PRODUCT CATALOGUE for the PLASTICS, PACKAGING and RUBBER INDUSTRY

Transcription

1 PRODUCT CATALOGUE for the PLASTICS, PACKAGING and RUBBER INDUSTRY CONTENTS Mica and ceramic bands 1 Flats, box and drum heaters 2 Incoloy band and aluminum encased elements 3 Cable entry angles and terminations 4 Air cooling heater jackets / Air heaters 5 Sealed nozzle heaters 6 Ceramic nozzle heaters 7 Coil heaters - flat 8 Mini coil heaters 10 Maxicoils - flat 11 Encapsulated coil heaters 12 Cartridge heaters 13 Infrared emitters 18 Tubular incoloy rod heaters 20 Melt pressure / temperature transducers 23 Therm-O-runner 24 Temperature controllers 26 Temperature sensors 29 Digital handheld thermometers 32 Heating element accessories 33 Temperature sensor accessories 34 Cables and accessories 35 Heat calculations 36 Thread sizes 37 Electrical formulas 38 Thermocouple chart 39 Page

2 MICA AND CERAMIC BANDS Heater bands, box and flat elements are used extensively in the plastics converting process. A typical feature of these elements is even heat distribution over a large surface area. Construction consists of heating wire, insulated with either mica-plates or ceramic formers. The elements are usually metal shrouded for mechanical strength. CERAMIC INSULATION BANDS Ceramic elements are thicker in construction (12mm) Maximum watts density of 7 W/cm² Operating temperature up to 600 C Ceramic elements used where high power rating or operating temperatures in excess of 250 C are required Ceramic elements are more durable than mica elements Ceramic elements should not be mounted and remounted on machines as this will reduce life expectancy MICA INSULATION BANDS Mica insulation offers thin construction (4mm) Watts density of 3.5 W/cm² Operating temperature up to 250 C For elements rated in excess of 4000W ceramic insulation is recommended SERRATED / FLEXIBLE BAND HEATERS - available on request. These are used on larger barrels where fitment of the heater is problematic due to lack of flexibility. 1

3 FLATS, BOX AND DRUM HEATERS DRUM HEATERS - Typically used for pre-heating chemical solutions to decrease viscosities Mica insulated Standard size: 565 x 200mm Wattage: 3000W Voltage: 230VAC Fitted with C thermostat Quick release clamps ensure easy removability Other sizes available on request BOX HEATERS Box heaters in mica are ideally suited for extrusion or similar dies Critically important to fit a 4mm or thicker backing plate to all mica flat and box heaters to ensure tight clamping and elimination of warping FLAT HEATERS Flat heaters in mica are ideally suited for extrusion or similar dies Critically important to fit a 4mm or thicker backing plate to all mica flat and box heaters to ensure tight clamping and elimination of warping Watts density of 3.5W/cm² Operating temperatures up to 250 C MEASUREMENT TOLERANCES INSULATION TEST 1000 VAC Mega 3.5MΩ HI POT / FLASH TEST 1500 VDC 10 ma PARAMETER TOLERANCE Band heaters (Mica & Ceramic) Diameter mm Width mm Hole diameter mm Other dimensions (cut outs etc) ± 2.0mm Resistance ± 5% (Except for expandable heaters, diameter is always internal and must be measured using a diameter tape) 2

4 INCOLOY BANDS / ALUMINUM ENCASED ELEMENTS IDEAL FOR EXTRUDER HEADS INCOLOY BAND HEATERS Sheathed tubular elements Diameter 8.0mm Elements bent, shaped and fitted into steel jacket Ideally suited for applications where there is water, moisture or corrosive gases present Made to customer s specifications Contact Swift s engineers for more technical information ALUMINUM ENCASED ELEMENTS Machined aluminium plates custom designed Fitted with either cartridge or incoloy elements Ideally suited for applications where moisture, water and other liquids can ingress the heater Lifespan of element can be extended by simply replacing the faulty heater Used primarily for extruders and bottle blowing machines Mounting: Good thermal contact between the elements and metal surface to be heated is essential. Due to the large surface area and flat construction, warping of elements will result in air gaps, causing hot spots and possible failure of the element. It is therefore important that elements are clamped on tightly and that clamps are tightened again when the element has reached operating temperature. Calculation of Maximum Power Rating (all dimensions in millimetres) Flat mica element : P max (watts) = Width x length x Box heater (mica) : P max (watts) = Width x ((length + depth) x 2) x Heater band (mica) : P max (watts) = Width x diameter x 3.14 x Ceramic elements : Multiply the power rating as calculated for mica elements by 2 3

5 TYPICAL CABLE ENTRY ANGLES AND TERMINATIONS AXIAL TANGENTIAL RADIAL TANGENTIAL ANGLED AXIAL ANGLED CABLE EXITS TERMINATION TYPES D W 15 H 0 Band Heater THREADED TERMINAL POSTS M4, M5 SMALL TERMINAL BOX SIZE (D) (W) (H) 50 x 25 x 25 W W D D H H CABLE WITH PROTECTION CAP CAP HEIGHT Min - 10mm Max - 15mm LARGE 3-PHASE TERMINAL BOX SIZES (D) (W) (H) 95 x 60 x x 180 x 100 STD TERMINAL BOX SIZE (D) (W) (H) 70 x 45 x x 50 x 50 FULL SHROUDED KETTLE PLUG STANDARD KETTLE PLUG SANDWICHED CABLE 4

6 AIR COOLING HEATER JACKETS / AIR HEATERS Swift Heat designs and manufactures cooling jackets to suit customer requirements Material of jacket can be 316 stainless steel, mild steel or aluminium Internal copper / brass / aluminium cooling fins can be supplied as an option Quick release clamps or standard anodized allen cap screws are fitted onto jacket Positioning of thermocouple holes, diameters, widths and type of termination terminal must be specified Cooling fans can be supplied as an extra Custom designed connecting towers are fitted onto jacket to retrofit centrifugal cooling fans AIR HEATERS These are used for hot air applications in softening, curing or bonding of glues, plastic materials or shrink wrapping of products. Manufactured by using mica or ceramic insulators and spiral elements Different wattages and voltages available Diameter and length of element to be specified Cross -sectional dimensions to be specified Type of electrical termination required Contact Swift s engineers for more information on designing complete hot air guns" 5

7 SEALED NOZZLE ELEMENTS - BRASS OR STAINLESS STEEL Sealed Nozzle Elements and Spru-bush elements are primarily used on plastic moulding machines and hot-melt applications. Standard Sizes: Sealed Nozzle Elements can be supplied in any diameter larger than 30mm Standard Width: 25mm, 30mm, 35mm, 40mm, 45mm and 50mm Rating: Maximum rating is 6 W/cm² up to 250 C Calculation of maximum power (all dimensions in mm) P max (Watts) = Width x Diameter x 0.19 Mounting: Good thermal contact between the element and metal surface to be heated is essential. It is therefore important that elements are clamped on tightly and that clamps are tightened again when the element has reached operating temperature. Storage and Commissioning: Elements are susceptible to moisture and should be stored or used in a dry environment. It is recommended to heat up the elements gently after a prolonged period out of commission. This allows moisture to escape and prevents damage to the elements. Some temperature controllers have a soft-start feature, but a similar result is achieved by turning the temperature controller down initially. Diameter mm STANDARD SEALED BRASS NOZZLES Width mm Watts/Volts W/230V 500/1000mm W/230V W/230V W/230V 500/1000mm W/230V W/230V W/230V W/230V W/230V 500/1000mm W/230V W/230V 500/1000mm W/230V 500/1000mm W/230V Cable Length mm 500/1000mm 500/1000mm 500/1000mm 500/1000mm 500/1000mm 500/1000mm 500/1000mm 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm * Above sizes ex-stock * Other sizes and voltages available on request 6

8 CERAMIC NOZZLES IN STAINLESS STEEL These high watts density nozzles (up to 8W/cm²) use a ceramic former in place of the conventional mica as an insulator. The former is placed into a stainless steel pipe which is then rolled to a specific diameter. The electrical connection is joined via a cap and braided cable. Ceramic nozzles ideally suited for temperatures in excess of 300 C viz. nylons etc Offers superior mechanical strength Available only as 25mm wide Minimum height 10mm ORDERING OPTIONS Internal diameter Wattage Voltage Length of cable Exit: axial, radial or tangental (see page 4) STANDARD SEALED CERAMIC NOZZLES Diameter mm Width mm Watts/Volts W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm W/230V 500/1000mm * Above sizes ex-stock * Other sizes and voltages available on request Cable Length mm 7

9 COIL HEATERS (FLAT) STANDARD FEATURES Offers uniform distribution of heating in confined spaces High watts densities, slim construction, small bending radius and durability against mechanical damage make coil heaters ideal for various applications Used widely in the Plastics and Packaging, Textile and Die-Casting industry Can be supplied with built-in thermocouple for applications where there is insufficient space to mount a separate temperature sensor Available in straight stick form for bending and insertion into machined grooves on tools. Alternatively, heaters are coiled by Swift s factory to the customers' specification. Standard coil heater with flat cross section (4.2mm x 2.5mm) Standard voltage 230 VAC 110 VAC available on request Exit: axial, radial or tangential (see page 9) Unheated zone 50mm plus potseal lead (25mm) 1000mm teflon insulated leads with Fg protective sleeving ( optional sprague or braided) ORDERING OPTIONS Internal diameter and coil length according to customer specifications Various wattages available With or without built-in thermocouple (J, K) With or without outer jacket (sleeved or with tightening nut) Other cross sectional sizes available on request Outer jacket or encapsulated for added robustness and better heat transfer properties Spacing of coils (see page 9) 8

10 COIL HEATERS - STANDARD SIZES Heated Length(H) (mm) COIL HEATERS 4.2 x 2.5mm without Thermocouple Total Length (mm) Wattage at 230V (Watt) COIL HEATERS 4.2 x 2.5mm with built-in Thermocouple type J Heated Length(H) (mm) Total Length (mm) Wattage at 230V (Watt) * Above sizes ex-stock * Above sizes ex-stock Potseal Unheated(U) Heated(H) 4.2 mm 2.5 mm 25mm 50 mm COIL HEATER EXITS SPACING OF COILS a b c AXIAL (HDC) WOUND TIGHTLY BOTH ENDS RADIAL (HDB) with or without 45 bend EVENLY WOUND b a TANGENTIAL (HDA) WOUND TIGHTLY ONE END ONLY Specify length for b Specify number of turns for a and c 9

11 MINI COIL HEATERS - HUSKY TYPE Available in a variety of sizes, wattages and clamping options in either flat, dual, round or rectangular cross section. Used in plastic injection moulding machines, hot melt applications and hot runners. STANDARD FEATURES Hermetically sealed 1.83m Teflon insulated lead wire ORDERING OPTIONS Built-in J thermocouple Ground wire Teflon coated high temperature lead wire Lead wire protection Axial clamp (cam or wedge) Screw clamp Cast housing SPECIFICATIONS Dielectric strength 1000 VAC Current leakage <0.1mA@240V DC Insulation resistance >100MSL@500VDC Watt densities exceeding 20W/cm² MINI COIL HEATERS - HUSKY TYPE Size Diameter Width Wattage/Voltage F 1.3 x 2.3* ø W/240V with clamping band (axial fitting) "Husky" F 1.3 x ø W/240V with clamping band (axial fitting) "Husky" F 1.3 x ø W/240V with clamping band (tangential fitting) std "Husky" F 1.3 x ø W/240V with clamping band (tangential fitting) std "Husky" F 1.3 x ø W/240V with clamping band (tangential fitting) std "Husky" F 1.3 x 2.3* ø W/240V with clamping band (tangential fitting) std "Husky" F 1.3 x ø W/240V with clamping band (tangential fitting) std "Husky" F 1.3 x ø W/240V with clamping band Items marked with (*) ex-stock 10

12 MAXICOILS (FLAT) STANDARD FEATURES Used widely in the Plastics, Packaging, Textile and Die-Casting industry Can be supplied with built-in thermocouple for applications where there is insufficient space to mount a separate temperature sensor Available in straight stick form for bending and insertion into machined grooves on tools. Alternatively, heaters are coiled by Swift's factory to the customers' specification 1000mm teflon insulated leads with Fg protective sleeving (optional sprague or braided) Standard coil heater with flat cross section (10mm wide x 3.8mm thick) Unheated zone 50mm plus potseal lead (25mm) Voltage 230V Potseal Unheated(U) Heated(H) 10 mm 3.8 mm 25mm 50 mm ORDERING OPTIONS With or without outer jacket (sleeved or with tightening nut) With or without built-in thermocouple (J, K) Exit: axial, radial or tangential (see page 9) Internal diameter and coil length according to customer s specifications Various wattages available Special lengths available on request Outer jacket for added robustness and better heat transfer properties Spacing of coils (see page 9) MAXI standard size 10 x 3.8mm with built in Thermocouple type J Heated Length(H) (mm) Total Length (mm) Wattage at 230V (Watt) * Limited stock available, confirm with Swift 11

13 COIL HEATERS ENCAPSULATED IN BRASS / BRONZE STANDARD DETAILS Coil heater encapsulated in brass / bronze with outer sheath of stainless steel Wall thickness 4.5 up to 5.5mm, depending on integrated coil heater For inside diameter, min. and max. length and wall thickness (see table below) Voltage : 230V Exit: axial, radial or tangential (see page 9) Connection option: 1000mm teflon leads with earth and fibreglass protective sleeving and / or sprague tubing ORDERING OPTIONS With or without built-in thermocouple (J, K ) Inside diameter Tolerance of inside diameter Outside diameter Length Spacing of coils (see page 9) Wattage Voltage Exit: axial, radial or tangential (see page 9) Connection length MINIMUM, MAXIMUM LENGTH AND DIAMETER Inside Diameter in mm Min. Length in mm Max. Length in mm Wall thickness in mm

14 CARTRIDGE HEATERS STANDARD FEATURES Compacted cartridge heaters have a supporting core which is centrally located very close to the outer sheath The inner space is filled with pure magnesium oxide powder and is highly compressed The bottom end of the cartridge heater is gas tight welded and the outside sheath ground for precision tolerance Diameters vary from standard to non-standard mm including imperial sizes OPTIONS Built-in thermocouple (Type J, K) Surface loads can vary from 5W/cm² to 30W/cm² Humidity resistant leads Specials can be manufactured on request Standard Tolerances Diameter mm Length < 130mm ± 2% > 130mm ± 1% Wattage ± 10% Special tolerances can be supplied on request Diameter mm Length ± 0mm PROFILE CARTRIDGES Elements with special heat distribution can be supplied on request. A profile cartridge heater is recommended to evenly heat in sealing bar applications. b a b a Standard heat distribution a - Temperature curve b - Resistance (on heating wire) Profile heat distribution a - Temperature curve b - Resistance (on heating wire) 13

15 CARTRIDGE HEATERS - TYPE O TERMINATION Diameter X length (mm) TYPE O 500mm NFg TAILS 6.5 x , 125, 160, x , 160, 200, x , 200, x , x , x , 160, 200, x , 200, 250, x , 250, 350, x , 315, x , 315, x , x , x , 250, x , 250, 315, x , 315, 400, x , 315, 400, x , 400, 500, x , 630 Wattage at 230V These are available ex-stock. Other sizes and wattages can be manufactured as a special INJECTION MOULDING Inside heating of nozzles HOT RUNNER SYSTEMS Heating of manifolds PACKAGING INDUSTRY Heating of welding bars 14

16 CARTRIDGE HEATERS - TYPE O TERMINATION Diameter X length (mm) TYPE O 500mm NFg TAILS 12.5 x , x , 315, x , 315, x , 315, x , 400, 500, x , 500, 630, x , 630, 800, x x , x , x , 400, x , x , x , 800, x x , x , x , 1800 Wattage at 230V These are available ex-stock. Other sizes and wattages can be manufactured as a special EXTRUSION Heating of die head TEXTILE INDUSTRY Heating of cutting knives PAPER INDUSTRY Heating of stamping rolls 15

17 CARTRIDGE HEATERS SPLIT CARTRIDGES Suitable for higher operating temperatures as the heater expands and fits tightly into the mould/die eg. Die casting machines Better performance in long cavities or worn holes Standard sizes available (12.5; 16mm diameter) Easier to remove from mould / die Even heat distribution over the length of the cartridge INSTALLATION OF CARTRIDGE ELEMENTS ² For good heat transfer between the cartridge and the mould a precise bore (ISO H7) is required. For high powered cartridges with a surface load in excess of 20 W/cm a press fit is necessary. Uneven bore surface or excessive tolerance of the bore results in hot spots, thus reducing the life span of the element. Excessive length of the cartridge protruding out of the tool will lead to overheating of the exposed length and eventual failure. The distance between cartridge and external tool surface should be at least equal to the diameter of the cartridge. The use of non-conductive anti-seize paste is recommended to allow easy removal of the cartridge once it needs to be replaced. POSITION OF HEATING CARTRIDGE INSIDE THE MOULD The distance in between the heating cartridges inside a mould should not fall below 1,5 x D. Distance to outer wall must be at least 1x D D D 1,5D D 1,5 D D 16

18 CARTRIDGE HEATER TERMINATION TYPES O/L = Overall length in mm / All cartridges made according to O/L TYPE A Nickel fibreglass flexible stranded leads. Crimped onto studs O/L O/L TYPE O Leads are fitted internally from within Cartridge offers maximum flexibility TYPE B Straight exit from within complete with shoulder Extra flexible galvanised conduit provides abrasion protection TYPE C Right angle from within - no protection Nickel fibreglass flexible stranded leads O/L L1 L2 TYPE Di (Block) Right angle extra flexible galvanised steel conduit provides abrasion protection TYPE Dii (Flush) Right angle extra flexible galvanised steel conduit provides abrasion protection O/L Ø Metric Ø Imperial Di L1 Di L2 Dii L1 DiiL2 L1 L2 6.5 ¼ (6.35) / 16 8 (7.94) / 8 (9.52) ½ (12.7) / 8 (15.88) ¾ (19.05) TYPE E Nickel fibreglass with ceramic beads Ideal for high temperature environment O/L TYPE F Straight exit from within - no shoulder Extra flexible galvanised steel conduit provides abrasion protection TYPE G Right angle from within - with protective sheath Extra flexible galvanised steel conduit provides abrasion protection TYPE N Exit both ends - either studs or nickel fibreglass TYPE EARTH RETURN 17

19 LONG WAVE CERAMIC INFRARED EMITTERS Emitter face is manufactured as either concave, flat or convex Radiant efficiency is 96% Maximum surface temperature is approx. 600 C Heat up / cool down time is approx.10 minutes Infra-red spectrum between 2.8 and 10.0 µmm, thus no visible light All wiring must use NFg cable and ceramic blocks (temperatures at back of emitter approx 400 C) Efficiency of heater is determined by its emissivity (absorption value) from % Emitters can be fitted with thermocouples (Type K preferable) V6 V3 V2 V1 STANDARD EMITTER SIZES Size Wattage Voltage V1 245 x 65mm 150W 230V V1 245 x 65mm 200W 230V V1 245 x 65mm 250W 230V V1 245 x 65mm 300W 230V V1 245 x 65mm 400W 230V V1 245 x 65mm 500W 230V V1 245 x 65mm 650W 230V V1 245 x 65mm 750W 230V V1 245 x 65mm 1000W 230V V2 123 x 65mm 125W 230V V2 123 x 65mm 150W 230V V2 123 x 65mm 200W 230V V2 123 x 65mm 250W 230V STANDARD EMITTER SIZES Size Wattage Voltage V2 123 x 65mm 325W 230V V2 123 x 65mm 500W 230V V3 125 x 125mm 200W 230V V3 125 x 125mm 250W 230V V3 125 x 125mm 300W 230V V3 125 x 125mm 400W 230V V3 125 x 125mm 500W 230V V3 125 x 125mm 600W 230V V3 125 x 125mm 650W 230V V6 123mm ø (screw in) 150W 230V V6 123mm ø (screw in) 250W 230V V6 123mm ø (screw in) 500W 230V 18

20 REFLECTOR ASSEMBLIES USING CERAMIC INFRARED EMITTERS Heating arrays are engineered to meet customer specifications Highly polished stainless reflector plates are fitted behind the ceramic emitters to allow for increased reflection to improve efficiencies Arrays are fitted into a stainless / mild steel frame, wired and connected to a control system Thermocouples can be fitted into ceramic emitter to measure temperature Cooling fans are mounted in outer backplate to extract hot air from emitter, thereby extending lifespan of assembly Arrays can be fitted with V1, V2 or V3 ceramic emitters (see additional info on Long Wave infrared emitters and standards sizes) for required wattages Emitters that are closely spaced in an array result in even heating Contact Swift s engineers for further assistance APPLICATION RECOMMENDED WATTAGE ELEMENTS Pre-heating plasitc foil / sheet / vacuum forming Manufacture of skin sheeting for packaging Stress curing ovens for synthetic fibres Gelling PVC paste / film on fabrics etc Heating paper-mâché for moulding / pressing Quick drying of rubber surfaced and glued paper Activation of adhesives and surface sealing Drying / curing plastic / latex emulsion / surfacing Setting nylon and perlon threads etc Heat / dry / fixing adhesives. boot and shoe trade Pre-heating rubber sheeting prior to extrusion Pre-heating of moulds for all industries Thermo / pressure forming Fibre-glass lay-up and moulding. Resin curing 19

21 TUBULAR INCOLOY ROD HEATERS Heater wire consists of a high temperature resistant 80 / 20 NiCr alloy Insulation is magnesium oxide (MgO) powder Incoloys are compacted thus at high sheath temperatures excellent electrical insulation and heat transfer is achieved Cold end pin (3a) is insulated against the sheath by means of a silicon tube (3b) Ingress of moisture is prevented by maintaining good electrical insulation between the connection ends which are sealed with a special sealing compound (3c) All heaters are annealed and ready to be formed into shape Standard Tolerances Resistance + 10% - 5% Length ± 1mm per metre Diameter 8mm ± 0.1mm Cold end pin (1) Element wire 3b 3c 3a (3) Outer sheath MgO powder UNHEATED LENGTH (mm) HEATED LENGTH (mm) ORDERING OPTIONS Diameters (6.3; 8.0; 11.2 and 16mm) Lengths (standard and non-standard) Wattages (standard and non-standard) Voltages (standard and non-standard) Termination types Cold ends (standard 90mm) other specify length in mm Mountings - flanged, boss or bush (see page 21) Shape / form (coiled, looped, straight, round, hairpin etc) Sheath material (incoloy, stainless steel, nickel plated or copper) 20

22 TUBULAR INCOLOY ROD HEATERS MOULD INCOLOY HEATERS Mould incoloy heaters are bent and shaped to fit snuggly into milled slots in backing plates for hot runners Various wattages, lengths, cold ends and terminations can be supplied according to customer specifications Contact Swift for more assistance Advisable to send mould in to Swift to ensure precise fitting 8mm minimum Bending diameter on centre line Inactive length i.e. cold end 8mm minimum Inactive length i.e. cold end Radius on centre line Cold end pin 25mm 17mm bending centres (must be bent in factory) MOUNTING BRASS BUSHES M12 x 16 - crimp-on or braze M12 x 25 - braze only M16 x 16 - crimp-on or braze M20 x 16 - crimp-on or braze CRIMP BUSHES M12 x 25 mild steel including 2 nuts and washer BOSSES 1¼ BSP brass hex to fit 32mm hole 1½ BSP brass hex to fit 42mm hole 2 BSP brass hex to fit 60mm hole 2 BSP stainless steel 316 round to fit 60mm hole 2½ BSP brass hex to fit 76mm hole BOSSES WITH TERMINAL COVER 2 BSP brass hex with terminal cover 2 BSP brass hex with pratley gland box

23 INCOLOY TERMINATIONS Pin only M5 posts. 650 C Max Supplied with M4 screw. 250 C Max Quick connect spade. 200 C Max 6mm Diameter brass kettle pin. 250 C Max 2 x 6mm Diameter brass pins complete with shroud and insulator. 250 C Max M4 Straight tab supplied with screw saddle. 350 C Max M4 Angle tab supplied with screw and saddle. 350 C Max Neoprene moulded end supplied with 10 amp neoprene covered tails length as required. Moisture proof 60 C Max Ceramic beaded tails over stranded NFg wire length as required. 400 C Max. Note : Limited bending radius Stranded leads Nickel stranded/fibre glass. 350 C Max Copper stranded / silicon. 200 C Max 22

24 MELT PRESSURE / TEMPERATURE TRANSDUCERS Gneuss melt pressure transducers operate on the proven principle of strain gauge technology. The pressure is transferred from the measuring membrane (sitting flush with the melt channel) via a capillary system to a second membrane. The capillary system is filled either with mercury or with a mercury-free medium. The second diaphragm is fitted with a strain gauge using the linear change in resistance in relation to deflection whereby an electric output signal is provided. STANDARD FEATURES Special membrane technology guarantees long life Anti-adhesion coating avoids damage caused by frozen plastic melts (Hastelloy C) Heated tip transducers available on request Indestructable protective sleeve offers maximum capillary protection Removable amplifier head Standard output signals, including V and ma Combined melt pressure / temperature sensors (Type J, K or Pt100) Standard accuracies (0,25 or 0,50%) Process connections (½" 20 UNF, M16, M18) Complete range of accessories, viz. insert bushes, bush fitting and bore cleaning tools, blanking plugs, indicators (pressure and temperature) and connector plugs and cable

25 THERM-O-RUNNER This system is unique by offering customers bumpless auto / manual transfer to percentage control on thermocouple failure. Each standard 19 inch slide in card (71 x 127mm) houses two-digital/analogue 48x48mm DIN size temperature controllers. Thus a half rack can accommodate 6 controllers, whilst a full rack will house 12 individual temperature controllers The system continuously monitors all input/output parameters such as T/C fault, heater fault or SSR fault, thereby carrying out second to second self diagnostics on these variables A continual scanning circuit ensures that if a fault condition is encountered at any point, then the scanning circuit will stop and indicate exactly which fault has occurred. Only once the error/fault has been rectified will the unit continue scanning 3-6 zone (half 19 rack) The compact unit snugly houses 40A SSR s, heat sinks, cooling fan and ultra-rapid fuses All thermocouple input circuits are protected via a T.V.S. (transient voltage suppressor circuit) The auxiliary supply is protected by using a metal oxide varistor to avoid damage to the circuit board via transient voltage spikes 7-12 zone (full 19 rack) 1-2 zone DESCRIPTION HALF 19 INCH RACK HALF 19 INCH RACK FULL 19 INCH RACK Power supply 230 VAC -±10% ac 50Hz 230 VAC - ±10% ac 50Hz 400 VAC - ±10% ac 50Hz Power consumption < 2W ( half-rack) < 5W (half-rack) < 10W (full-rack) SSR 2 x 40A 6 x 40A 12 x 40A Fuses (ultra rapid) 2 x 16A 2 x 16A - manifold heaters 4 x 16A - manifold heaters 4 x 6.33A - tip heaters 8 x 6.33A - tip heaters Housing dimensions c/w 80mm (W) x 140mm (H) 226mm (W) x 140mm (H) 440mm (W) x 140mm (H) 4 rubber feet & handles x 402mm (D) x 402mm (D) x 402mm (D) Power supply cable 3 metres, 3 x 4mm² in PVC 3 metres, 3 x 4mm² in PVC 3 metres, 5 x 4mm² in PVC 24

26 THERM-O-RUNNER To further enhance the power of the Therm-O-Runner, all of the monitored variables can be viewed on any P.C. via the RS485 interface port available. Software to enable and monitor this is provided by Swift STANDARD FEATURES Standard 19 inch rack (71mm wide x 127mm long) slide in cards for all systems Slide in cards can house one or two standard DIN 48 x 48m temperature controllers Slide in card is microprocessor based, thereby enhancing functionality of system Latest S.M.D. technique used on P.C. board to maximize space savings for electronic components Percentage power control for thermocouple failure performed through software on microprocessor Expandability on cards is available on all systems Heater fault indication and detection Thermocouple reverse polarity indicators and detection Fuse fault indication and detection SSR fault indication and detection Continual scanning via LED monitors all fault conditions Thermocouple fault condition will be indicated via flashing LED, which is directly proportional to the percentage power output signal being activated RS 485 communication link is provided for interface to P.C. or laptop Software is provided for continual data monitoring, thereby enabling exact times, fault conditions and dates when errors occurred to be viewed or printed The PID auto tuning control of heaters is a superior control algorithm compared to traditionally used on / off control types. This intelligent control allows for increased accuracy in temperature control. This is important when processing plastics with a narrow processing temperature band Technical specifications Operating temperature range: 0 to +50 C Impulse withstand: 2.5kV peak, 1/50 us, 0.5 J Response time (local): 1 second Response time (remote): <20 seconds (64 devices on bus) Serial interface: RS-485, baud 8 data bits Thermocouple protection circuit: ESD (electrostatic discharge) Cable length of heaters and thermocouples: 2 metres

27 TEMPERATURE CONTROLLERS VT30 programmable P.I.D. controllers VT26 fuzzy logic P.I.D. programmable controllers VD low cost programmable controllers Standard facia sizes: 48 x 48mm, 48 x 96mm (vertical), 96 x 48mm (horizontal), 72 x 72mm, and 96 x 96mm VERTEX VT 30 RANGE - dual display STANDARD FEATURES Selectable inputs (Thermocouple, RTD, or Linear signals) P.I.D. control Ramp / Soak profiles (8 segments) 2 alarm outputs (selectable) Universal supply VAC (50/60 Hz) Auto / manual bumpless transfer Output: Relay, SSR or continuous ( ma, mv, V, V) VERTEX VT 26 RANGE - dual display STANDARD FEATURES Selectable inputs (Thermocouple, RTD, or Linear signals) Fuzzy logic P.I.D. control Soft - start Auto / manual bumpless transfer Ramp / Soak functions 2 alarm outputs (selectable) Standby and latch can be combined with 8 different alarm functions Universal supply VAC (50/60 Hz) Output: Relay, SSR or continuous ( ma, mv, V, V) ORDERING OPTIONS Output 2 for cooling PV or SV retransmission ma remote set point input RS 485 communication Master / slave transmission Power supply: 24V ORDERING OPTIONS Output 2 for cooling PV or SV transmission ma remote set point output RS 485 communication link Master / slave transmission Power supply: 24V 26

28 TEMPERATURE CONTROLLERS VERTEX VD RANGE - single display STANDARD FEATURES Selectable inputs (thermocouple, RTD, or linear signals) P. D. or on / off control 3 alarm outputs (selectable) Universal supply VAC (50/60 Hz) Output: Relay, SSR or continuous ( ma, mv, V, V) ORDERING OPTIONS Retransmission R485 communication link 2nd and 3rd alarm optional STANDARD FEATURES Display: dial, deviation, digital Non-programmable Type J, K, Pt100 Facia sizes: 48 x 48mm, 72 x 72mm, 96 x 48mm, 96 x 96mm Control action: most common on / off, P or P.D. Temperature ranges: C, C, C, C, C Outputs: Relay, SSR 1 x relay (high / low) ANC TEMPERATURE CONTROLLERS PERCENTAGE CONTROLLERS TECHNICAL SPECIFICATIONS Supply: 230 VAC Output: 5 Vdc, pulsing voltage output, adjustable via a multi-turn potentiometer Mounting: 11 pin base or 96 x 96mm panel mounting Power consumption: 3 VA Indication: Power and heater on via LED

29 FACIA / CUT-OUT SIZES VERTEX RANGE VT 30 / 26 SERIES; VD SERIES 45mm 98mm 45mm 92mm 45mm 78mm 69mm 78mm 69mm 92mm 78mm 92mm 78mm 92mm 45mm ANC RANGE ND / 657 series 45mm 81mm 45mm 114mm 45mm 92mm 272 / 671 series 45mm 98mm 45mm 202 / 301 / 302 / 601 / 605 / 607 series 92mm 104mm 371 / 675 / 677 series 69mm 98mm 92mm 45 69mm 28

30 TEMPERATURE SENSORS THERMOCOUPLE A thermocouple is a temperature sensing device constructed of two dissimilar wires fused at one end to form a junction Construction is either mineral insulated cable where the thermocouple conductors are embedded in a closely compacted (MgO) powder which is surrounded by a metal sheath forming a hermetically sealed assembly, or a tube and wire assembly known as a general purpose thermocouple (GPT) As the sensor is heated / cooled an emf in the form of millivolts is generated which provides an indication of the temperature Available in simplex, duplex and triplex All thermocouples come standard with ungrounded junctions Grounded junctions available on request RESISTANCE TEMPERATURE SENSORS (RTD) The electrical resistance of a conductor varies according to its temperature and this forms the basic principal of resistance thermometry A PT-100 is a precision platinum resistor that exhibits 100Ω at 0 C RTD s have a positive temperature co-efficient. As the temperature rises, the resistance increases positively Available in simplex and duplex only ORDERING OPTIONS Thermocouple type (J, K, T, E) Resistance thermometer types (Pt100) Number of junctions (simplex, duplex, triplex) Diameter of sheath Length of sheath Material of sheath (316, 310 (K only)) Mounting type (spring and cap, plate, block, pipe clamp etc, see page 30) Connection type (plug, cable, lead, potseal etc, see page 30) Construction type (mineral insulated MI or wire and tube) Conductor wire size (0.22mm², 0.5mm², 1mm²) Temperature rating Cable type (PVC, teflon, silicone or Fg stainless steel) Pocket material (310, 316, 446, other)

31 THERMOCOUPLE ASSEMBLY TYPES ADJUSTABLE SPRING AND BAYONET LIMITED ADJUSTMENT BAYONET STRAIGHT LIMITED ADJUSTMENT BAYONET ANGLED LIMITED ADJUSTMENT BAYONET STRAIGHT WITH POTSEAL LIMITED ADJUSTMENT BAYONET ANGLED WITH POTSEAL M.I. CABLE WITH POTSEAL BRASS SHIM TYPE PLATE TYPE SWIVEL STUD STRAIGHT SWIVEL STUD ANGLED PIPE CLAMP BLOCK TYPE WITH PIN BLOCK TYPE WITHOUT PIN MELT TEMPERATURE PROBE LUG TYPE SWIVEL STUD ANGLED WITH ARBURG HEAD ADJUSTABLE COMPRESSION FITTING AND TERMINATION HEAD TUBE AND TERMINATION HEAD NO FITTING 30

32 TEMPERATURE SENSORS C C Temperature Range of Sensors PT 100 Type T Type K Type J Pt 100 thin film 200 C Pt 100 ceramic bulb 650 C Accuracy of thermocouples Type K Type J Type T Temperature C C Accuracy of PT100 sensors Pt100 Class B Temperature C Pt100 Class A Pt100 1/10 Class B

33 DIGITAL HANDHELD THERMOMETERS STANDARD FEATURES Type K thermocouple input Switchable resolution 0.1 / 1 With C and F switching Max / min function Data hold function Room temperature compensated Flip-up stand Backlight LCD display Standard type K probes include a 1 metre flexible cable with miniature plug to match the thermometers Probes can be manufactured to customer specifications STANDARD RANGE OF PROBES 3,2mm ø x 200 / 500mm 6mm ø x 500mm 3,2mm ø x 300 / 500mm HANDHELD TYPE K STRAIGHT ROUNDED PROBE HANDHELD TYPE K ANGLED ROUNDED PROBE HANDHELD TYPE K SPIKE PROBE 6mm ø x 300 / 500mm 6mm ø x 300 / 500mm 4,76mm ø x 300mm HANDHELD TYPE K SURFACE PROBE WITH SPRING STEEL MEMBRANE HANDHELD TYPE K ANGLED SURFACE PROBE WITH SPRING STEEL MEMBRANE HANDHELD TYPE K EXPOSED AIR PROBE 32

34 HEATING ELEMENT ACCESSORIES 1. Heatsinks 2. Solid state relays 1. Single Din rail mount Current rating 40A Size: 80 (L) x 50 (W) x 70 (H) 5 way Din rail mount Size: 250 (L) x 67 (W) x 67 (H) Heatsink paste (10g) 3. Multi-pin connectors (c/w glands) 2. AA Series Input / output VAC Current ratings 10, 25, 40A VAC input only DA Series Input VAC Output Vdc Current ratings 10, 25, 40A VAC input only VA Series (Potentiomenter) Input / output VAC Current ratings 25, 40 A 4. Ceramic connector blocks 5. Ultra rapid ceramic fuses and fuse holders 3 4, 6, 10, 16, 24 pin, 16A (male / female inserts) Top and side entry hoods Panel mount bases Single / double latch available 6. Anti - seize paste 4. 5A - 2 way 15A - 2 way 30A - 2 way 15A - 3 way 400 C 400 VAC Other sizes available on request 7. Bakelite plugs / sockets 5. 6,33A fuses size 6 x 31mm 10A, 25A fuses size 14 x 51 40A fuses size 14 x 51 Fuse holder for above, 8. CEE silicone kettle plugs / sockets 6. Paste 450g tub, rated 1600 C Spray 400ml can, rated 1600 C 7. Flat 3 pin kettle plug Panel mount Male shroud socket 16A / 250 VAC / 200 C 9. Ceramic kettle plugs 8. Silicone straight 444 / SI Panel mount Male shroud socket 444 / I 16A / 250 VAC / 200 C 9. Ceramic straight 344K / A / PG Ceramic angled 344K / AWI / PG Ceramic insert spares 16A / 250 VAC / 300 C 10. Silicone straight 344P / S2 Silicone angled 344P / SI / WI 16A / 250 VAC / 200 C 10. Silicone kettle plugs

35 TEMPERATURE SENSOR ACCESSORIES 1. Standard thermocouple compensating male plugs 2. Standard thermocouple compensating female jacks Available as type J, K, T, R, S In-line Available as type J, K, T, R, S In-line Panel mount (with ears) 3. Mini thermocouple compensating male plugs 4. Mini thermocouple compensating female jacks 3 Available as type J, K, T In-line 4. Available as type J, K, T In-line Panel mount (with ears) 5. RTD (Pt 100) plugs / jacks 6. Standard and mini panel mount thermocouple compensating jacks 5. Mini - 3 pin flat Standard - 3 pin round In-line 6. Available as type J, K, T Standard - round Mini - round 7. Nickel plated caps 8. Compression fittings 7. Sizes M11, M12, M13 for 6mm spring Sizes M12, M13 for 8mm Other sizes available on request 8. Available in brass / stainless steel Standard sizes ¼", ½" NPT for 4,76 and 6.0mm tube Other sizes available on request 9. Mini and standard clamps 10. Barrel adapters 9. Cable clamps for use with thermocouple compensating plugs / jacks 10 ¼", 3 8 " Barrel adapter for 12,13, 15mm double slot cap 1 8" Barrel adapter for 11mm single slot cap Other sizes available on request 34

36 CABLES AND ACCESSORIES 1. Multi-core PVC insulated copper cable 1. Temperature rating (90 C) Sizes: 1.5 mm² 15A 2.5 mm² 30A 4.0 mm² 40A 2. Multi-core silicone rubber insulated copper cable 3. Multi-core NFg stainless steel braided cable (copper nickel plated core) 5. Thermocouple, Fg insulated compensating cable 7. Thermocouple, RTD stainless steel Fg insulated compensating cable 9. Thermocouple, RTD P.V.C. insulated compensating cable 11. Electro galvanised sprague tubing 2. Temperature rating (200 C) Sizes: 1.5 mm² 15A 2.5 mm² 30A 4.0 mm² 40A 3. Temperature rating (350 C) Sizes: 0.75 mm² 8A 1.5 mm² 10A 2.5 mm² 15A 4. Temperature rating (350 C) Sizes: 0.2 mm² 2A 0.5 mm² 3A 0.75 mm² 5A 1.0 mm² 10A 1.5 mm² 15A 2.5 mm² 20A 4.0 mm² 25A 6.0 mm² 30A 5. Temperature rating (350 C) Available in type J, K, T, R, S Sizes: 2 x 0.22 mm² 2 x 0.50 mm² 6. Temperature rating (200 C) Available in type J, K, T, RTD, R, S Sizes: 3 x 0.50 mm² 2 x 0.50 mm² 4 x 0.50 mm² (K only) 6 x 0.50 mm² (K only) 7. Temperature rating (350 C) Available in type J, K, T, RTD, R, S 2 x 0.22 mm² 2 x 1.00 mm² 2 x 0.50 mm² 3 x 0.50mm² 3 x 0.22 mm² 8. Temperature rating (200 C) Available in type J, K, T, RTD, R, S Sizes: 2 x 0.50 mm² 2 x 0.22 mm² 3 x 0.50 mm² 4 x 0.50 mm² 9. Temperature rating (90 C) Available in type J, K, T, RTD, R, S Sizes: 3 x 0.22 mm² 2 x 0.22 mm² 2 x 0.50 mm² 10. Temperature rating (250 C) Sizes: 2, 5, 8, 10, 16, 20 mm diameter 11. Flexible galvanised sprague Sizes: ID 4.76, 7.00, 9.5 and 13 mm 12. Galvanised steel braid Sizes: ID 9.0 mm 4. Single-core high temperature NFg cable (pure nickel core) 6. Thermocouple, RTD silicone insulated compensating cable 8. Thermocouple, RTD teflon insulated compensating cable 10. Fg sleeving 12. Stainless steel braiding 35

37 HEAT CALCULATIONS Calculate kilowatts required to heat the material Step 1 m x c x C P = 860 x heat up time (hours) Step 2 Calculate kilowatts required to overcome heat losses which are determined by the installation. viz. Indoors, outdoors, thermal insulation etc. In most cases use 20% of the sum of Step 1 m = mass (kg) c = specific heat (refer tables below) C = temperature rise ( C) Eg. A steel block weighs 150kg and needs to be heated up within 3 hours to a temperature of 200 C. Calculate the total kw requirement. Step 1 P = 150 x 0.12 x x 3 Step 2 = 1.26 x 20% Total kilowatts = kw To calculate watts density of a 1510W cartridge element with a diameter of 20mm and length of 150mm Watts density (W/cm²) = W/cm² = watts (W) heated surface area (cm²) Wattage π x D x L 1510 W/cm² = x 20 x 150 W/cm² = 16 = 1.26 kw THERMAL PROPERTIES OF GASES & VAPOURS Substance Specific Heat Air Alcohol Argon Carbon Dioxide Carbon Monoxide Chlorine Helium Hydrogen Nitrogen Oxygen Sulphur Dioxide THERMAL PROPERTIES OF SOLIDS Substance Specific Heat Brass Carbon Copper Glass Iron, cast Iron, wrought Lead, solid Lead, melted Nickel Rubber Solder (50% lead - 50% tin) Steel Tin, solid Tin, melted Zinc THERMAL PROPERTIES OF LIQUIDS Substance Specific heat Acetic Acid Alcohol Benzine Glycerine Oil, cotton seed Oil, olive Paraffin, melted Petroleum Water

38 BRITISH STANDARD PIPE THREADS IN INCHES Size Overall Core Pitch Depth Radius Effec. T.P.I. O.D.P. Diameter ¼ ½ ¾ ¼ ½ ¾ I.S.O. METRIC COARSE THREADS IN MILLIMETRES Overall Diameter Core Pitch Depth Flat Effec. Tapping Drill Clearance Drill

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