Coil & Cable Heaters
Coil & Cable Heaters
Coil & Cable Heaters
Cable heaters are highly versatile, high performance mini-tubular heaters that are used in applications where a large amount of heat is required in a confined space. These heaters are fully annealed and can be bent into various shapes and configurations. Their standard cross-section is round but can be formed into a square or a rectangle to improve heat transfer. The sheath material is stainless steel 304, which provides adequate resistance against temperature oxidation and corrosion. The heating core type depends on the electrical and thermal characteristics of the heater. The core is made by embedding either Nickel-Chrome mini-coils or straight, solid resistive wires inside a highly compacted Magnesium Oxide insulating medium. The connection between the main power leads and the internal fine wires is done inside transition adaptors. These adaptors, which remain relatively cold and protect the power leads during operation, have larger diameters than the heater cross-section. Cable heaters can have up to 35w/in2 watt-density and can operate at temperatures as high as 1200°F in a continuous mode (1500°F intermittent).
| Coil & Cable Heater Cross-sections | |
| Round | 0.094″ |
| Round | 0.125″ |
| Round | 0.150″ |
| Round | 0.188″ |
| Round | 0.25″ |
| Square | 0.13″x0.13″ |
| Rectangular | 0.09″x0.145″ |
| Rectangular | 0.10″x0.175″ |
Uses of Coil Heaters
Coil heaters are special cable heaters that have been shaped into a coil. These heaters are successfully used as powerful heating cells in plastic injection molding hot-runner nozzles. Coil and cable heaters can accommodate “J” or “K” type thermocouple sensors which are positioned internally at the tip or in the middle of the heater. Moreover, coil and cable heaters can have a profiled or a distributed-wattage configuration. It should be noted that although cable heaters are malleable and can acquire any shape, they should be formed into a final shape in a single attempt. Forming and bending operations harden the outside stainless-steel shell, and additional annealing might become necessary if re-changing the form is required
- Applications
- Terminations
- Tips
- Standard Products
Typical Heating Applications of Coil Heater:
- Hot Runner Nozzles
- Cutting & Sealing Bars
- Medical Equipment
- Rod, Pipe & Tube Heating
- Heat Tracing
- Semiconductor Manufacturing
- Forming Dies
- Printing & Laminating Presses
Termination Orientation
Plain leads with high-temperature sleeving
High temperature Teflon leads (480° F) with a fiberglass jacket exiting from a transition bracket. This bracket is sealed with high temperature cement.
Stainless steel braid
The stainless steel braid, which is crimped to the transition bracket, provides abrasion resistance and maintains high flexibility.
Stainless steel armor
Stainless steel armor is less flexible than stainless steel braid. It provides protection from contamination and abrasion. This style is standard on heaters.
Installation Tips For Coil Heaters
- The inside diameter of a coil heater is 0.020” smaller than the nominal diameter of a nozzle. This is done intentionally to secure a positive grip at all times. During installation, a coil heater should be screwed to its proper position. Pushing forcefully, or slightly opening the coil to facilitate installation could permanently damage the heater.
- During installation, only the straight cold section could be slightly bent. This should be done in a single attempt. The bending radius shouldn’t be less than 0.5”. It is always recommended to contact our factory when modifications of form are required.
- The straight cold section can withstand temperatures of up to 1500° F. However, to protect the lead wires, the temperature of the section beyond the transition adapter should be maintained below 480° F.
- Usually the sensing tip of a thermocouple is located at the end of the last loop of a coil heater. Care should be taken to insure that the last loop is properly gripping the nozzle.
Coil Heaters Available from Stock
| Part # | OEM EQ # | I.D. | Length | Watts | Volts | Lead Length Type | Ground Yes/No | Cold Lead | Type J T/C | Profiled Heat |
|---|---|---|---|---|---|---|---|---|---|---|
| BK51492 | SSTC-62-90 | 0.5 | 1.45 | 250 | 240 | 36″ FLX HOSE | Yes | 2 | Yes | Yes |
| BK51992 | SSTC-72-90 | 0.5 | 1.95 | 250 | 240 | 36″ FLX HOSE | Yes | 2 | Yes | Yes |
| BK52502 | SSTC-42 | 0.5 | 2.5 | 450 | 240 | 48″ FLX HOSE | Yes | 1/1 | No | No |
| BK52592 | SSTC-42-90 | 0.5 | 2.5 | 450 | 240 | 48″ FLX HOSE | Yes | 2 | No | No |
| BK54601 | SSTC-31 | 0.5 | 4.62 | 300 | 120 | 48″ FLX HOSE | Yes | 1/1 | Yes | Yes |
| BK54691 | SSTC-31-90 | 0.5 | 4.62 | 300 | 120 | 48″ FLX HOSE | Yes | 2 | Yes | Yes |
| BK54602 | SSTC-32 | 0.5 | 4.62 | 300 | 240 | 48″ FLX HOSE | Yes | 1/1 | Yes | Yes |
| BK54692 | SSTC-32-90 | 0.5 | 4.62 | 300 | 240 | 48″ FLX HOSE | Yes | 2 | Yes | Yes |
| BK60902 | SCH0003 | 0.625 | 0.975 | 225 | 240 | 42″ SS BRAID | Yes | 2 | Yes | Yes |
| BK62002 | SCH0081 | 0.625 | 2 | 300 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK62502 | SCH0082 | 0.625 | 2.5 | 350 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK63002 | SCH0083 | 0.625 | 3 | 400 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK63502 | SCH0084 | 0.625 | 3.5 | 425 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK64002 | SCH0085 | 0.625 | 4 | 500 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK65002 | SCH0086 | 0.625 | 5 | 500 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK66002 | SCH0087 | 0.625 | 6 | 500 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK71402 | SCH0060 | 0.75 | 1.44 | 250 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK71702 | SCH3142 | 0.75 | 1.75 | 315 | 240 | 42″ SS BRAID | Yes | 2 | Yes | Yes |
| BK71902 | SCH0061 | 0.75 | 1.94 | 300 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK72402 | SCH3242 | 0.75 | 2.44 | 315 | 240 | 42″ SS BRAID | Yes | 2 | Yes | Yes |
| BK72432 | SCH0062 | 0.75 | 2.44 | 350 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK72902 | SCH0063 | 0.75 | 2.94 | 400 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK73402 | SCH0064 | 0.75 | 3.44 | 425 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK74402 | SCH0065 | 0.75 | 4.44 | 500 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK75402 | SCH0066 | 0.75 | 5.44 | 500 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK82102 | SCH0088 | 0.875 | 2.13 | 400 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK82602 | SCH0089 | 0.875 | 2.63 | 450 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK83102 | SCH0090 | 0.875 | 3.13 | 550 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK83602 | SCH0091 | 0.75 | 3.63 | 700 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK86102 | SCH0094 | 0.875 | 6.13 | 1000 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK84102 | SCH0092 | 0.875 | 4.13 | 800 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
| BK85102 | SCH0093 | 0.875 | 5.13 | 900 | 240 | 36″ SS BRAID | Yes | 2 | Yes | Yes |
FAQs
How to use a coil heater?
The coil is wrapped around a mating part and power is applied to produce heat.
How much does it cost to run a coil heater?
The cost is based on the watts and volts used to run the application.
Are electric coil heaters safe?
Bucan coil heaters are designed to be safe for all electrical applications.
How much electricity does a coil heater use?
This is dependent of the wattage and voltage required.
Does a coil heater produce carbon monoxide?
The electric coil does not produce carbon monoxide
Can coil and cable heaters be used in food processing equipment?
If your application is a fit for a coil heater, yes they can be used.