on most band heaters unless otherwise specified. For use with leads, crimp terminals, or bus bars. Includes high temperature washers and nuts. |
|Threaded Terminals [T2]:|
|Type T2 Screw Terminals are available on any clamping or construction variation. They are recommended for narrow band heaters where screw terminals are preferred or the C2 terminal box protection is required |
|Threaded Terminals [T3]:|
|Type T3 Screw Terminals are available on any clamping or construction variation. It is the preferred design on band heaters over 3" (76.2 mm) wide or when C3 terminal box is required. |
|Ceramic Terminal Covers:|
| consist of two individual ceramic parts. |
|Button Terminals: |
| Low Profile Button Terminals are available on any clamping or construction variation. Button terminal locations are similar to T1, T2, or T3. |
|Straight Lead Wires:|
| Straight Lead Wires are available on any clamping or construction variation. The lead wires exit through a brass grommet. The standard supple leads are 10" long with 3" of fiberglass sleeving.|
If longer leads are required, specify when ordering.
|Lead Wires At Opposite Ends:|
| Lead Wires At Opposite Ends are available on any clamping or construction variation. Well suited lead termination for small band heaters. |
|Lead Wires on Each End:|
|Lead Wires On One Side are available on any clamping or construction variation.|
The preferred termination on all small diameter and width band heaters.
|Lead Wires on One End:|
|Lead Wires On One End are available on any clamping or construction variation. A suitable lead termination for small band heaters. |
|Abrasive Resistant Lead Terminations:|
|Wire Braid Leads: |
| Stainless steel over braid is most commonly specified in applications where leads may be subjected to abrasion due to movement of the application. Lead wires may be rubbing together or passing over sharp objects. |
|The Stainless Steel Braid is also available for all wire termination styles |
|Straight Armor Cable: |
|Used over leads in areas where more protection is necessary. Selected for similar applications as the stainless steel braid, in addition to applications where non-fluid contamination may come in contact with the leads. This lead protection is not as flexible as over the braid. Stainless steel square lock construction |
|Right Angle Armor Cable:|
| Right Angle Armor Cable is available on any clamping or construction variation. Armor cable provides far superior protection to lead wires where abrasion is a constant problem. |
This "Elbowed" terminal is selected when the leads are required to exit the heater in a definite direction and away from the heater surface.
|Terminal Boxes are available on any clamping or construction variation. It is a simple and economical way to protect employees from electric shock or prevent electric shorts that can result from exposed wiring on band heater electrical installations. |
|Quick Disconnect High Temperature Plugs:|
|High Temperature Quick Disconnects are available on any construction or clamping variation.The combination of plug and cup assembly along with armor cable covered leads eliminate all live exposed terminals or wiring that can be a potential hazard to employees or machinery. class='blacknormal'> Stainless steel over braid is most commonly specified in applications where leads may be subjected to abrasion due to movement of the application. Lead wires may be rubbing together or passing over sharp objects. |
- Disconnect electric power to the machine and/or heaters prior to installing or replacing heaters.
- Do not install heaters in areas where combustible gases, vapor or dust is present.
- Use as many narrow band heaters as the application will permit. 11?2" through 3" wide heaters are recommended.
- Using a heater that closely matches the wattage requirements will decrease the frequency of cycling and temperature overshoot, thereby increasing the life of the heater.
- Make certain that all barrel surfaces are clean and have a smooth finish. Any contaminants or imperfections on the surface can cause premature heater failure.
- MATRUSREE expandable type Mica Band Heaters may be opened once at the gap to fit on the barrel. Do not open these heaters beyond their specified heater diameter.
- Do not open MATRUSREE one-piece Non-Expandable Type Mica Band Heaters. Opening of these heaters can damage Mica Insulation and will create electrical short circuits.
- Position heater bands on the barrel.
- Securely tighten heater bands around the barrel. Clamping force must be equally distributed on heaters with more than one set of clamping brackets. Recommended clamping bolt torque is 10 ft/lbs.
- For heaters with screw terminals, remove the top nut and flat washers from the power screw terminals. Do not remove or loosen the bottom nut on the power screw terminals. The bottom nut is tightened to 60 inch/lbs. at the factory. A loose bottom nut may cause premature heater failure.
- All electrical wiring of heater bands should be done by a qualified electrician.
- Use only Stainless Steel or other high temperature lugs to prevent material degradation when exposed to high temperatures over a prolonged period of time.
- DO NOT USE COPPER OR PLATED COPPER LUGS.
- Use only lead wire with high temperature insulation and proper gauge size.
- When connecting power leads to screw terminals make certain that barrels of terminal lugs are not facing down toward the heater case, which will create a short circuit. Tighten the top nut to 30 inch/lbs.
- Make certain power lead wires do not make contact with hot heater surface to avoid degradation of lead wire, as this can cause electrical short circuits.
- Make sure the voltage input to the heater bands does not exceed the voltage rating that is stamped on the heater band.
- It is recommended that an amperage reading is taken for each heater to totally insure correctness of wiring.
(Amps = Watts/Volts)
- Insulate all live electrical wires per applicable safety standards.
- Begin heater band re-tightening procedure. Be sure to wear protective gloves.
- Energize heater bands and allow the heater to reach 300°F (149°C). This usually takes between 3 and 5 minutes.
- Turn off power and immediately re-tighten the heater bands to 10 ft./lbs. Turn power back on.
- Install shrouds around the machine to meet applicable safety requirements.
- Once installed, check surroundings to make sure that contaminants won't get on the heater while the unit is in operation. Accumulation of contaminants on heaters can cause premature heater failure.
- Insulating blanket installations must have band heater retightening sequence (#12) completed before blanket installation. Lead wires must exit the insulation blanket as soon as possible; do not entrap lead wires between heater sheath and insulation blanket.
- It is imperative that upon start-up of new machines at customer facilities, all of the aforementioned parameters are double checked by qualified field service personnel.