Omega MPP Specification

Page 1

Nozzle Band Heaters

Construction Characteristics

The ideal solution for applications that require high watt densities (Watt/in

Band heaters are capable of temperatures up to 760°C (1400°F) and watt densities up to 23.25 Watt/cm (150 Watt/in2). The recommended maximum watt density for a specific application will depend on the heater size and its operating temperature.

Unbreakable Power Screw Terminals

Only these band heaters offer this unique screw terminal design. The stainless steel power screw terminals are resistant to over-torquing.

) and/or high operating temperatures.

Specially formulated mineral insulated tape providing excellent thermal conductivity and dielectric strength is used to insulate the nickel chrome resistance wire from the stainless steel sheath. The heater assembly is formed under pressure to a precise diameter with a thin low-mass cross section, assuring fast heat-up rates and reduced cycle times.

Superior Clamping Mechanism

The clamping brackets are formed from the outer sheath of the heater, providing a unique one-piece built-in construction strap. The clamping power is generated through barrel nuts and socket head screws, which as an integral part of the built-in strap, provide superior clamping force for maximum performance and optimal heater life.

Innovative Lead Terminations

Smaller size band heaters are powered-up by means of lead wire terminations. To insure a resilient connection that will withstand abrasion, mechanical abuse and keep contaminants out of the transition area, a specially designed stainless steel transition cap with a built-in strain relief was developed. The cap is welded to the sheath and the cavity is filled with insulating cement, sealing the band heater from contaminants.

Single Port IglooTM Covers

Unique Igloo Ceramic Covers

To eliminate exposed wiring/screw terminals on band heater installations, a 90° double port ceramic cap was designed. This unique and exclusive Igloo ceramic terminal insulator fits over the entire terminal and lug, leaving no exposed wiring.

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Specifications & Tolerances

Nozzle Band Heaters

If non-standard widths or tighter tolerances are required,

contact OMEGA.

Performance Ratings

Maximum Temperature: 760°C (1400°F)

Nominal Watt Density: Nozzle Bands, Under 3" Diameter: 4.7 to 15.5 Watt/cm

(30 to 100 Watt/in2)

Barrel Bands, 3" and Greater in Diameter:

3.1 to 10.9 Watt/cm2 (20 to 70 Watt/in2)

Maximum Watt Density: 23 Watt/cm2 (150 Watt/in2) dependent on heater size, operating temperature and termination

Electrical Ratings

Maximum Voltage: 480 Vac per termination

Dual Voltage: Available depending on heater configuration

Maximum Amperage:

Lead Wire Termination: 10A Screw Terminations: 8-32UNF—20A, 10-32UNF—25A

Resistance Tolerance: +10%, −5%

Wattage Tolerance: +5%, −10%

Diameter/Width Limitations

One-Piece Construction Expandable Construction Two-Piece Construction

Width Inside Diameter Inside Diameter Inside Diameter in mm in mm in mm in mm

1 25.4 1 to 10 25.4 to 254.0 n/a n/a 3 to 25 76.2 to 635.0 11⁄2 38.1 1 to 14 25.4 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0

2 50.8 11⁄2 to 14 38.1 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0

21⁄2 63.5 11⁄2 to 14 38.1 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0 3 76.2 11⁄2 to 14 38.1 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0 31⁄2 88.9 13⁄4 to 14 44.5 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0

4 101.6 2 to 14 50.8 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0

41⁄2 114.3 21⁄4 to 14 57.2 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0 5 127.0 21⁄2 to 14 63.5 to 355.6 21⁄2 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0 51⁄2 139.7 23⁄4 to 14 69.9 to 355.6 3 to 14 63.5 to 355.6 3 to 25 76.2 to 635.0 6 152.4 3 to 14 76.2 to 355.6 3 to 14 76.2 to 355.6 3 to 25 76.2 to 635.0 61⁄2 165.1 31⁄4 to 14 82.6 to 355.6 31⁄4 to 14 82.6 to 355.6 31⁄4 to 25 82.6 to 635.0

7 177.8 31⁄2 to 14 88.9 to 355.6 31⁄2 to 14 88.9 to 355.6 31⁄2 to 25 88.9 to 635.0

71⁄2 190.5 33⁄4 to 14 95.3 to 355.6 33⁄4 to 14 95.3 to 355.6 33⁄4 to 25 95.3 to 635.0

8 203.2 4 to 14 101.6 to 355.6 4 to 14 101.6 to 355.6 4 to 25 101.6 to 635.0

Physical Size Construction Limitations

Nominal Gap—Built-In Bracket:

Less than 44 mm (13⁄4") Diameter: 6 mm (1⁄4") 44 to 51 mm (13⁄4 to 2") Diameter: 8 mm (5⁄16") 51 to 127 mm (2 to 5") Diameter: 10 mm (3⁄8") 127 mm to 0.46 m (5 to 18") Diameter: 13 mm (1⁄2")

Greater than 0.46 m (18") Diameter: 19 mm (3⁄4")

If a larger gap is required for probes or thermocouples, specify when ordering.

Maximum Inside Diameters: One-Piece: 355.6 mm (14")*

Expandable: 355.6 mm (14")* Two-Piece: 635.0 mm (25") Over 635.0 mm (25") will require multiple segments.

Contact OMEGA.

* Note: OMEGA recommends two-piece construction for heaters 10" ID and greater.

Standard Widths: 25.4 to 203.2 mm (1 to 8")

Width Tolerance: 2.4 mm (±3⁄32")

Exposed electrical wiring on band heater installations is a violation of Electrical Safety Codes including O.S.H.A.

Additional Limitations

• For heaters less than 102 mm (4") in diameter, the maximum width is twice the diameter.

• Heaters with standard brackets are available from 25 to 203 mm (1 to 8" wide, while heaters with low profile brackets are available from 25 to 152 mm (1 to 6") wide.

• 25 mm (1") diameter heaters are only available in 25 to 38 mm (1 and 11⁄2") widths.

• For heaters from 254 mm (10") diameter up to 0.6 m (25") diameter, OMEGA recommends using 2-piece construction for superior clamping. Over 0.6 m (25") diameter, 3 or 4 segments are

recommended.

• Combinations of some minimum and maximum variations may not be available. Contact OMEGA with your special requirements.

• Post terminals are only available on heaters greater than 64 mm (21⁄2") in diameter and 38 mm (11⁄2") in width.

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Nozzle Band Heaters

Maximum Watt Densities

Maximum Allowable Watt Density

The chart displays the maximum Watt Density curves for various diameter

heaters. Use this chart

when determining the appropriate wattage value for your chosen heater.

Be aware that certain factors will require you to derate the watt density (Watt/in2) of your heater selection.

CAUTION: Failure to adhere to the maximum allowable watt density per heater size will result in poor operating life.

Calculating Maximum Watt Density

Watt Density–w/cm2 (dashed lines)

Watt Density–w/in

(solid lines)

Factors to be taken into consideration:

A. Type of controls

B. Voltage variations

C. Machine cycling rate

D. Type of resin being processed

E. Coefficient of thermal expansion and conductivity

of the cylinder

F. Designing a heater that closely matches the wattage

requirement will decrease the frequency of cycling and temperature overshoot, thereby increasing the life of the heater

Once these factors have been established, proceed with the following steps:

1. Determine the maximum operating temperature.

2. Calculate the total wattage required to obtain the maximum operating temperature.

3. Determine the quantity and size of the heater bands to be used. Due to clamping concerns, 51 through 76 mm

(2" through 3") wide band heaters have long proven to be

the most efficient and reliable in most cylindrical heating applications.

4. Determine individual band heater wattage by dividing the total required wattage by the quantity of band heaters selected.

5. Determine the band heater’s heated area by subtracting unheated (cold) areas created by screw terminals, gaps, holes, and cutouts.

Nominal Unheated Areas

Construction Style Cold Area to Subtract

One-piece band 1" × width One-piece expandable band 11⁄2" × width

Two-piece band 2" × width

For each hole or cutout add to the cold area from the Table

the (Hole size +

to use in the following formula to calculate the heater watt density.

Watt Density Formula

Watt Density = (Watt/in2) (3.14×Band ID×Band Width)–(Cold Area)

6. Check in the above graph that the calculated watt density does not exceed the maximum recommended watt density. Locate the maximum cylinder temperature required on the left-hand side of the graph, follow the horizontal line until it intersects with the line of the band heater being used, and read directly down to obtain the maximum recommended watt density (watt/in2).

7. If the calculated watt density is higher than the recommended value, it must be corrected or it will cause poor heater life. This can be accomplished by using more band heaters or lowering the heater wattage.

8. Should you have a problem in selecting the proper band

heater or establishing watt density for your application,

contact OMEGA.

⁄2") × heater width. This is total cold area

Wattage

Correction Factors

For heaters wider than 76.2 mm (3"),

reduce maximum allowable watt density from chart by 20%.

For applications using insulating shroud, reduce maximum allowable watt density from chart by 25%.

Do not use insulating blankets if heater temperatures are above 649°C (1200°F). Failure to adhere will result in premature heater failure.

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Nozzle Band Heaters

Nozzle Band Heaters Available Through the Terminator Program

Model Numbers listed are for heaters with Type W2 termination—right-angle wire braid leads [305 mm (12") leads, 254 mm (10") stainless steel braid]. Other terminator program terminations and options can also be applied to stock heaters (see To Order chart below ).

To Order

Model No. Inner Dimension Width

MPP50101 —

— MPP50206

MPP50301 MPP50401

— MPP50601

MPP50701 MPP50801

MPP51101 MPP51202

— MPP51401

MPP51701 —

— MPP51801

MPP51901 MPP52001

MPP52301 MPP52402

MPP52501 MPP52602

— MPP52903

— MPP53001

— MPP53202

— MPP53401

— MPP53501

MPP53801 MPP53901

— MPP54301

— MPP54401

— MPP54601

MPP54701 MPP54801

— MPP54901

MPP55051 MPP55101

— MPP55401

— MPP55801

MPP55901

MPP56001

— MPP56101

Ordering Example: MPP55051, nozzle band heater, 120V, 750 watt, 305 mm (12") leads.

25.4 1 25.4 1 150 10.9 70 WB

25.4 1 25.4 1 225 16.3 105 WB

25.4 1 38.1 1

31.8 1

38.1 1

44.5 1

⁄4 25.4 1 250 13.2 85 WB

⁄4 25.4 1 275 14.6 94 WB

⁄4 38.1 11⁄2 350 12.4 80 LB

⁄4 38.1 11⁄2 350 12.4 80 WB

⁄2 25.4 1 200 8.4 54 OB

⁄2 25.4 1 300 12.5 81 OB

⁄2 38.1 11⁄2 300 8.4 54 LB

⁄2 38.1 11⁄2 450 12.5 81 LB

⁄2 50.8 2 300 6.3 40 LB

⁄2 50.8 2 450 9.4 61 LB

⁄2 76.2 3 350 4.9 31 LB

⁄2 76.2 3 500 7.0 45 LB

⁄4 38.1 11⁄2 300 6.9 44 LB

⁄4 50.8 2 750 12.9 83 LB

⁄4 63.5 21⁄2 550 7.6 49 LB

⁄4 76.2 3 1000 11.5 74 LB

⁄2 200 9.7 62 WB

⁄2 250 12.1 78 WB

⁄2 300 14.5 93 WB

50.8 2 25.4 1 350 10.3 66 OB

50.8 2 38.1 1

⁄2 400 7.8 50 LB

50.8 2 50.8 2 750 11 71 LB

57.2 2

63.5 2

⁄4 25.4 1 350 8.9 58 OB

⁄4 63.5 21⁄2 1000 10.2 66 LB

⁄2 25.4 1 400 9.0 58 OB

⁄2 38.1 11⁄2 500 7.5 49 LB

Watt

Watt Density

Watt/in

Clamping/

Construction120V 240V mm inch mm inch Watt/cm

Ordering Information

Order by model number for heaters with Type W2

termination. Call OMEGA for model numbers for heaters with other Terminator Program terminations and options.

Custom Engineered/Manufactured

Heaters can be application specific; therefore for sizes,

electrical ratings, terminations and any other design features not listed OMEGA will custom manufacture to your specifications. Consult us with your requirements.

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Nozzle Band Heaters

Model numbers listed are for heaters with screw terminal terminations—Type T2 or T3X. Model numbers for heaters with other terminations will be assigned at time of order.

To Order

Inner Dimension Width

Model No.

MPP00230

MPP00231

MPP00232

MPP00233

MPP00234

MPP00235

MPP00236

MPP00237

MPP00238

MPP00186

MPP00239

MPP00240

MPP00241

MPP00187

MPP00242

MPP00243

MPP00244

MPP00245

MPP00246

MPP00247

MPP00248

MPP00249

MPP00250

MPP00188

MPP00251

MPP00189

MPP00252

MPP00253

MPP00254

MPP00255

MPP00190

MPP00256

MPP00257

MPP00258

MPP00259

MPP00191

MPP00260

MPP00261

Ordering Example: MPP00232, nozzle band heater, 120V, 1100 watt, screw terminals.

76.2 3 38.1 1

82.6 3

88.9 3

92.1 3

⁄4 63.5 21⁄2 1100 120 7.4 48 1 pc NB T3X

⁄4 63.5 21⁄2 1400 240 9.4 61 1 pc NB T3X

⁄2 50.8 2 800 240 6.2 40 1 pc NB T3X

⁄8 38.1 11⁄2 650 240/480 8 52 Exp NE T2

101.6 4 38.1 1

114.3 4

⁄2 63.5 21⁄2 1250 240 5.9 38 1 pc NB T3X

127 5 38.1 1

133.4 5

139.7 5

⁄4 38.1 11⁄2 600 240/480 4.6 30 Exp NE T2

⁄4 38.1 11⁄2 1000 240/480 7.7 49 Exp NE T2

⁄4 76.2 3 1700 240/480 6.1 39 Exp NE T3X

⁄4 114.3 41⁄2 2400 240/480 5.7 37 Exp NE T3X

⁄4 114.3 41⁄2 2700 240/480 6.4 41 Exp NE T3X

⁄2 38.1 11⁄2 1000 240/480 7.2 47 Exp NE T2

⁄2 38.1 11⁄2 1300 240/480 9.4 61 Exp NE T2

152.4 6 38.1 1

165.1 6

171.5 6

⁄2 38.1 11⁄2 1250 240/480 7.4 48 Exp NE T2

⁄4 38.1 11⁄2 815 240/480 4.6 30 Exp NE T2

⁄4 38.1 11⁄2 1000 240/480 5.7 37 Exp NE T2

⁄4 101.6 4 2600 240/480 5.2 34 Exp NE T3X

⁄4 127 5 3700 240/480 6 39 Exp NE T3X

⁄4 152.4 6 3750 240/480 5 33 Exp NE T3X

177.8 7 38.1 1

190.5 7

193.7 7

⁄2 38.1 11⁄2 1500 240/480 7.5 49 Exp NE T2

⁄8 76.2 3 1800 240/480 4.2 27 Exp NE T3X

⁄8 114.3 41⁄2 3150 240/480 4.9 32 Exp NE T3X

203.2 8 38.1 1

228.6 9 38.1 1

241.3 9

285.8 11

⁄2 76.2 3 3000 240/480 5.6 36 Exp NE T3X

⁄4 76.2 3 2400 240/480 3.7 24 Exp NE T3X

⁄4 127 5 5100 240/480 4.7 31 Exp NE T3X

Watt Voltage

⁄2 500 240 6.3 41 1 pc NB T2

⁄2 525 240 6.6 43 1 pc NB T2

⁄2 625 240/480 6.8 44 Exp NE T2

⁄2 725 240/480 7.8 51 Exp NE T2

⁄2 800 240 7.3 47 1 pc NB T2

⁄2 1000 240/480 8.1 52 Exp NE T2

⁄2 1000 240/480 6.5 42 Exp NE T2

⁄2 1400 240/480 9.1 59 Exp NE T2

⁄2 1250 240/480 6.8 44 Exp NE T2

⁄2 1500 240/480 8.2 53 Exp NE T2

⁄2 1250 240/480 5.8 38 Exp NE T2

⁄2 1600 240/480 7.5 48 Exp NE T2

⁄2 1500 240/480 6.1 40 Exp NE T2

⁄2 1750 240/480 7.2 46 Exp NE T2

Watt Density

Watt/in

Style

Clamping/

Construction Terminalmm inch mm inch Watt/cm