Caloritech Elements and Specialty Heaters

Caloritech Elements and Specialty Heaters

Thermon Process Heating

Caloritech™ Catalog: Section A

Elements and Specialty Heaters

Calvane™ heaters, tubular heaters, bolt heaters, tubular band heaters, mitosis heaters, finned tubular heaters, cartridge heaters, strip and finned strip heaters, hot plate/drum heaters, casting heaters, transit heaters.

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Description

BC - Band Heater

The Caloritech™ BC Band Heater is an aluminized steel strip heater formed to a semicircle. A spring at the terminal end keeps the heater halves in contact with the barrel and compensates for thermal expansion. The other end is fastened by a captive chrome plated allen screw for ease of installation. These heaters are typically used to heat the barrels of plastic injection and extrusion machines, kettles, pipes and other cylinders.

Features & Benefits At A Glance

  • Designed for 240V operation; insulated for 600V
  • Two band heaters can be connected to accommodate a 480V supply
  • 1.5″ +/- 0.0156″ (38 mm +/- 0.39624 mm) wide; 0.375″ +/- 0.0156″ (9.5 mm +/- 0.39624 mm) thick
  • Standard diameters available from 5″ to 20″ (127 mm to 508 mm)
  • Outputs from 580 W to 3 kW
TBH - Tubular Band Heater (Calrod® type*, 51 mm Width)

The Caloritech™ Tubular Band Heater (Calrod® type*, 2″ Width (51 mm)) is designed for highly concentrated heating applications, such as clamping on to extruder barrels, nozzles, pipes or vessels. Multiple TBH heaters can be mounted side by side and wrapped with high temperature insulation to further improve efficiency. The unit consists of two heating elements held in place by a stainless steel band with a threaded swivel type clamping device.

Features & Benefits At A Glance

  • 2″ (51 mm) width tubular band heating elements
  • Available in a range of wattages, from 400 W to 1700 W (at 120V and 240V) and 300 W to 1275 W (at 208V); incoloy® elements suitable for up to 600V are used in the larger models
  • Lightweight and portable, with unit weights ranging from 1.6 lbs to 2.5 lbs (0.7 kg to 1.2 kg) depending on the size of the heater
  • 3.5″ to 10.75″ (88 mm to 272 mm) standard diameters available to fit a range of standard pipe sizes, from 3″ to 10″ (76 mm to 254 mm)
  • Terminal housings available
  • Custom wattages, diameters and widths are available on special order; check factory for availability
TBW - Tubular Band Heater (Calrod® type*, 127 mm Width)

The Caloritech™ Tubular Band Heater (Calrod® type*, 127 mm Width) is designed for highly concentrated heating applications, such as clamping on to extruder barrels, nozzles, pipes or vessels. Multiple TBW heaters can be mounted side by side and wrapped with high temperature insulation to further improve efficiency. The unit consists of two tension bolts and two double hairpin heating elements held in place by a stainless steel band with a threaded swivel type clamping device.

Features & Benefits At A Glance

  • 5″ (127 mm) width tubular band heating elements
  • Available in a range of wattages, from 1500 W to 4500 W
  • Available in a range of standard voltages, from 120V to 600V
  • Lightweight and portable, with unit weights ranging from 4 lbs to 8 lbs (2 kg to 4 kg) depending on the size of the heater
  • 6.625″ to 16″ (168 mm to 406 mm) standard diameters available to fit a range of standard pipe sizes, from 6″ to 16″ (152 mm to 406 mm)
  • Terminal housings available
  • Custom wattages, diameters and widths are available on special order; check factory for availability
IXS - Bolt Heater (Stud Heater)

The Caloritech™ IXS Bolt Heater (Stud Heater) is designed for insertion into large hollow studs. When energized, the heater is intended to expand the length of the stud to facilitate wrench tightening of the nut. These heaters are generally used in pairs or sets to achieve uniform bolt tension.

Typical applications include assembly and disassembly of turbines, engine heads, dies, cylinders and large flanged connections. It should be noted that although the heaters are of premium quality, the elevated element sheath temperatures experienced in these applications can result in relatively brief heater life. However, limiting heater “on” time during a heating cycle to the minimum required can prolong service life.

Features & Benefits At A Glance

  • Suitable for hole diameters ranging from 0.5″ to 1″ (12.7 mm to 25.4 mm)
  • Heater diameters range from 0.49″ to 0.984″ (12.4 mm to 25.0 mm)
  • Heated lengths range from 12″ to 60″ (305 mm to 1524 mm)
  • Standard voltages range from 120V to 600V, depending on heater size
  • Standard wattages range from 850 W to 8000 W, depending on heater size
  • Relatively lightweight units range in weight from 4 lbs to 9 lbs (2 kg to 4 kg), depending on heater size
  • Custom lengths, diameters and wattages are available on special order; check factory for availability
FV - Calvane™ Heater

The Caloritech™ FV Calvane™ Heater is a compact, lightweight and economical electrical heating source that features durable Calrod® type* construction for easy, efficient installation and long life. These heaters are used primarily in natural and forced convection heating applications, such as aircraft and transit car comfort heating. They are ideal for installations that require size and weight control, where heater sheath temperatures below
316°C (600°F) can be maintained.

Features & Benefits At A Glance

  • Available in three configurations to satisfy a range of installation requirements: plain fins for field modification to accommodate user installed hardware; with holes/slots in the fins; and mounted on back plates
  • Patented Calvane™ heating element with aluminum sheath and integrally extruded fins for an extended heat transfer surface
  • Nickel chromium resistance wire or ribbon and high grade magnesium oxide insulation combine to provide maximum life expectancy
  • Lengths available up to 120″ (3048 mm); two standard widths of 2.25″ (37 mm) and 3.25″ (83 mm) available
  • Extended heat transfer area of 5 sq. in/in on the 2.25″ (57 mm) width and 7 sq. in/in on the 3.25″ (83 mm) width
  • Standard unit voltage of 120V; standard units rated at 250 W/ft
  • Low watt density
  • Rapid start-up and cool down periods
  • No magnetic noise
  • Low pressure drop
  • Provides resistance to shock and vibration damage
  • Easily isolated for high voltage applications
C - Cartridge Heater

The Caloritech™ C Cartidge Heater represents the highest commercial grade of heater available on the market today. They feature high grade nickel chromium resistance wire uniformly wound on a premium quality MgO core and welded to termination points; the core is then carefully centered in a compacted and MgO-filled high temperature 321 stainless steel casing, and stranded leads with silicon-impregnated mica glass insulation are fixed to the termination points.

These heaters offer a convenient and efficient means of heating metal dies, platens, molds, heat sealing tools, hot plates and more. Most units can also be fitted with threaded bushings for liquid heating applications.

Features & Benefits At A Glance

  • Available to fit hole diameters ranging from 0.25″ to 1.30″ (6 mm to 32 mm)
  • Standard available lengths range from 1″ to 36″ (25 mm to 914 mm), depending on hole diameter and wattage selected; lengths up to 100″ (2540 mm) available on custom order
  • Standard available wattages range from 30W to 4.7kW, depending on hole diameter and heater length selected; special wattages available on custom order
  • Available in standard voltages of 120V or 240V; special voltages available on custom order
  • Special sheath/casing materials available on custom order
  • Moisture resistant welded end cap provides a gas tight seal; optional lead wire construction includes silicon potting, Teflon® seals and Teflon® leads
  • Standard 10″ (254 mm) fibreglass insulated nickel leads; special lead lengths or spliced extended leads available on custom order
  • Optional armoured cable or wire mesh sleeving for mechanical protection of lead wires
  • Optional thermocouple available
  • Optional ground wire available
MH - Mitosis Cartridge / Specialty Tubular Heater

The Caloritech™ MH Mitosis Cartridge/Specialty Tubular Heaters are custom designed to meet special process conditions and withstand much higher operating temperatures than conventional tubular heaters. Common applications include insertion into machined holes to heat dyes and platens, high temperature furnaces, simulated fuel elements for nuclear reactors, pressurizer heaters, dryout heaters in large generators and multizone heating.

Features & Benefits At A Glance

  • Available in three configurations: two, four or six terminals at one end with the opposite end hermetically sealed; two, four or six terminals at one end with the opposite end not hermetically sealed; three or four terminals at each end
  • Mitosis shape subject to variation depending on specific heater requirements that determine the number and size of individual “cells”
  • Achieves excellent service life at process temperatures up to 875°C (1600°F)
D - Drum Heater

The Caloritech™ D Drum Heater is a portable lightweight heat source designed for standard 5, 25 or 45 gallon drums but versatile enough for use on any similar sized vessel where quick adjustable heating is required. Please note that these heaters are not intended for use on pressure tight containers or in hazardous environments.

Features & Benefits At A Glance

  • constructed from rust-resistant aluminized steel
  • available in standard voltages of 120V or 240V
  • standard wattages range from 1500W to 3000W
  • low maintenance
  • easy installation
  • built-in thermostat
  • heavy-duty cord and plug
  • CSA certified
HPH - Hot Plate Heater (Industrial Heavy-Duty)

The Caloritech™ HPH Industrial Heavy-Duty Hot Plate Heater is designed for heavy-duty use in industrial environments. The unit consists of a robust Caloritech™ heating element pressed into a groove on the underside of an aluminum heating plate to provide efficient heat transfer and uniform surface termperatures. The element is end sealed to resist moisture and contamination during use. Typical applications include heating viscous liquids or holding the temperature of cleaning solutions, glues, waxes or epoxies during use.

Features & Benefits At A Glance

  • 10″ (254 mm) plate diameter designed to nest under a 20 L pail, optimizing contact of the heating surface with the pail
  • Rated at 120V 1200 W for plug-in to a standard 15 amp grounded wall receptacle
  • 8 ft (2400 mm) cord facilitates placement
  • Adjustable range thermostat from 10°C to 120°C (50°F to 250°F) senses plate temperature; built-in pilot light goes off after plate temperature reaches the set point
  • Unit weight of 10 lbs (4.5 kg)
MC - Cast-In Immersion Heater

The Caloritech™ MC Cast-In Immersion Heater is used for melting soft metals such as solder, tin, lead and babbitt at temperatures up to 510°C (950°F). The standard units are available in three styles to accommodate a range of installations: over-the-side, through-the-bottom and through-the-side. Custom designed units are also available for specialized applications, such as non-standard single phase and three phase metal melting heaters, heating plates, heat storage systems and corrosive fluid heaters.

Features & Benefits At A Glance

  • Large diameter, heavy wall steel element
  • Iron casting
  • General purpose terminal box
  • Rated up to 3 kW at 120V and 10 kW at 240V; two 240V heaters rated 2 kW and above can be connected in series to a 480 volt supply
  • Watt densities available at 30 W/in2, 14 W/in2 and 20 W/in2 (through-the-bottom model only)
  • The through-the-side and through-the-bottom models supplied with a non-asbestos, high temperature gasket
PGH - Pilot Gas Heater

The Caloritech™ PGH – Pilot Gas Heater is specifically designed to heat the pilot tube gas stream of an automatic pressure reducing valve. It combines a high efficiency aluminum casting with a digital temperature controller to maintain the pilot tube gas stream temperature regardless of the gas flow rate. The precise temperature control of this heater prevents damage to valve seals caused by freezing of entrained moisture while maintaining a temperature low enough to prevent damage by overheating.

Features & Benefits At A Glance

  • Digital indicating display of operating temperature and setpoint
  • Internally adjustable temperature setting
  • Impact resistant tempered glass
  • Compact size
  • x-Max® anodized aluminum enclosure
  • Multiple conduit entries
  • 3/8″ NPT inlet and outlet connections
  • High limit protection
  • No maintenance required
FS - Finned Strip Heater

The Caloritech™ FS Finned Strip Heater is a versatile and economical heating source typically used across a wide range of applications, including surface heating (platens, dies, molds, tanks, piping); process air heating (drying cabinets, ovens, baking ovens, vacuum dehydrating ovens, moisture protection for motors); dropping resistors for line applications in railroads and load banks; winterizing (hoppers, conveyors, ducts, car heating, thawing); original equipment (air conditioning, laboratory equipment, food packaging, ovens, presses, drying equipment). The fins improve heat transfer in free or forced air heating applications.

Features & Benefits At A Glance

  • Constructed of specially selected, high grade materials, including high temperature alloy resistance wire, corrosion-resistant aluminized steel sheath (suitable for maximum sheath temperature less than 538 °C (1000°F) and 0.022″ (0.559 mm) thick cadmium plated steel fins
  • Controlled coil process and placement assures uniform heat distribution over the entire active surface of the heater
  • Special refractory material possesses excellent heat transfer characteristics, superior insulation properties and rigid vibration resistance to provide a heavy-duty heating unit
  • Slotted mounting tabs allow lineal expansion during initial heat-up period
  • Rated at 120V or 240V, depending on size; secondary insulators must be used when voltage to ground exceeds 300V
  • High-voltage models rated up to 600V when secondary insulators are used
  • Maximum amperage of 48 amps
  • Wattage ranges from 725 W to 2100 W depending on size of heater
  • Overall length limit of 42.5″ (1080 mm); effective length limit of 39″ (991 mm)
SD - Strip Heater (Terminals at Each End)

The Caloritech™ SD Strip Heater with terminals at each end is a versatile and economical heating source typically used across a wide range of applications, including surface heating (platens, dies, molds, tanks, piping); process air heating (drying cabinets, ovens, baking ovens, vacuum dehydrating ovens, moisture protection for motors); dropping resistors for line applications in railroads and load banks; winterizing (hoppers, conveyors, ducts, car heating, thawing); original equipment (air conditioning, laboratory equipment, food packaging, ovens, presses, drying equipment).

Features & Benefits At A Glance

  • Constructed of specially selected, high grade materials, including high temperature alloy resistance wire and corrosion-resistant aluminized steel sheath (suitable for maximum sheath temperature up to 538°C (1000°F) or corrosion-resistant stainless steel sheath (suitable for maximum sheath temperature up to 649°C (1200°F)
  • Controlled coil process and placement assures uniform heat distribution over the entire active surface of the heater
  • Special refractory material possesses excellent heat transfer characteristics, superior insulation properties and rigid vibration resistance to provide a heavy-duty heating unit
  • Slotted mounting tabs allow lineal expansion during initial heat-up period
  • Rated at 120V or 240V, depending on size; secondary insulators must be used when voltage to ground exceeds 300V
  • High-voltage models rated up to 600V when secondary insulators are used
  • Maximum amperage 48 amps
  • Wattage ranges from 100 W to 1250 W for the aluminized steel sheath and 100 W to 1500 W for the stainless steel sheath, depending on the size of the heater
  • Overall length limit of 42.5″ (1080 mm); effective length limit of 39″ (991 mm)
SS - Strip Heater (Terminals at One End)

The Caloritech™ SS Strip Heater with terminals at one end is a versatile and economical heating source typically used across a wide range of applications, including surface heating (platens, dies, molds, tanks, piping); process air heating (drying cabinets, ovens, baking ovens, vacuum dehydrating ovens, moisture protection for motors); dropping resistors for line applications in railroads and load banks; winterizing (hoppers, conveyors, ducts, car heating, thawing); original equipment (air conditioning, laboratory equipment, food packaging, ovens, presses, drying equipment).

Features & Benefits At A Glance

  • Constructed of specially selected, high grade materials, including high temperature alloy resistance wire and corrosion-resistant aluminized steel sheath (suitable for maximum sheath temperature up to 538°C (1000°F) or corrosion-resistant stainless steel sheath (suitable for maximum sheath temperature up to 649°C (1200°F)
  • Controlled coil process and placement assures uniform heat distribution over the entire active surface of the heater
  • Special refractory material possesses excellent heat transfer characteristics, superior insulation properties and rigid vibration resistance to provide a heavy-duty heating unit
  • Slotted mounting tabs allow lineal expansion during initial heat-up period
  • Rated at 120V or 240V, depending on size; a limited selection of 287V heaters available; secondary insulators must be used when voltage to ground exceeds 300V
  • High-voltage models rated up to 600V when secondary insulators are used
  • Maximum amperage of 48 amps
  • Wattage ranges from 125 W to 1500 W for the aluminized steel sheath and 250 W to 1500 W for the stainless steel sheath, depending on the size of the heater
  • Overall length limit of 42.5″ (1080 mm); effective length limit of 39″ (991 mm)
KX - Finned Tubular Heater (Calrod® type*)

The Caloritech™ KX Finned Tubular Heater (Calrod® type*) is typically manufactured to custom specifications based on the customer application, where steel fins are spirally wound over a heating element and then metallurgically bonded by furnace brazing, leaving negligable thermal resistance at the joint.

They are normally used for forced convection heating applications with outlet air temperatures up to 300°C (572°F), such as forced circulation, air or gas heating systems like ducts, fan forced electric heaters, recirculating ovens and loading resistors. Finned tubular heaters offer distinct advantages over open coil heaters, including minimized risk of fire or electrical shock, longer service life and less overall required maintenance.

Features & Benefits At A Glance

  • Various combinations of fin thickness, width and pitch available depending on requirements
  • Four surfaces finishes available: bare steel, nickel plated, aluminum painted and black enamel
  • Operating temperatures will vary depending on air velocity, air temperature and watts per square inch
  • Standard element diameters range from 0.260″ to 0.540″ (7 mm to 14 mm)
  • Watt density of 10 W / sq.in on standard heaters; custom watt densities are available for lower velocities or higher outlet temperatures upon request
  • Installation using brazed, crimped or welded plates; standard units have have factory installed fittings for this purpose
IX - Formed Unfinned Tubular Heater (Calrod® type*)

The Caloritech™ IX Formed Unfinned Tubular Heater (Calrod® type*) can be used in most heating applications that require process heating temperatures up to 750°C (1382°F). These tubular elements can be clamped, immersed, cast into metal or spaced away from the work as radiant heaters. They can also be positioned in ducts or vessels for heating air and other gases.

These units can be factory formed into virtually any shape, and inside bending diameters as small as one element diameter are sometimes possible. All Caloritech™ tubular heater styles offer a selection of sheath diameters and material options, including copper, steel, stainless steel and incoloy®.

Features & Benefits At A Glance

  • Easy and convenient installation
  • Available in a wide variety of sheaths, diameters and ratings
  • Electrically isolated sheath
  • Placement of heat source to specification
  • Compact, space-efficient design
  • Precise and versatile heat control
  • Long life with minimal maintenance required
  • Excellent internal electrical insulation and heat conduction
HX - Straight Unfinned Tubular Heater (Calrod® type*)

The Caloritech™ HX Straight Unfinned Tubular Heater (Calrod® type*) can be used in most heating applications that require process heating temperatures up to 750°C (1382°F). These tubular elements can be clamped, immersed, cast into metal or spaced away from the work as radiant heaters. They can also be positioned in ducts or vessels for heating air and other gases. All Caloritech™ tubular heater styles offer a selection of sheath diameters and material options, including copper, steel, stainless steel and incoloy®.

Features & Benefits At A Glance

  • Easy and convenient installation
  • Available in a wide variety of sheaths, diameters and ratings
  • Electrically isolated sheath
  • Placement of heat source to specification
  • Compact, space-efficient design
  • Precise and versatile heat control
  • Long life with minimal maintenance required
  • Excellent internal electrical insulation and heat conduction

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