Domestic Heating Comfort Air - Supporting sustainable energy systems
>> The Backer Group The Backer Group produces and sells components and systems for electric heating. The base technology is originally steel tubular elements, produced at the head office plant in Sösdala, Sweden since the start of the company in 1949. The continuous growth of the company, both organically and by numerous acquisitions, has contributed to the expansion of the product range and the integration of new technologies. Today, the product range also comprises elements based on other materials and technologies such as aluminium, cast iron, ceramics, flexible materials, PTC, as well as various equipments for temperature control. The Backer Group now includes some 30 production units and over 3000 employees, that all contribute to the extensive and wide technical know-how of today. Backer supplies companies in industries like the automotive industry, the domestic heating industry, the white goods industry, the train and wind mill industry, as well as several other industries, demanding different solutions for their specific applications. Tubular elements Printed elements PTC Elements Wire elements Heating cables IR-& Halogen elements Temperature control Domestic Heating White Goods, Household appliances Transport, Automotive Medical, science Process, Projects From idea to validated serial production Development work is carried out in several of the Backer companies around the world. A development and validation centre has been established at our head office in Sweden where crucial knowledge and experience from our different technology bases and previous product developments at our different sites are gathered. Partnering up with Backer means that you get more than 60 years of core experience from a wide range of technologies and product applications. Backer offers you guidance in all the steps of the product design from the original idea, through product development and validation of the product, to the final serial production. Designing for the future A dedicated team of designers, project engineers and technical experts work in close collaboration with our product area managers and customers designers in the development of new products and future solutions. With our large customer base and wide spread organization, Backer stays keenly aware of the market tendencies and future demand for energy and heating systems. Element production combining high volume and high flexibility Advanced spinning machines make the unique inner core of the electric heating element. Elements with a proven lifetime of 20+ years. The variety of products that Backer supplies to different industries puts high demand on the element production process and the logistic set-up. By the selection of production unit and production process for each product Backer has the possibility to optimize the process for each customer and product specification, depending on the demands on parameters like technology, flexibility, volume, proximity and cost. Each of our production units offers different advantages and the solution can therefore be tailored to meet vertically any demand of electric heating elements. Other available solutions to further improve the flexibility of element supply are logistic centre, safety stock, complete EDI solutions or alternative electronic material handling. 2 www.backer.se Elements gently filled with Magnesium oxide, evenly distributed at precise quantities in filling machines for tube lengths up to 8 meters and in diameters from 5 to 35 millimeters.
Electric Heating Applications >> The choice of heat source for domestic heating will depend on several factors. Independently, Backer produces heating elements for numerous electric heating applications as well as for equipment using electric heating elements as complementary heat source or for functions where electric heating is needed. Elements for domestic heating applications such as electric radiators, convectors and towel dryers, have been produced since the very start of Backer and are still one of the largest product areas in the Backer group. During the last few years, the demand of new heating elements has been intensified and Backer is continuousely testing complementary technologies in the development of elements for electric heating applications. Accumulating radiators p. 4 Radiators p. 4, 5, 6, 7, 8, 9 Convectors p. 4, 5, 6 Heating fans p. 5 Mirror Heater p. 9 Towel Rails p. 6, 7, 9 Floor Heating p. 9 Thinking Green The importance of sustainable energy solutions is well recognized today and Backer brings Ecofriendly thinking to all products and into all the steps of the product development process. In applications for electric domestic heating, the reduction of element power, control of element heating temperatures and actual element heating time, contribute to limiting the energy consumption and thus some of the effects on our environment. Elements can also be designed to combine or integrate alternative heat sources like water based systems with heat pumps, solar heating, pellet burners etc. www.backer.se 3
>> Tubular Elements Straight tubular elements Bent tubular elements Spiral elements Heating elements Ø: 6.4, 8.5, 10, 12, 14, 16, 18 mm Accessories: nipples, fixing plates, M4, wiring etc. Heating elements Ø: 6.4, 8.5, 14, 16, 18 mm Accessories: nipples, fixing plates, M4, wiring etc. Heating elements Ø: 6.4, 8.5 mm Accessories: nipples, fixing plates, M4, wiring etc. Tube materials Mild steel - Grade D; Stainless steel - EN 1.4301 EN 1.4404 UNS S31254 UNS N08904 Incoloy 800 Incoloy 825 Ferritic stainless steel materials - 1.4510 1.4512 1.4521; Copper - C12200 Accessories Nipples, fixing plates, M4, wiring, flat pins. Backer The Original The first patent of the tubular element with magnesium oxide was taken by Christian Backer already back in 1926. Using the accumulated experience and know-how of element production, Backer still offers various tubular elements based on the same technology for a wide range of applications. Temp C Heating and cooling times tubular Ø 8.5mm 800 700 600 500 400 300 200 100 0 0 50 100 150 200 Time min. High temperatures increasing versatility Backer s extensive experience in the production of tubular elements has facilitated the development of new products with new materials especially when there s a need to stretch the performance of the production to reach improved product features. One advantage with the basic tubular element is the range of temperature levels that can be attained, from lower standard temperatures to high performance materials reaching more than 900 C. Backer offers a wide range of materials of which several for high temperature applications. High temperatures / low cost The various material properties that exist for tubular elements not only contribute to multiple choices of element temperatures but is also a very cost efficient way to create element heating from electric power. It can be used either as single source or in combination with other materials thus increasing the scope of heating performances of the basic element. >> Applications: Accumulating Radiators, Fan Heaters, Radiators, IR Elements 4 www.backer.se
Finned Tubular Elements >> Square finned elements Surface enlarged element Ø (brick dim): 8 (50x25), 8.5 (50x25), 10 (70x40), or 14 (80x40) mm Fin material: Alu zink or stainless steel Accessories: nipples, fixing plates Finned elements Surface enlarged element Ø (d/d): 6.4/18, 8/18 8/24, 8.5/22 8.5/28 10/20 10/26, 12/22 12/28, 14/34 16/32, 18/34 mm Fin material: SS1160, EN 1.4301 Accessories: nipples, fixing plates d d D D Example of brick dimensions Bifilar, avaliable in 8.5 and 14 mm Tube materials Mild Steel- Grade D, Stanless steel: EN 1.4301 EN 1.4404 EN 1.4541 Incoloy 800 EN 1.4828 Connections One or two end connection : M4, cables flat pin or acc. to customer spec. 700 Heating and cooling times finned elements 600 500 High temperature for high performance convection The heating element is a main contributor to the efficiency of heating appliances, also to the convector. Using the possibilities of high temperature materials in the tubular elements, the efficiency of the natural convection application can be increased in combination with round or square fins around the tube. Temp C 400 300 200 100 0 0 50 100 150 200 Time min. Reducing element temperature or size of element Adding fins to the tubular element, creating natural air convection, will help cooling off the element in operation. This will give the options of either bringing down the element temperature or allowing the use of a smaller element with higher surface load when this is required. >> Applications: Convectors, Radiators, IR Elements, Heat Curtains, Heating Fans www.backer.se 5
>> Aluminium Elements Finned X-profile Finned I-profile I-profile Ceiling heating profile Aluminium profile 61x71, 65x84 or 67x89 mm (widthxdepth) Length: 215-1570 mm W/length cm: 20-30 W Max temp: 350 C Aluminium profile Width: 80 or 100 mm Length: 215-1510 mm W/length cm: 12-15 W Max temp: 350 C Aluminium profile Width: 80 or 100 mm Length: 215-1510 mm W/length cm: 15 W Max temp: 350 C Aluminium profile Width: 180 mm Length: 350-1270 mm. W/length cm: 15-20 W Max temp: 285 C Materials Aluminium AA6060, AA6063 Accessories Flat pins, wiring, fixing devices Connections Wiring or tab terminals, 1.5, 2.5 pins Heating and cooling times alu elements (painted on one side) Towel dryer 350 300 Temp C 250 200 150 100 50 0 0 50 100 150 200 Time min. Anodized or painted profiles max 285 C Ready-to-install Improving convection and interior climate The aluminium element has the advantages of silent running and with its lower working temperature, not burning the dust in the air. This prevents any burned smell and blackened wall paper above the convector. Aluminium profile towel dryer, complete with fixing device and connection cable with hidden on-off switch. Optimizing radiation The excellent heat conductive properties of the aluminium material will assure a fast and reactive heating of the element. With different kinds of surface treatments and surface designs the element radiation surface can be increased to optimize element size. By using a painted or anodized surface, thus increasing the element emissivity, radiation will be optimized. >> Applications: Radiators, Ceiling heating, Convectors, Towel heaters 6 www.backer.se
Tubular elements for liquid radiator applications >> Insulation Class I Insulation Class II Insulation Class I 14 or 16 mm tubular element. Lengths 215-1510 mm Power range: 300-2000 W 14 or 16 mm tubular element insulation class II Lengths 215-1510 mm. Power range: 300-2000 W 6.4 mm tubular element in lengths 80-1900 mm Power range: 300-2000 W Materials EN 1.4551; Ø14 mm: EN 1.4541, Steel DIN 2394; Ø16 mm: EN 1.4301, Steel DIN 2394 Accessories Control units - digital or manual (see separate section in this broshure), built-in thermostat 70-150 C, meltfuse, builtin- thermistor (NTC), pocket tube for thermostat, PTC; Then max 230V Connection Different types of connections Wiring Flat terminal pin Fast connection 70 Heating and cooling times Insulation class II We can supply integrated thermostat and temperature control (NTC). Also availiable in a protective tube. Temp C 60 50 40 30 20 10 0 0 50 100 150 200 Time min. For better air quality One way to reduce element and air temperature variations has been to use liquid in the radiators and convectors and thus using the inertia as a balance. Also limiting the radiator / convector temperatures and hence, lowering the speed in which the room air is heated, the air humidity is better preserved. Low temperature radiation is generally less apparent. Applications defining the element design - designing for safety Several parameters need to be considered when designing heating elements to obtain the best function for each application. One of the most important for liquid radiators is probably safety. In addition to complying with regulations and norms, increased safety could be obtained by a more rigorous dimensioning of thermal cut-offs, thermostats, element insulation etc. >> Applications: Electric water heater, Solar heating, Radiators, Heat pumps, Towel heaters www.backer.se 7
>> Elements for dry radiator applications Soap stone Insert element with customized dimensions. Heating element in wire/mica with insulation class II Ceramic Insert element with customized dimensions. Heating element in wire, insulation class I Aluminium/Quarz sand Insert element with customized dimensions. Heating element from tubular element with insulation class II Cast-iron Mounted element with customized dimensions. Heating element from tubular element, insulation class I (without brackets). Steel Element Mounted element with customized dimensions. Heating element from tubular element, insulation class I (without brackets). Cast-aluminium Mounted element with customized dimensions. Heating element from tubular element, insulation class I (without brackets). Interchangeable insert elements or customized fixing Temp C 0 0 50 100 150 200 250 300 The best way of eliminating liquid leakage is to eliminate the liquid. Backer offers several options of heating elements to choose from, all of which can be mounted into a radiator body with either interior square standard openings or with bracket fixations. Using a class I element, adapted fixations might be needed to assure necessary insulation. The inserted heating element both transfers heat to the aluminium body, creating natural air convection, and acts as a radiation element at the same time. The various element types are designed to meet different demands of for ex. heat accumulation, reactivity, temperatures, insulation class, price, etc. 400 350 300 250 200 150 100 50 Heating and cooling times elements for dry radiator appl. Time min. Soapstone Ceramic Alu/quartz sand Cast iron Cast aluminium Steel plate Stabilizing temperature levels When searching to minimize the on-time of the radiator and thus reducing the energy consumption, the element properties have an important roll to play in combination with the radiator control equipment. Whether using element inertia or fine tuned control equipment to regulate the element temperatures and heat-up times, the choice of specific element materials is important to meet the specific requirements. >> Applications: Electric radiators 8 www.backer.se
Flexible heating elements >> FRTP Etched Foil Polyester, PVC, PEN, Silicone MICA Aluminium Foil Fibre reinforced thermoplastic Max width: 800 mm Power density: 0.1 W/cm² (up to 0.7 immersed) Voltage: Up to 690V AC/DC 1~or 3 ~ Max width: 600-800 mm Power density: Polyester: 3 W/cm² PVC: 0.1 W/cm² PEN: 4 W/cm² Silicone: 1.3 W/cm² Voltage: Up to 230V AC/DC 1~or 3 ~ Max width: 600 mm Power density: 15W/cm² Voltage: Up to 690V AC/DC 1~or 3 ~ Dimensions according to customer specification. Power: 50-250W Voltage: 110-240V >> Features Stiff, extremely durable Superior impact resistance Water resistant Possible to laminate to pictures or metal parts >> Features Uniform heat output Long life product Even heat transmission Water proof Very flexible >> Features Sandwiched between layers of mica Can be used assembled in open air, typically for radiators or heating panels >> Features Low weight Self adhesivie Suitable for ceiling heaters Heating Cables For more information about our heating cables see separate catalogues. Wide range of applications Flexible heating elements offer many advantages such as even heat distribution, fast heat-up, compact design, low weight and power density. This makes the field of application broad and diversified. The foil heater can be designed in almost any shape and the large choice of insulation materials makes it possible to use flexible heaters in almost any application. The even heat distribution also makes the foil heater energy efficient. Bathroom mirror heating Ready-to-install Steam free mirrors Complete installation kit with foil in different shapes and sizes and connection cables for 230V. Improving radiator performance Under floor heating Ready-to-install For wooden and laminate floors Complete installation kit for under floor heating, incl. cables, temperature control unit and heating foil for 230V. Heating element inertia improves the heat accumulation and provides a longer cooling time. On the other hand, it also means longer time is needed to heat up the element. Various foil heating elements mounted on or closed to the front panel can here offer a perfect combination, providing instant heat radiation evenly distributed on the front panel, until the main heat source has reached the set temperature. >> Applications: Radiators, Bathroom mirror heaters, Heating panels, Under floor heating, Towel dryers, Ceiling heaters www.backer.se 9
>> Temperature controls & safety Thermal fuse Elements in Ø 8.5, 14 or 16 mm can be equipped with a thermal fuse, which can be replaceble and easily pulled out from the element and replaced with a new unit. NTC Sensor An NTC sensor placed inside the heating element (Ø 14 or 16 mm) provides a quicker, more precise control of the temperature, that can be used to save energy and increase the radiator and towel dryer performances. Avaliable for 300-2000 W. Thermostats Backer supply different external thermostats as well as built-in thermostats. Examples of controls Temperature auto-regulation by PTC Controling element temperature The Backer heating elements can be designed to fit with various temperature control units. For towel-dryer appliances, Backer can provide complete sets of control unit with heating element with different functions. To simplify the towel-dryer function, Backer can also provide self-regulating PTC heating elements (no control unit needed). Comfort Energy consumption Safety Economy More than just safety It is of crucial importance to control the temperature of the elements in the heating device. The design of the Backer heating elements is always done to ensure that safety and valid regulations are met. In some elements, thermostats and thermal fuses (cut-offs) can be integrated. For others, PTC chips can be built into the element. When integration of element temperature control is not possible or convenient for the specific application, it can be placed outside of the element, connected to a thermostat tube or directly to the element. To save energy and money, high precision on the temperature control is an advantage. To quickly level the temperature of the element and to get a more precise temperature setting, Backer offers both class I and class II elements with NTC sensor. Customized design - maintained functionality Backer offers different temperature control boxes for towel dryers to control both the element and the bathroom air temperature. In addition to the standard control boxes, individually designed boxes can also be obtained to match the design of the towel dryer and the local market demand. The choice of the temperature control box can thus be done based on the need of both technical features, level of requested temperature control, type of heating element, norms and regulations, aesthetics, etc. 10 www.backer.se
Validating serial products >> Mastering the design The basis for an optimized heating appliance is a well designed heating element. Backer uses state of the art design computer programs in both the heating element design as well as in simulations and controls of material properties. (Pro/Engineer 3D-Cad, X-ray equipment, PTC Mechanica FEM-simulation, PDMlink etc.) Various test and validation methods will then give the necessary input to help verifying each of the key features of the heating element that provide the needed performance - adapted for consumer or industrial applications. Testing for high performance The premises of Backer Sweden include a well equipped laboratory used in the design, testing and validation of the Backer heating elements. Various control and cycling methods are used to test the estimated life time of the element and to make sure the applicable norms and regulations are met. To ensure realistic real life values when testing domestic heating appliances we use various eqipment such as: Simulation room for tests of the final heating application in home environment. FLIR infrared camera for thermal pictures of the heat distribution and temperature levels of the element. Climate chamber for verification of the element s sealing and insulation values. Noice testing room for stress tests to verify noiseless or soundless elements. Ensuring element quality As a way to monitor and secure the total product quality, various standards have been put in place in different industries. Supplying customers in industries like the automotive, white goods and the domestic heating industry, Backer has gained experience and knowledge from various quality systems. This knowledge is exploited and used both in our development, in the production and in our validation of the finished product to secure the product quality and assure customer satisfaction. In addition to certifications like ISO 9001 and 14001, Backer works with Total Quality Management and Lean Manufacturing as a way to continuously improve our processes and products. In this way, we give our customers an added value to the product offering that will contribute to the end users long term satisfaction. All Backer heating elements comply with the European regulations EN 60335-1 as well as WEEE, ROHS and REACH. www.backer.se 11
Backer Alpe, S. de R.L. de C.V Venado Street No. 45 Col. Los Olivos, Tlahuac C.P. 13210 Mexico Tel +52-55 584 505 05 www.backeralpe.com Backer BHV AB Fabriksgatan 11 SE-280 10 Sösdala, Sweden Tel +46-451 661 00 info@backer.se www.backer.eu Backer BHV AB/ Div. Calesco Västra Åvägen 11 SE-734 51 Kolbäck Sweden Tel +46-220 453 00 www.calescofoil.se Backer BHV/Calesco France Sarl 47 rue Maurice Flandin F-69003 Lyon France Tel +33-472 13 23 38 www.calescofoil.se Backer EHP, Inc. 4700 John Bragg Highway Murfreesboro, TN. 37127, US Tel +1-615 907 6900 www.backerehp.com Backer EHP, Inc. Arizona y Florida S/N Col. Parq. Industrial Rio Gran. C.P. 88186, Nuevo Laredo, Tamaulipas Mexico Backer ELC AG Wynentalstrasse 1 CH-5723 Teufenthal Switzerland Tel +41-628 376 280 www.backerelc.ch Backer Elektro CZ a. s. Policská 444 CZ-539 16 Hlinsko Czech Republic Tel +420-469 802 524 obchod@backer-elektro.cz www.backer-elektro.cz Backer Facsa S.L. Ctra De Ribes, km 50 ES-08591 Aiguafreda Spain Tel +34-938 44 26 00 backerfacsa@facsa.es www.backerfacsa.es Backer Fer s.r.l. Via Statale 255 no 293 IT-440 47 Sant Agostino Italy Tel +39-05 32 35 00 00 backerfer@backerfer.com www.backerfer.com Backer sales Office France 1, Bd de lóise, F-95030 Cergy Pontoise, Cedex France Tel +33-680 410 252 www.backer.eu Backer Heating Technologies Inc. 1390 Gateway Drive, Unit 2 Elgin, IL 60124, US Tel +1-847 931 13 04 www.backerhti.com Backer Heating Technologies (Shenzhen) Building No. 5 Hong Hua Ling Industrial Estate LongXi Village Long Gang District, Shenzen China Tel +86-755 289 303 69 Backer OBR Sp. z.o.o. u.l. Glowackiego 39 PL-74 200 Pyrzyce Poland Tel +48-91 481 99 00 info@backerobr.pl www.backerobr.pl Danotherm Electric A/S Næsbyvej 20 DK-2610 Rødovre Denmark Tel +45-36 73 22 22 danotherm@danotherm.dk www.danotherm.dk Danotherm Electric A/S An den Drei Hasen 4 DE-61440 Oberursel Germany Tel +49-6171 88 77 11 www.danotherm.dk Eltop Praha s.r.o Provoz Miretice 32 CZ-539 55 Miretice Czech Republic Tel +420-469 344 176 obchod@eltoppraha.cz www.eltoppraha.cz Heatrod Elements Ltd. Holloway Drive, Wardley Ind. Estate Worsley,Manchester M28 2DP, UK Tel +44-161 794 61 22 www.heatrod.com Lund & Sorensen Maserativej 4 DK-7100 Vejle Danmark Tel +45-75 85 78 22 info@ls-elvarme.dk www.ls-elvarme.dk Lund & Sorensen Electric Heating Accessory (Tianjin) Co., Ltd. Fuyuan Road bei Tianjin Hi-Tech Industrial Park Wuqing Develpment Area Wuqing, Tianjin 301700 China Norske Backer A/S Postboks 203 NO-2201 Kongsvinger Norway Tel +47-628 28 828 marked@norskebacker.no www.norskebacker.no Oy Meyer Vastus AB FI-07230 Monninkylä Finland Tel +358-19 574 02 00 info@meyervastus.fi www.meyervastus.fi REBA Div. Resistors Branch of Backer Fer s.r.l. Via Parca Alto Milanese 1 IT-21052 Busto Arsizio (Mi) Italy Tel +39-0331 35 13 95 backerfer@backerfer.com www.backerfer.com Structurgruppen AB Magasinsgatan 8C SE-434 37 Kungsbacka Sweden Tel: +46-300 566 400 www.structurgroup.se Copyright 2012 Backer BHV AB www.backer.se