Tempco Cast-In Cross Head Die Heaters
The challenging operating parameters these Cast-In Heaters are required for are primarily due to the presence of excessive contamination, high watt densities and high temperature as well as unusual physical and dimensional requirements. Cast-In Heaters are less susceptible to contamination problems, and can operate at higher temperatures with higher watt densities. In addition, the design is structurally better suited to accommodate holes and cutouts without compromising the heater’s electrical and mechanical integrity. As a standard, Cross Head Die Heaters are typically designed in aluminum as a one-piece band with a single slot that can be slid over the die and clamped with stainless steel clamping straps. For higher temperature or high watt density requirements, bronze or brass alloys can be used.
Eagle Sensors & Controls, Division of Excel Automation LLC, is an authorized Tempco distributor. Contact us for sales & technical support for Tempco heaters, Tempco sensors, Tempco temperature controllers, Tempco process heating systems & all other Tempco products.
Cast Materials
Aluminum
Material: Standard Aluminum 319 (Optional Aluminum 356 in Learn More)
Maximum Surface Temperature: 700°F (371°C)
Density (lb/in3): 0.101
Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 12.7 @ 68° – 572°F
Thermal Conductivity (BTU-in/hr-ft2-°F): 754
Bronze
Material: Bronze
Maximum Surface Temperature: 1350°F (732°C)
Density (lb/in3): 0.272
Coefficient of Linear Thermal Expansion (in/in/°F × 10-6): 9 @ 68° – 572°F
Thermal Conductivity (BTU-in/hr-ft2-°F): 437
Electrical Terminations
Type S: Heavy Duty Ceramic Insulators (Standard)
Standard unless otherwise specified.
.315″ diameter heater has 8-32 screw terminals.
.430″ diameter heater has 10-32 screw terminals.
Type T: Mica Insulator
Mica insulator is the same diameter as the heating element.
.260″ diameter heater has 6-32 screw terminals.
.315″ diameter heater has 8-32 screw terminals.
.430″ diameter heater has 10-32 screw terminals.
Type T7: Ceramic Insulator
Ceramic insulator is the same diameter as the heating element.
.260″ diameter heater has 6-32 screw terminals.
.315″ diameter heater has 8-32 screw terminals.
.430″ diameter heater has 10-32 screw terminals
Type C4: Heavy Duty Ceramic Insulator with Terminal Cover
Heavy duty ceramic insulator with terminal cover.
.315″ diameter heater has 10-32 screw terminals.
.430″ diameter heater has 10-32 screw terminals.
Type P: Plain Pin
Plain terminal pin. Specify Length “L.”
Standard 1/2″ (12.7 mm) pin length.
Type R: Mica Washers
Mica washers with 90° blockhead screw terminal with 10-32 screw threads.
Available for .315″ and .430″ diameter heaters.
Type R2: Mica Washers with Lead Wire Connection
Mica washers with blockhead and through hole for lead wire connection. Eliminates the use of ring terminals.
Available for .315″ and .430″ diameter heaters.
Accepts 6-14 gauge wire.
Type E: Right-Angle Lug
Right-angle lug welded to pin with mica washer insulators and 10-32 binding head screw.
Available for .260″, .315″ and .430″ diameter heaters.
Type L and L9: Terminal Lug and Pin
Terminal lug spot welded to pin with 10-32 binding head screw.
Available for .260″, .315″ and .430″ diameter heaters.
Type L represents straight; Type L9 represents 90° to pin. Specify lug orientation.
Type SF and SF9: Quick Disconnect Spade Tabs
Quick-disconnect spade tabs spot welded to pin.
Available for .260″, .315″ and .430″ diameter heaters.
Type SF represents straight. Type SF9 represents 90° to pin. Specify tab orientation.
Type F: Flexible Lead
Flexible lead: insulated stranded wire crimped to cold pin. Crimp connection is insulated with fiberglass sleeving.
Available for .260″, .315″ and .430″ diameter heaters.
Wire insulation rated to 250°C, 450°C optional. Specify lead length.
Type R1: Flexible Armor Cable
Flexible Armor Cable provides excellent protection to lead wires against abrasion and contaminants.
Available for .260″, .315″ and .430″ diameter heaters. Specify cable length and lead length. Style may vary from depiction depending on heater diameter and cable diameter used.
Type R1A: Stainless Steel Wire Overbraid
Stainless Steel Wire Overbraid provides flexibility and excellent protection to lead wires against abrasion.
Available for .260″, .315″ and .430″ diameter heaters. Specify stainless steel wire overbraid length and lead length.
Style may vary from depiction depending on heater diameter and braid diameter used.
Type MR: Strain Relief and Lead Wire – Moisture Resistant
Moisture resistant shrink strain relief and lead wire with or without stainless steel overbraid.
Available for .260″, .315″ and .430″ diameter heaters. Specify lead wire and overbraid length.
Maximum operating temperature is 350°F (177°C).
Type TS: Teflon® Sleeving over Lead Wire
Contamination seal shrink-down Teflon® sleeving over the heater and lead wire splice. Provides a good moisture resistant seal. Maximum operating temperature 500°F (260°C).
Available for .260″, .315″ and .430″ and diameter heaters. Specify lead length.
Termination Protection
Type C2: Standard Terminal Box (on flat pad)
Type C2 is an individual terminal box for protecting the terminals on each Cast-In Band Heater half and on many other Cast-In Heater designs with one set of heater terminals.
The C2 box design requires a flat pad on half-round castings or a flat surface on other casting designs for mounting. It is made from heavy gauge, rust-resistant sheet metal. The cover is removable for easy access to terminals. The box has two 7/8″ diameter knockouts opposite each other for standard 1/2″ BX connectors.
Type EP: Explosion & Moisture Resistant Box
Cast iron explosion and moisture resistant boxes should be used in areas where the surrounding air may become contaminated with combustible gases or a high humidity level may exist. Installation requires one box per Cast-In Heater half and they are brazed to the tubular heater. The standard box has one 1/2″ NPT hub.
Type MPR: Moisture Resistant Box
This design has a moisture resistant die cast aluminum box with a non-removable polyurethane gasket in the lid. Lid is secured with captive stainless steel screws. Body and lid are painted in basic industrial gray; interior contains copper ground screw. Box is mounted to a plate that is brazed to the element. Available in a wide variety of sizes.
Type MR1: Moisture Resistant Box with Shield
This design incorporates the MPR housing style along with a perforated tube shielding unheated extensions of the tubular heating elements. This feature provides mechanical strength to the element extension and prevents overheating of the terminals, reducing possible premature failure from corrosion and oxidation.
None
This Cast-In will not have Terminal Protection.
Additional Options
125 RMS Standard
RMS Surface Finish as defined in ASME B46.1 — RMS is the root mean square of the profile height deviations from the mean line, recorded within the evaluation length. The standard surface finish for the machined surface of Tempco cast-in heaters is 125 RMS. Consult Tempco if a different surface finish is required.
Special Features
Electroless Nickel-Plated — A plating technique (without using an electric current) used to deposit a coating of nickel on a substrate to prevent corrosion, wear and also as a protective coating.
Teflon Coating — Teflon is non-reactive so it is often used in containers and pipework for reactive and corrosive chemicals.
Hard coat anodizing — Anodizing increases resistance to corrosion and wear.
Magnaplate — Strong wear and corrosion resistance non-stick coating that withstands high temperatures.