BAND HEATERS

component parts

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BAND HEATERS
component parts

OVERVIEW APPLICATIONS
WATTCO™ band heaters are the ideal solution for high watt densities »» Injection molding
and high operating temperature applications, especially for the plastics »» Blow-molding
industry. The various types of band heaters available at WATTCO™ include »» Plastic extrusion
mica insulated band heaters and ceramic band heaters. »» Container, pipe, or tank heating
»» Pharmaceutical applications
»» Applications in the food industry
KEY FEATURES
»» Top quality mica of various thicknesses
»» Maximum sheath temperature: 900°F
SELECTING WATTCO™ MICA BAND HEATER
The following sections will help you select the WATTCO™ mica band
»» External metallic sheath includes a special alloy
heater that meets the requirements of your application. Please call us at
»» Broad range of construction designs, clamping mechanisms, and 1-800-4WATTCO (1-800-492-8826) if you need further assistance.
electrical terminal types

BENEFITS
»» Energy efficient
»» Economical
»» Reliable
»» Versatile
»» Top quality mica and resistance wire
»» Uniform heat distribution

UNDERSTANDING WATT DENSITY

The following information will help you understand watt density in order
to select the proper wattage for your application.
»» Wattage will affect the durability and performance of your heater.
To prevent heater failure, do not exceed the maximum recom-
mended watt density for a specific heater size.

CLAMPING MECHANISMS Watt density (W/in ) =

WATTAGE
Select among the following clamping mechanisms, based on the
requirements of your application. (3.14 x Inner Diameter x Width) – (Cold Section)

Each clamping mechanism has its own features and benefits that will
improve the service life of your mica band heater and directly affects the MODEL COLD SECTION
quality of the heat transfer.
ONE-PIECE 1" x WIDTH
See page 3 for details.
TWO-PIECE 2" x WIDTH

HOLES AND CUTOUTS (SIZE + 1/2") x WIDTH

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 BAND HEATERS
component parts

CLAMPING MECHANISM FEATURES

Straps are tightly clamped around the cylinder’s surface and distribute the drawing force uni-
INDEPENDENT
formly around the band heater. This force is transferred to the inside windings and improves heat
STRAP
transfer by providing effective surface contact and eliminating air gaps.

Same features as the independent strap.

BUILT-IN
The top sheet is made into a strap by placing barrel nut fasteners on either side of the gap.
BARREL NUTS
Barrel nuts are used for holes and cutouts, as an alternative to independent straps.

Design is similar to that of the built-in barrel nut.

Made of an independent strap fastener that is spot
SPOT-WELDED
welded to the top sheet on each side of the gap.
STRAPS
This type of clamping mechanism is used to accommodate
a heated section below the fastener.

FLANGE The most economical clamping mechanism.

LOCK-UP Designed for narrow heaters.

Basic design for limited space above the heater.

WEDGE LOCK Composed of clamp slides (wedge shape) on the lips of the heater on either side of the gap.
Standard height between the inner diameter and the highest point of the wedge lock is 5/16”

Suitable for quick detachment.

LATCH AND
The clamp releases with a flip of thumb.
TRUNION
In the fastened position, the spring-loaded ¼-20 bolt absorbs the thermal expansion.

Designed for a two-section heater band.

A piano hinge is required on one side of the heater. Any other type of clamp
HINGES
can be used on the other side.
Clearance between the 2 sections of the hinge’s side is 5/16”.

Made of independent straps, built-in barrel nuts, and spot-welded straps

SPRING-LOADED with longer screws with die springs.
BARREL NUTS Springs tightly affix the band heater for thermal expansion.
¼-20 screws included.

Designed for two-section partial heaters.

If a complete band heater cannot be used due to an obstruction, a large gap must be
CLAMPING PADS created in order to fasten the heater to the cylinder on either side of the gap.
Do not use clamping pads on both sides of the same section of the heater.
Thermal expansion may cause the heater to detach from the cylinder.

NEED ASSISTANCE? Please call us at 1-800-4WATTCO (1-800-492-8826) if you need further assistance.

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BAND HEATERS
component parts

ELECTRICAL TERMINATIONS PROTECTIVE TERMINAL BOX

Select among the following electrical terminations based on the Select among the following electrical terminations based on the
requirements of your application. Each termination has its own features, requirements of your application. Each termination has its own features,
benefits, and limitations. Please consider the following factors when benefits, and limitations. Please consider the following factors when
selecting your termination type: selecting your termination type:
»» Diameter
»» Width
»» Voltage
»» Amperage
»» Operating temperature
»» Electrical safety
»» Cost
Terminal box

TERMINATION CATEGORIES W

Screw terminals
»» Features: H
o Stainless steel screw terminals
o Convenient
o Economical L
o Recommended for high amperages of a maximum of 30 amps
o Maximum temperature: 840°F
W W L H
»» Styles: G1 1 5/8" 2" 1 5/8"

G2 2" 2 1/4" 1 3/4"

TERMINATION CATEGORIES CON'D

Lead wire terminals
»» Features:
o Internally connected high temperature wire.
o Safer electrical connection.
o Maximum amperage: 20 amps.
Ceramic protective cover
»» Styles:

Lead wire terminals

»» Protects against abrasion for non-flexible elements.
Note: »» Straight lead exit / 90° bend.
»» Brass fittings for secured termination.
»» Ceramic terminal covers are an economical solution to prevent
electrical shocks and shorts.
»» Standard screw size: No. 10-32.
»» No. 8-32 screws are provided for specific applications.

Amor Cable

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 BAND HEATERS
component parts

STAINLESS STEEL BRAID PLAIN LEAD WIRE

»» For applications with regular movements or with a risk of abrasion. »» For applications without risk of abrasion or contamination.
»» Includes heat shrink sleeving at leads’ end to protect the braid form »» Standard temperature wire with fiberglass insulation: 840°F.
fraying. »» Teflon insulated wire available.

Used mostly with nozzle heaters Exiting on both sides of the gap

Straight lead exit Straight lead exit

Low profile terminal cover Used mostly with nozzle heaters

180° from gap 180° from gap

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BAND HEATERS
component parts

CONSTRUCTION MODELS HOW TO INSTALL

When selecting the construction model of a WATTCO™ mica band heater, »» Clean the cylinder properly.
please consider the following factors: »» Firmly tighten the heater on the cylinder.
»» Maximum performance »» Gently tap the rims with a plastic mallet.
»» Ease of installation »» Tighten the heater again.
»» Compensate for thermal expansion by using large diameter heaters
The most popular construction models are: with spring-loaded fasteners.
»» Slightly open the one-piece model heater and
One piece slide it to the cylinder.
»» For a heater installed on a barrel without extensive expansion »» Use a two-piece or a flexible model when completely
»» Diameter: 5/8” to 22” opening the heater.
»» Width: 5/8” to 14”

Two or more pieces

»» Easy to install
»» Convenient for large barrels
»» Diameter: 2” to 44”
»» Width: 5/8“ to 14”

FACTORS TO CONSIDER WHEN

SELECTING WATT DENSITY
»» Select narrower heaters for superior heat transfer (1” – 2.5” wide).
»» Select watt density according to the operating temperature.
»» Select the corresponding wattage for your application in order to
prevent short cycling and inefficient operation.
»» Consider the safe heating pattern of the heated material, the
thermal conductivity, and coefficient of expansion of the cylinder
when determining puissance.

NEED ASSISTANCE?
Please call us at 1-800-4WATTCO (1-800-492-8826) if you need further
assistance.

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 CERAMIC BAND HEATERS
component parts

OVERVIEW ELECTRICAL TERMINATIONS

Durable, WATTCO™ ceramic heaters provide excellent energy efficiency Select among the following electrical terminations based on the
with their built-in ceramic fiber jackets. Unlike mica band heaters, ceramic requirements of your application. Each termination has its own features,
heaters transfer heat through conduction and radiation and do not benefits, and limitations.
require tightening around the cylinder. Flexible, these heaters come in a
A - Post terminals
wide variety of terminal styles, and with different clamping mechanisms,
holes and cutouts. »» The most popular termination style
»» For high amperage applications

KEY FEATURES
»» Nickel-chrome wire in a outer wall composed of interlocking
B - Terminal box
ceramic tiles.
»» Inside medium-high temperature heaters up to 1200°F »» Protects screw terminals against
»» Outside shell temperature: 350° - 450°F damage and exposure
»» Built-in ceramic fibre insulating mat.
»» Stainless steel jacket.
»» Minimum diameter: 2”
C - Stainless steel braided leads
»» Minimum width: 1”
»» Thickness with ¼” insulation: 5/8” »» Flexible
»» Regular gap: 3/8” »» Protects lead wires from abrasion
»» Maximum watt density: 45 w/in
»» Broad range of terminal types and thicknesses of ceramic fiber
insulation mats.
D - Armor cable
»» Protects against abrasion and
BENEFITS contamination
»» Energy efficient
»» Energy saver
»» Highly flexible
E - European connector
»» Durable
»» Maintains heat »» For easy removal of power leads
»» Provides uniform heat distribution »» Convenient electrical connections to
»» CSA and CE certified replace a failed heater.

APPLICATIONS
F - European connector
»» Injection molding
»» Blow-molding »» For limited clearance above the heater
»» Plastic extrusion
»» Container, pipe, or tank heating
»» Process applications

SELECTION GUIDELINES
SELECTING WATTCO™ CERAMIC BAND HEATER
»» Current amperage limitation for direct lead wire exit: 10 amps.
The following sections will help you select the WATTCO™ ceramic band »» For applications with higher amperage: couple lead wires and the
heater that meets the requirements of your application. Please call us at terminal box.
1-800-4WATTCO (1-800-492-8826) if you need further assistance. »» European plugs are suitable for 16 amps applications.
»» For an internal winding balance, install terminals at 180° according
to the gap.

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