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:: Ceramic Band Heaters ::
 
MATRUSREE ELECTRO HEATS Designs and Manufactures Industrial Electric Tubular Heaters that set the industry Standard for excellence. Matrusree ceramic heaters are medium- to-high temperature heaters that have 1200 F as a maximum working temperature. These durable heaters have built-in ceramic fiber jackets that make them energy efficient. Matrusree heaters are available with different terminal styles, are fully flexible, and can accommodate holes and cut-outs.

In Matrusree Ceramic Band Heater(MCBH) heater, nickel-chrome wire is embedded in a flexible outer wall made of special, interlocking ceramic tiles, which are assembled like a brick wall. A ceramic fiber insulating mat and a stainless steel jacket cover this assembly. This construction prevents heat loss and reduces electrical consumption by 20%. An energized MCBH heater will have a temperature of 350- 450 F on its outside shell when the inside temperature is maintained at 1200 F. To improve the conservation of energy, different thicknesses of ceramic fiber insulation mats are available. Heat is transferred from a ceramic heater to the surface of an application through conduction and radiation. This is why a tight grip on the cylinder is not as critical as in other types of heaters. Moreover, over tightening should be avoided, since the pressure on the insulation mat reduces its insulating efficiency. MCBH heaters are made by using different combinations of ceramic tiles, which are available only in specific lengths. Consequently, the width of a MCBH band falls within a certain incremental range. MCBH ceramic band heaters can be manufactured with different clamping mechanisms, termination styles, holes and cut-outs.

Ceramic Band Heaters transmit heat through both conduction and radiation. The element winding is designed to run at maximum temperature and heat the ceramic blocks to the point where they radiate energy into the barrel as well as conduction through being in contact with the barrel. Due to this effect, the fit is not as critical as in other types of bands.
Features & Construction Details:
  • Reduce power consumption
  • Conserve heat
  • High degree of flexibility
  • Uniform heat distribution
  • Built-In Thermal Insulation
  • Conserves Electrical Energy
  • Minimum Heat Loss
  • Fully Flexible For Easy Installation
  • Good Temperature Uniformity
  • Longer Heater Life
  • Various Constructions and Terminations
  • Heats Through Conduction and Radiation
  • Designed to Your Specifications
Standard Specifications and Tolerances of Ceramic Insulated Band Heaters. If tighter tolerances are required consult Matrusree.
Band Material:
Stainless steel screw terminals connected to solid nickel pins designed to provide maximum amperage carrying capacity.

Built-In ceramic fiber insulation 1?4" thick standard on all Ceramic Bands will reduce power consumption by 25 to 30 percent. Further reduction can be obtained with optional 1?2" thick insulation. Specially designed mounting brackets with 1?4"-20 socket cap screws are used to securely draw the heatingelement assembly against the cylinder evenly and tightly across its entire width. Brackets are located 180 from the screw terminals.

Helically wound nickel-chrome resistance wire strung through specially designed ceramic insulating bricks.

Stainless steel housing with serrated edges provides maximum flexibility for ease of installation.
Available Dimensions:
  • Sheath Material: Stainless Steel
  • Insulation Material: Ceramic Fiber Blanket
  • Standard Thickness: 1?4"
  • Double Thickness: 1?2"
  • Overall Thickness: Standard Insulation: 5?8"
  • Double Insulation: 3?4"
  • Minimum Width: 1"
  • Standard Width Increments: 1?2"
  • Maximum Width: Dependent upon the ratio of diameter to width
  • Width Tolerance: 1" to 3 1/2" : 1/16"
      4" to 6 1/2" : 1/8"
      Over 6 1/2" : 1/4"
  • Minimum Diameter: 2"
  • Maximum Diameter-One-Piece: 21"
  • Two-Piece: 44"
  • Nominal Gap: 3?8", 1?8"
Electrical Ratings:
  • Maximum Voltage: with Screw Termination 480 VAC
  • Maximum Recommended Voltage w/Leads: 240 VAC
  • Maximum Amperage: lead wire termination: 10 amp (per circuit) screw terminations: 25 amp
  • Resistance Tolerance: +10%, -5%
  • Wattage Tolerance: +5%, -10%
Performance Ratings:
  • Maximum Temperature: 1600F (875C)
  • Nominal Watt Density: 20-45 W/in2 (3-7 W/cm2)
  • Maximum Watt Density: 45 W/in2
Typical Application:
  • Injection molding machines
  • Plastic extruders
  • Blow-molding machines
  • Container, pipe or tank heating
  • 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
  • Other process applications
Construction:
Ceramic Band Heaters are manufactured in a full range of standard construction variations, physical dimensions, electrical ratings, and a complete arrangement of screw terminals and lead terminations.

However, these standard Ceramic Band Heater variations and terminations do not represent the extent of our capabilities. Matrusree engineering staff, with many years of experience in heat processing and temperature control applications, can assist you in designing the right Ceramic Band Heater for your specific application.
Standard

The basic Matrusree Ceramic Band Heater design consists of a helically wound resistance coil made from nickel-chrome wire, evenly stretched and precisely strung through specially designed ceramic insulating bricks, forming a flexible heating mat. The ceramic heating mat along with 1?4" thick ceramic fiber insulation is installed in a stainless steel housing made with serrated edges, providing maximum flexibility for ease of installation. This allows the use of wider band heaters, eliminating the need for numerous narrow width and two-piece band heaters.
Double Insulated

For situations requiring additional insulation for lower external temperatures and increased electrical energy savings, Matrusree offers Double Insulated Ceramic Bands with a full 1?2" thick ceramic fiber insulation. This will decrease power consumption by 35 to 37 percent when compared against un insulated band heaters.

Two of the most commonly used band heaters are:
One-Piece Band: The One-Piece Ceramic Band Heater is the basic design most often specified by OEM's and processors. It is available with all types of insulation, construction styles, clamping or termination variations.
Two-Piece Band: The Two-Piece Ceramic Band Heater is commonly used on sizes larger than 21" diameter or when it would be inconvenient to use one-piece heater. It is available with all types of insulation, construction styles, clamping or termination variations.
Quality Control
From raw materials through the finished product, MATRUSREE maintains the highest standards in the industry through a series of Quality Control/Assurance checks.
  • Ceramic fiber insulation - Built-In ceramic fiber insulation 1?4" thick standard on all Ceramic Bands will reduce power consumption by 25 to 30 percent. Further reduction can be obtained with optional 1?2" thick insulation. Specially designed mounting brackets with 1?4"-20 socket cap screws are used to securely draw the heating element assembly against the cylinder evenly and tightly across its entire width. Brackets are located 180 from the screw terminals

  • Alloy Wire- It is important to use the correct wire gauge to carry the Amperage required. A wire not large enough can overheat, become brittle and break. The ambient temperature must also be considered in choosing the correct type of wire and insulation. Make sure wiring to terminals is tight. Keep terminals away from heat if possible.
Clamping:
Ceramic band heaters offer several variations in construction and clamping styles.
Built-In Bracket-Standard:
The Built-In Bracket is the basic design most often specified by OEM's and processors. The standard screw used is 1/4-20. It is available with all types of insulation, construction styles, or termination variations.
The Built-In Bracket can also be supplied with a spring loaded screw. The spring loaded clamp aids in absorbing thermal expansion.
Flange Lock-up (Ears):
The Flange Lock-up (Ears) is available with all types of insulation, construction styles, or termination variations.
Shell Overlap:
The Shell Overlap design is the preferred method of providing a thermocouple mounting hole in a ceramic band heater. It is available with all types of insulation, construction styles, clamping or termination variations.
The metal strap is continued over the gap and a hole is provided. This allows for thermocouple mounting without a hole in the heater.
Inner Liner:
The stainless steel Inner Liner is specially used to retard contamination from entering into the ceramic blocks. It will decrease heat transfer slightly. It can be supplied solid or perforated to improve heat transfer. The Inner Liner is available with all types of insulation, construction styles, clamping or termination variations.
Latch and Trunion:
The spring loaded Latch and Trunion clamping system is ideal for bands over 12" in diameter to absorb thermal expansion and facilitate installation on large bands. The Latch and Trunion clamping system is available with all types of insulation, construction styles, or termination variations.
TERMINATION:
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 with all types of insulation, construction styles, or clamping variations. It is considered to be standard on most band heaters under 2" in width unless otherwise specified. Includes high temperature washers and nuts.
Threaded Terminals [T3]:
Terminals are available with all types of insulation, construction styles, or clamping variations. 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.
Ceramic Terminal Covers- Available on all threaded terminals. Covers available separately
Straight Lead Wires:
Straight Lead Wires are available with all types of insulation, construction styles, or clamping variations. They are used primarily on small diameter bands where clearance is limited. If applicable, screw terminals should always be specified due to the high heat generated by ceramic bands. The standard flexible leads are 10" long. If longer leads are required, specify when ordering
Straight Wire Braid Leads:
Straight Wire Braid Leads are available with all types of insulation, construction styles, or clamping variations. Wire braid leads offer sharp bending not possible with armor cable. If applicable, screw terminals should always be specified due to the high heat generated by ceramic bands. The standard leads are 10" of wire braid over 12" of flexible leads. If longer leads are required, specify when ordering.
Straight Armor Cable:
Straight Armor Cable is available with all types of insulation, construction styles, or clamping variations. Armor cable provides far superior protection to lead wires where abrasion is a constant problem. If applicable, screw terminals should always be specified due to the high heat generated by ceramic bands. The standard leads are 10" of armor cable over 12" of flexible leads. If longer leads or electrical connectors are required, specify when ordering.
Right-Angle Armor Cable:
Right-Angle Armor Cable is available with all types of insulation, construction styles, or clamping variations. It is used where space is limited and abrasion is a constant problem. If applicable, screw terminals should always be specified due to the high heat generated by ceramic bands.
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.
Installation:
  1. Disconnect electric power to the machine and/or heaters prior to installing or replacing heaters.
  2. Do not install heaters in areas where combustible gases vapor or dust is present.
  3. Reduce the number of narrow or two-piece bands used on the barrel. Ceramic bands are very flexible and can be made in large widths and one-piece construction for easy installation. This eliminates heat losses between narrow bands and sharply reduces costly installation labor.
  4. 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.
  5. When replacing any other type of non-insulated band heater with Matrusree ceramic band heaters, you can decrease your total operating wattage by approximately 15 to 20 percent.
  6. To prevent overheating and heater failure, adequate temperature controls should be installed. The thermocouples must be kept free of contaminants and checked for good response to temperature changes. A bad thermocouple can be the cause of destroying an entire heating zone due to overheating. Matrusree offers a wide variety of temperature controls and thermocouples from stock for immediate delivery. Consult the index of this catalog for appropriate pages.
  7. Make certain that all barrel surfaces are clean and free of contaminants. During operation, the band heaters and cylinder surface must be kept free of all contaminants that might liquefy under heat and find their way into the heater windings, carbonizing and becoming conductive. The smallest amount of contamination can cause electrical shorts, creating heater failure.
  8. Position heater bands on the barrel.
  9. Take up all the slack by tightening the low thermal expansion outer housing until the serrated edges come firmly in direct contact with the cylinder. A rawhide mallet can be used to lightly tap the outer edges-only to get uniform contact as you tighten the clamping screws. Do not over tighten to the point where the serrated edges begin to collapse and thrust outward. At this point you are compressing the ceramic insulation and decreasing its insulating value. Unlike all other types of band heaters, ceramic bands heat by radiation as well as conduction and they do not require the same clamping force that is essential with all other types of band heaters.
  10. 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.
  11. All electrical wiring of heater bands should be done by a qualified electrician.
  12. Use only lead wire with high temperature insulation and proper gauge size. See page 15-12 in the accessories section
  13. 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.
  14. Make sure the voltage input to the heater bands does not exceed the voltage rating that is stamped on the heater band.
  15. . It is recommended that an amperage reading is taken for each heater to totally insure correctness of wiring. (Amps = Watts Volts)
  16. Insulate all live electrical connections per applicable safety standards.
  17. Install shrouds around the machine to meet applicable safety requirements.
  18. 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.
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