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Electrical heat tracing · up to 1000 °C HEAT safe · accurate · reliable www.hillesheim-gmbh.de Process Engineering · Process Technology · Chemistry
Hillesheim GmbH Am Haltepunkt 12 D-68753 Waghäusel Tel.: +49 7254 / 9256-0 E-Mail: info@hillesheim-gmbh.de www.hillesheim-gmbh.de Technical specifications in this catalogue may vary according to the state of development. Revision status: January 2026
® Company portrait Giving and conserving heat Welcome to Hillesheim GmbH Do you need to transfer liquid media or gases from A to B without tem- perature loss? Or do you want them to be heated from temperature X to temperature Y? Heating and heat maintenance: Competent, innovative and economical If you are looking for a technically and economically optimal solution for such tasks, you can rely on us. We provide the accumulated know- how of more than 45 years of application experience. Thousands of electrical heating systems that we have designed and manufactured (heated hoses, heating tapes, heating mats) are still operating today – even after decades of service at our customers. Individual solutions for trace and surface heating From our extensive and reliable product range, we put together the technology that best suits your needs. Our materials cover temperatures up to 1000 °C, including the associated control technologies. We work closely with you to meet the specific requirements of your in- dustry and to provide optimal solutions tailored to your specifications. Explosion protection – an important part of our portfolio In industries that work with potentially explosive materials (e.g. chemi- cal engineering), it is critically important to consistently implement measures for explosion prevention and protection. This includes the avoidance of effective ignition sources. Production sites and factories that present a significant explosion risk due to the materials they process require heating elements that meet strict requirements. You can rely on our EX heating solutions to meet these requirements, as they are ATEX certified. Industrial heating solutions – on the cutting edge of technology Our developments set the standards for state-of-the-art technology in our field – and often stay one step ahead. Today’s know-how is the result of solutions developed together with our customers. You can benefit from this knowledge today. Challenge us. I
® Are you looking for electrical heat tracing? We have the right product! For more than 45 years, we have been developing and manufacturing customised electrical heating systems – individually tailored to the requirements of our customers. Benefit from our many years of experience and heat up your installations with Hillesheim products – Made in Germany! Quality • Reliability • Punctuality • Hillesheim II
® Contents 1. General information and data . . . . . . 1 -10 2. Industrial heating hoses . . . . . . . . . 11 – 34 3. Analytical heating hoses . . . . . . . . . 35 – 48 4. Flexible trace heaters . . . . . . . . . . . 49 – 70 5. Surface heating elements . . . . . . . . 71 – 84 6. Electrical heaters . . . . . . . . . . 85 – 106 7. Control technology . . . . . . . . . . . 107 – 120 III
® Description and structure of a Hillesheim heating hose Whenever hot and warm media have to be transported from a device to another part of the device or plant without heat loss and the lines are not intended to be rigidly routed, flexible heating hoses are recommended as conveying elements. In most applications, it is necessary to maintain the product temperature at a predefined value. By using Hillesheim heating hoses, a constant temperature of the material conveyed is ensured through to the application site, without the material temperature being influenced by ambient temperatures and heat losses along the way. Why heating hoses are used: ◾ To keep media fluid for processing ◾ To achieve their optimum properties for processing ◾ To avoid condensation of gaseous media ◾ To process in a more rational way (robotic applications) ◾ To ensure consistent quality ◾ To avoid having to produce in a particular place ◾ To connect moving parts and devices Connection fitting Hose end cap Outer protective braiding Thermal insulation Connection cable Heating conductors Metal braiding Temperature sensor Plug connection Inner core The structure shown is a schematic representation of the heating hose. There may be differences, however, depending on the hose type and application. Similarly, the structure can change with new developments and advancements. 2
® Application examples Plastics processing Injection moulding Extrusion, Co-extruders Mould-making Adhesives and dosing systems Hot-melt equipment Adhesive robots Packaging equipment Dosing equipment Surface technology Bitumen plants Spray-coating plants Airless equipment Isolation technology Packaging foam equipment PUR foam equipment 2-component equipment 4-component equipment Process and environmental technology Exhaust gas stations Exhaust gas measurement technology Sampling probes Flue gas analytical Emission measurements Chemical thermal process engineering Heavy fuel oil systems Chemical pipelines Fluid metals Silo heating systems Explosion hazard areas Ex-heated hoses Ex-heated plates Ex-control technology Transportation technology Transfer and delivery hoses Silo and levelling hoses Plant and apparatus engineering Filling and sealing equipment Food processing Tool heating 3
Electrical heating info ® Information about Hillesheim heating hoses Electrical engineering: The mains power and sensor cables are prepared for connection to the specified mains voltage (measurement voltage) and the sensor type. The standard connection design complies with the CE standard (DIN-VDE). Designs can be realised in accordance with other directives (UL, CSA, SEV...). The heating system is designed such that optimal heat distribution is achieved over the entire length of the heating hose. Hillesheim heating hoses are equipped with temperature sensors and have to be monitored with the suitable controllers. For unsupervised operation, we can fit additional sensors (thermal switch, temperature fuses ...) or additional temperature sensors for connection to controller/ limiter combinations. Attention! Standard heating hoses must not be operated in explosion-risk-areas. Only our specially explosion-protected heating hoses with ATEX-approved components may be used in explosion-prone areas. Nominal diameter: The nominal diameter (inner diameter) (DN for short) is determined from the flow rate and the viscosity of the medium. Standard sizes for hoses are 4....50 mm. Larger diameters are available on request (also see Transfer and delivery hoses). Pressure hoses: The pressure hose type is usually determined from the same parameters as the nominal diameter. The required operational pressure also applies in this case. Other selection criteria, such as heat transfers, bending radii or strong pulsing loads are also important parameters. Please always refer to the tables for bending radii and operating pressures. We also heat special hoses made of Viton, silicone, NBR ... that can also be provided by the customer. Attention! The pressure specifications in the table are defined at 20...50 °C. Increasing temperatures reduce the pressure loading capacity. Please observe temperature correction factors. Connection fittings: The selection of fittings is dependent on the nominal diameter and the pressure loading capacity (light, medium and heavy duty fitting series) of the hose. The heating hose may have different fittings attached on both ends. Open ends without fittings and many types of special fittings (clamp, flange, milk pipe ...) are also possible. Temperature sensors: Our heating hoses come equipped with Fe-CuNi (J) thermoelements as standard. NiCr-Ni (K) thermoelements and PT100 PTC sensors in 2, 3 or 4-wire connections are also possible. Other thermoelements and PTC/NTC sensors are available on request. A variety of sensors may also be installed depending on the application. The HTI and HTP integral controllers monitor the temperature directly at the heating wire with PTC response, without additional sensors on the heating system. Control lines: The heating hose can have electrical connections, flexible empty pipes for air, test gas or fluid media or combinations of these incorporated. The entry and exit points and the relevant connecting elements (extension connectors, couplings ...) have to be specified. Parallel pickups allow further loads to be connected. Wire cross-sections and pipe diameters depend on the loads connected. Connection cable: As described in the 'Connection cable outlet' sheet, the mains cable exits from the end caps. Industrial hoses have 1.5 m analysis lines and 3.0 m connection cables as standard. Special designs with recessed cable outlets, other dimensions, separated cables for heating, sensors and control lines ... are possible. 4
® Electrical heating info Plug connections: The plug connections on Hillesheim standard heating hoses are equipped with a plug compatible with our controllers. The HT63 temperature controller is provided with a round socket as standard. Please note that for unsupervised operation. there must be an additional safety device (limiter, temperature fuse...) fitted in the heating system. We can also supply our hoses without plugs for connecting the cable to terminals or for fitting to customer plugs. We use plug connectors from many well-known manufacturers. We can also fit their plugs on our hoses for you if you state the order reference and the pin configuration. Heating-up time / Safety: Under normal conditions (closed room, approx. +20 °C) the time for Hillesheim heating hoses to heat up to 200 °C is 15 to 30 minutes. Before putting your system into operation, it has to be ensured that the medium in the hose and in the connection parts has reached its processing temperature. Bending loads and blockages in the fittings can damage the hose before the processing temperature is attained. Please read the operating instructions and assembly guidelines before starting operation for the first time. Certification DIN EN ISO 9001:2015 5
Installation recommendations ® Along the lines of DIN 20066 Pulling on the ends of rolled hoses causes torsional stress and can subject them to bending radii smaller than is permissible. Hoses are not to be twisted. Wrong Right Remedy: unroll the ring of hose rather than pulling it off. Hose lines should be installed in such a manner that they are free of tensile stress in all operational states; similarly, jamming stress (i.e. axial compression along the length) on short lengths of hose is to be avoided. Axial compression due to incorrect installation or space-reducing motion degrades the hose's pressure resistance. Compensation of expansion due to hoses installed in straight sections can lead to their destruction. Remedy: place elbow fittings at connecting points. Do install straight sections of hose which are subjected to a large range of motion, make such hose connections in a U-shape. axial compression Stauchbelastung Zugbeanspruchung tensile stress When connecting hose lines to moving parts, the hose length must be calculated such that the hose's smallest permissible bending radius is not underrun in any possible position and/or that the hose is not subjected to tensile stress. 6 bending radius to small sufficient distance zu kleiner Biegeradius ausreichender Abstand abrasion Abrieb sufficient distance ausreichender Abstand
® Installation recommendations Wrong Right Avoid twisting the hose when connecting it to moving parts, particularly when motion and bending take place in the same plane. This can be achieved through proper installation or design measures (e.g. swivel joint). The danger of kinking is particularly high for handheld devices. Remedy: Depending on the operating position, install a elbow or kink protection (e.g. corru- gated hose). r min d ø 5 , 1 ≈ d ø r m i n For installation in an arc, a hose length should be selected such that the intended bend can be formed beyond a length of ≈ 1.5 d0 ; kink pro- tection may also be necessary (e.g. hard cap). It is disadvantageous to allow free-hanging spans. Remedy: supports or counterweight rollers. bending radii to small zu kleine Biegeradien Hose lines should be installed as close as possible to their natural position, whereby their smallest permissible bending radius must be observed. Additional stresses on the hose can be avoided through the use of suitable fittings and adapters. * The bending radius refers to the neutral axis. r min 7
Installation recommendations ® Wrong Right 500–1000 abrasion Abrieb ausreichender sufficient distance Abstand Heat build-up will occur if heating hoses are routed through a closed channel or shaft. Remedy: hoses may not touch one another. Further- more, sufficient ventilation is to be provided. If, for example, powder-like substances, adhesives or other thermally insulating materials accumulate on heating hoses, then overheating will occur at such points. Remedy: eliminate the cause with regular cleaning to remove such materials. Heat build-up is caused by incorrect wrapping of the heating hose with other materials. The heating hose will overheat at such points. If the sensor area is wrapped, then the remainder of the hose will cool off. Bundling or routing that permits contact between hoses will lead to overheating at these points of contact. Remedy: route with open space between hoses. Do not fasten clips or brackets so tightly that they cause the hose's outer braiding to be pressed inter- nally against the heat conductor. Disregard for this rule can lead to damage of the protective braiding and the hose. Openly routed hose lines along paths where there is vehicle or pedestrian traffic are to be protected against damage from abrasion and deformation, e.g. by using hose bridges. Appropriate measures can be taken to arrange and affix hose lines to prevent them from being damaged externally by external mechanical influences. To the extent necessary, hoses are to be secured in place, e.g. by protective jackets. Sharp-edged components should be avoided. Hose brackets are to be avoided at points where they would prevent the heating hose's natural free movement and length changes. heat protection Wärmeschutz Where hose lines are exposed to high external tem- peratures, they must either have sufficient physi- cal separation from the external heat source or be protected by appropriate measures (e.g. shielding). 8
® Protection type / protection class Protection types for electrical equipment according to EN 60529 Protection types against solid foreign objects, denoted by the first numeral First numeral Short description Definition 0 1 2 3 4 5 6 Not protected Protected against solid foreign objects 50 mm diameter and larger Protected against solid foreign objects 12.5 mm diameter and greater Protected against solid foreign objects 2.5 mm diameter and greater Protected against solid foreign objects 1 mm diameter and greater Dust-protected Dust-tight – The object probe, a sphere of 50 mm diameter shall not fully penetrate The object probe, a sphere of 12.5 mm diameter shall not fully penetrate The object probe, a sphere of 2.5 mm diameter shall not fully penetrate The object probe, ball 1 mm diameter must not penetrate at all Ingress of dust is not completely prevented, but dust shall not penetrate in a quantity to interfere with satisfactory operation of the device or impair safety No ingress of dust * Note: The full diameter of the object probe must not pass through an opening of the enclosure Protection type against water, denoted by the second numeral Second nu meral Short description Definition 0 1 2 3 4 5 6 7 8 9 Not protected Protected against falling water drops Protected against falling water drops when the enclosure is tilted up to 15° Protected against spraying water – Vertically falling drops shall have no harmful effects Vertically falling drops shall have no harmful effects when the enclosure is tilted at any angle up to 15° on either side of the vertical Water sprayed at an angle up to 60° on either side of the vertical shall have no harmful effects Protected against splashing water Water splashed against the enclosure from any direction Protected against water jet Protected against powered water jets Protected against the effects of temporary immersion in water Protected against the effects of continuous immersion in water Water at high pressure / steam jet cleaning shall no harmful effects Water projected in jets against the enclosure from any direction shall no harmful effects Water projected in powerful jets against the enclosure from any direction shall no harmful effects Ingress of water in quantities causing harmful effects shall not be possible when enclosure is temporarily immersed in water under standardised conditions of pressure and time Ingress of water in quantities causing harmful effects shall not be possible when enclosure is continuously immersed in water under conditions which shall be agreed between manufacturer and user but which are more severe than for numeral 7 However, these conditions must be more stringent than those described under numeral 7 Example numerals IP 6 8 Protection classes Electrical devices and enclosures require safety requires protective measures to prevent exposed metal parts from conducting electric current in the event of a fault. Classification into protection classes provides information about the given measures taken. Protection class Symbol Protective measures I II III All exposed metal parts are galvanically connected to one another and also connected to the mains protective earth conductor. The device is appropriately isolated such that it has no exposed metal parts that can conduct electric current in the event of a fault. A protective earth conductor is not implemented. The device is operated on low voltage, not in excess of 42 V, which is obtained from a safety transformer or battery. 9
Type codes Industrial heating hoses ® Heating hose Sensor Outer protection Fitting Pressure hoses 1 = H 100 2 = H 200 4 = H 400 5 = H 500 6 = H 600 7 = H 700 8 = H 800 9 = H 900 H 0 = Fe-CuNi 0 = polyamide standard 0 = without 1 = Fe-CuNi + limiter braiding 1 = DKR steel 2 = PT100 1 = stainless steel braiding 2 = RSL/RSS steel 3 = PT100 + limiter 2 = galv. steel braiding 3 = DKR-V2 A 4 = NiCr-Ni 3 = PA corrugated hose 4 = RSL/RSS-V2 A 5 = NiCr-Ni + limiter 4 = metal ring corr. hose 5 = DKR-V4 A 6 = limiter 7 = without sensor 8 = HTI controller 5 = textile glass braiding 6 = RSL/RSS-V4 A 6 = PU corrugated hose 7 = DKJ steel 7 = silicone outer skin 8 = DKL steel 9 = PT100 + 2nd PT100 8 = rubber hose 9 = BDN steel T1 T2 T3 T4 T5 TAW T46 Nominal length in dm DN Thermal insulation Heating conductor Connection Pressure hose Insulation Outer protection Fitting Determination of the nominal length Fitting DKR Pressure hose Fitting RSL Rated power Watt/metre at 230 V ~ for standard heating hoses: Nominal length NL Type H 100 H 700 H 200 H 800 H 900 H 900 H 400 DN mm 100 °C 170 °C 200 °C 250 °C 4 80 100 6 100 120 450 °C / 350 °C 600 °C 80 °C 70 8 120 140 220 330 70 40 10 140 160 250 375 90 45 12 160 200 280 420 90 45 16 200 260 310 465 120 50 20 260 330 400 600 120 50 25 330 380 460 690 32 380 440 610 900 40 440 550 50 550 660 660 990 880 1300 55 60 70 85 70 40 approx. mm Outer Ø with standard braiding: Special power and voltage ratings on request. 40 Tolerances Rated power / rated voltage + 5 % / -10 % Diameter Length ± 10 % ± 2 % Test voltage for heating hoses (230 V rated voltage) 2000 Volt high voltage test heating conductor – PE conductor 12
® Pressure hoses – Industrial T 1 Smooth PTFE hose with one braided layer of stainless steel wire (1.4301), max. operating temperature 250 °C DN (NW) mm 4 6 8 *operating pressure / bar 275 240 200 Bending radius / mm 50 75 100 10 175 120 12 150 135 16 20 135 100 25 80 160 200 250 T 2 Smooth PTFE hose with two braided layers of stainless steel wire (1.4301), max. operating temperature 250 °C DN (NW) mm 6 8 10 12 16 20 25 *operating pressure / bar 275 250 225 200 175 150 130 32 70 40 50 Bending radius / mm 75 100 120 135 160 200 250 500 850 T 3 Smooth PTFE hose with two wound layers and one braided layer of steel wire, max. operating temperature 250 °C DN mm 6 8 * operating pressure / bar 500 475 Bending radius / mm 60 85 10 475 110 12 450 150 16 400 175 20 300 200 25 275 240 32 250 275 T 4 Corrugated PTFE hose one layer of stainless steel wire (1.4301), 200 °C max. operating temperature DN mm * operating pressure / bar Bending radius / mm 25 62 90 32 62 100 40 51 150 50 34 180 All information is subject to change. 13
Pressure hoses – Industrial ® T 46 Corrugated PTFE hose inside smooth with stainless steel spirals and steel braiding, max. operating temperature 250 °C DN mm * operating pressure / bar Bending radius / mm Also available antistatic 12 50 40 16 50 50 20 60 60 25 40 70 32 45 90 40 40 50 25 110 150 T 5 Corrugated stainless steel hose (1.4404 or 1.4571) with one braided layer of stainless steel wire (1.4301), max. operating temperature 550 °C Reference values for the light design: DN mm * operating pressure / bar Bending radius / mm 4 6 8 10 100 150 100 100 12 65 16 65 20 40 25 50 32 25 40 40 50 25 80 80 120 130 140 160 170 190 260 300 320 Hoses made of stainless steel may be used virtually without limitation in the range -190 °C up to max. +550 °C for liquids and gaseous media in all industries, and are completely diffusion resistant; not suitable for chlorides, bromides and other halogens. Attention! – The pressure specifications in the table are defined at 20...50 °C. Increasing temperatures reduce the pressure loading capacity. Please observe temperature correction factors * Operating Pressure: temperature correction factor for T1 – T4, 100 °C x 0,95; 150 °C x 0,9; 200 °C x 0,83; 250 °C x 0,6 * Operating Pressure: temperature correction factor for T5, 100 °C x 0,7; 200 °C x 0,6; 250 °C x 0,55; 350 °C x 0,49; 500 °C x 0,46; 550 °C x 0,4 * Operating Pressure: temperature correction factor for T46 by design The hoses made of PTFE T1, T2, T3, T4, T46, can be universally employed in the range from -70 °C to +250 °C and are characterised by their un- usual chemical stability; they are only unstable in the presence of com- pounds containing fluorine, as well as alkaline metals sodium or po- tassium and halogens. It is essential that you observe the minimum bending radius, since if this is exceeded this will cause the pressure hose to leak thus making the complete heating hose unusable or no longer repairable. We ac- cept no liability for such damage. Recommendation: For dynamic load, double of the minimum bend- ing radius should be kept, in order to achieve a longer life! All information is subject to change. 14
® Fittings – Industrial DKR Universal conical nipple, union nut inch (BSP) *2 DN mm G = thread / inch 4 6 8 10 12 16 20 25 32 40 G 1/8"-28 G 1/4"-19 G 3/8"-19 G 3/8"-19 G 1/2"-14 G 3/4"-14 G 1"-11 G 1"-11 G 11/4"-11 G 11/2"-11 G 1/4"-19 G 1/2"-14 G 5/8"-14 G 11/4"-11 G 11/2"-11 RSS L (mm) d (mm) RSL/RSS Pipe connection light / heavy duty series DN mm 4 6 8 10 12 16 20 25 32 40 RSL L (mm) d (mm) 25 25 26 26 28 30 32 30 35 38 6 8 10 12 15 18 22 28 35 42 27 29 29 29 33 39 44 44 41 8 10 12 14 16 20 25 30 38 DKS 18 x 1.5 20 x 1.5 22 x 1.5 24 x 1.5 30 x 2 36 x 2 42 x 2 52 x 2 15 DKL/DKM/DKS Universal conical nipple, union nut metric thread light / heavy duty series DN mm Thread DKL DKM 4 6 8 10 12 16 20 25 32 40 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 22 x 1.5 26 x 1.5 30 x 2 36 x 2 45 x 2 52 x 2 30 x 1.5 38 x 1.5 45 x 1.5 52 x 1.5
Fittings – Industrial ® DKJ Nipple with 74° tapered JIC, union nut UNF thread DN mm 4 6 8 8 8 10 10 12 16 20 25 32 40 UNF = thread 7/16" -20 UNF 1/2" -20 UNF 1/2" -20 UNF 9/16" -18 UNF 5/8" -18 UNF 9/16" -18 UNF 3/4" -16 UNF 3/4" -16 UNF 7/8" -14 UNF 11/16" -12 UNF 15/16" -12 UNF 15/8" -12 UNF 17/8" -12 UNF BDN Flanged nut flat sealing, union nut inch / metric DN mm G = thread / inch Series L Series M Series S 4 6 8 10 12 16 20 25 32 40 G 1/8"-28 G 1/4"-19 G 3/8"-19 G 3/8"-19 G 1/2"-14 G 3/4"-14 G 1"-11 G 1"-11 G 11/4"-11 G 11/2"-11 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 22 x 1.5 26 x 1.5 30 x 2 36 x 2 45 x 2 52 x 2 18 x 1.5 20 x 1.5 22 x 1.5 24 x 1.5 30 x 2 36 x 2 42 x 2 52 x 2 30 x 1.5 38 x 1.5 45 x 1.5 52 x 1.5 The stability of the heating hose must include the fitting. Normally the heating hose fittings are supplied in machining steel with Cr-VI free surface coating. Special fittings are available in 1.4305 and 1.4571 and in many other materials. In addition, heating hoses can also be sup- plied with flanges, small flanges, clamp pipe connections or pipe con- nections (DIN and ASA*1). Fittings with internal PTFE *3 or PFA *4 coating are available. *1 ASA = US standard *2 BSP = British Standard Pipe * These fittings are also available as external thread. *3 PTFE = polytetrafluorethylene *4 PFA = perfluoralkoxyl Fitting Crimping ferrule Pressure hose Contraction Fitting DN hose 16 DN mm 4 6 8 10 12 16 20 25 32 40 Inner Ø may vary depending on the fitting Inner Ø mm Fitting 3.0 4.5 6.0 7.5 10.0 12.5 16.0 20.1 27.5 31.5 Please note that the fit- tings cause a reduction in the hose throughput.
® Outside protective hoses – Industrial PA standard protective braiding Material PA 6, polyamide Temperature stability Very flexible, available in various colours +150 °C * Metal protective braiding Material steel, galvanised or stainless steel Temperature stability Very flexible, very good protection against abrasion +300 °C to +500 °C * PA corrugated hose / PUR corrugated hose Material polyamide PA6 PA12 PUR Temperature stability Very flexible, highly recommended for applications on robots, non- crush, flame-retardant, non halogen +100 °C * +120 °C * +90 °C PUR corrugated hose with steel coil Material PU (polyurethane) Temperature stability Very flexible, highly recommended for applications on robots, non- crush, flame-retardant, non halogen +90 °C * Metal ring corrugated hose Material steel, galvanised Temperature stability Very flexible, non-crush, very resistant against sharp objects and swarf +250 °C * Textile glass braiding Material textile glass - black Temperature stability Very flexible, very good protection against abrasion, protection against falling glowing swarf etc. standard for H 900 series +400 °C * Silicone outer skin Material silicone smooth - black/white Temperature stability Very flexible, smooth surface, easy-to-clean, moisture-proof +200 °C * Rubber outer protection Material rubber Temperature stability Outer textile patterned, abrasion resistant, weather resistant, conductive +80 °C * * The temperature stability relates to brief contact with a correspondingly hot environment. In case of prolonged use above the operating temperature of the external protective hose, the structure of the heating hose must also be changed accordingly. 17
End caps – Industrial ® Hard cap Tear and twist protection The fibreglass reinforced PA hard cap is firmly bonded with the basic hose. This prevents tearing or twisting of the cap due to heat expansion or strong movements of the heating hose. Bending protection The hard cap shifts the bending point of the basic hose behind the fitting and therefore neutralises the critical transition hose - fitting and increases the service life of the heating hose. Connection A terminal block is integrated in the connection space of the hard cap to which the connecting wires may be connected. This allows the connecting cable to be replaced without great effort. The hard caps are available for heating hoses up to DN 25. Option: Miniature control unit integrated in the hard cap For further information see chapter Control technology Rated voltage Switching power Power switch Control range Setting Housing material Protection type Response Sensor Inputs 230 V / 50 Hz 1000 W - 1500 W triac in zero-crossing 0 ... 254 °C setpoint 2 °C steps with a DIP switch PA glass-fibre reinforced IP42 / Cast: IP65 two-point controller sensor PT100 / HTI cable glands Soft cap Temperature stability The soft cap made of silicone or elastomer is characterised by its high temperature stability. Space requirement Their suppleness means they fit snugly around the ends of the heating hose and thus require less space than hard caps. Kink protection Their kink protection and the inner strain relief prevents hoses kinking and the mains cable from being pulled out. The soft caps are available for heating hoses up to DN 50. 18
® Connection cable outlet – Industrial Hard cap – made of polyamide PA6 glass-fibre reinforced Soft cap – made of silicone or elastomer bent up forward forward hose sided or frontal hose sided or frontal hose sided (Standard) hose sided (Standard) combined 19
Industrial heating hoses ® H 100 / H 700 / H 200 / H 800 series 250 °C Standard heating hose Applications: Heat-loss free transport of: oil, grease, resin, tar, paint, water, carbon dioxide, plastic, moulding compounds etc. Deployable pressure hose made of PTFE of DN 4 – 50 mm; pressure load depending on the nominal diameter up to 600 bar. Operating temperature H 100 100 °C H 700 170 °C H 200 200 °C H 800 250 °C Rated voltage Rated power 230 V AC/DC (other voltages up to 500 V) Watt/metre, see type codes Pressure hose type see Pressure hoses Connection fitting steel / stainless steel, see Fittings Heating Thermal insulation heating conductor, structure according to DIN, moisture-proof with protective braiding heat stabilized, closed-pore silicone foam up to 250 °C elastomer foam up to 170 °C Outer protective braiding polyamide, black, options possible Hose end caps PA hard cap or elastomer cap Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT100 and integral control system (HTI) possible Connecting cable 1.5 m Plug connection round connector Production lengths from 0.3 to 50 m depending on DIN Protection type up to IP54 (EN 60529), protection class I Tolerance Operating temperature ±10 °C Temperature control using our controllers, in chapter Control technology. Extended usages according to customer requirements with special equipment possible. Connection fitting Hose end cap Outer protective braiding (polyamide) UL Versions UL-compliant hose solutions are available for selected series within defined technical limits. Details available upon request. Thermal insulation (silicone foam or elastomer foam) Thermal insulation (textile braiding) Temperature sensor Heating conductor Pressure hose Inner core PTFE Plug connection Connecting cable 20
® Industrial heating hoses H 200 Special series 250 °C Heating hose for adhesive application systems Applications: Heat-loss free transport of: adhesives, hot-melt etc. Deployable pressure hose made of PTFE of DN 4 – 50 mm; pressure load depending on the nominal diameter up to 600 bar. Operating temperature 100 °C 170 °C 200 °C 250 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power Watt/metre depending on selection Pressure hose type see Pressure hoses Connection fitting steel /stainless steel, see fittings Heating Thermal insulation heating conductor, structure according to DIN, moisture-proof with protective braiding heat stabilized, closed-pore silicone foam up to 250 °C elastomer foam up to 170 °C Outer protective braiding polyamide, black, options possible Hose end caps PA hard cap or elastomer cap Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT100 Ni 120 Connecting cable dependent on the installation Plug connection special plug dependent on the installation Control lines number according to customer require- ments Production lengths from 0.3 to 50 m depending on DIN Protection type up to IP54 (EN 60529), protection class I Tolerance Operating temperature ±10 °C Extended usages according or customer requirements with special equip- ment possible. (Manual - or robotic application, diffusion-sealed version). Connection fitting Hose end cap Outer protective braiding (polyamide) Replacement hoses available for all common hot-melt application systems. Connecting cable Thermal insulation (silicone foam or elastomer foam) Thermal insulation (textile braiding) Electrical supply (control lines) for application pistol or nozzle head Temperature sensor Heating conductor Pressure hose Inner core PTFE Plug connection 21
Industrial heating hoses H 800 Special ® 250 °C Heating hose system for co-extrusion in the plastics industry For very high temperatures and pressure loads. The H 800 series heating hose systems combined with the T3 PTFE series pressure hose are very often used as connection hoses between a co- extruder and a tool. Rigid connections and a multitude of connection elements are eliminated, which would normally need to be individu- ally heated, insulated and controlled. The flexible connection consid- erably simplifies tool changing and maintenance. The H 800 also com- pensates thermal expansion and vibrations. The heating system can be easily fitted in your installation. Operating temperature 250 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power see table below Pressure hose type T3 PTFE, see Pressure hoses Connection fitting Fitting (optional) Heating Thermal insulation stainless steel, 1.4305; 1.4571; 1.2316; The fitting is tapered on the inside and polished so that little or no material can stick to it. See table below loose and fixed flanges according to DIN and ASA are possible heating conductor, structure according to DIN, moisture-proof with protective braiding heat stabilized, closed-pore silicone foam up to 250 °C Outer protective braiding polyamide, black, options possible Hose end caps PA hard cap or elastomer cap Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT100 Connecting cable Plug connection 1.5 m optional Production lengths from 0.3 m to 50 m Protection type up to IP54 (EN 60529), protection class I Tolerance Operating temperature ±10 °C DN DKS BDN Pressure loading capacity Fitting inner Ø Bending radii Rated power T3 8 10 12 16 preferably heavy duty series; union nut metric union nut in inch at 250 °C operating temperature Minimum bending radius in operating state M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 30 x 2.0 G 3/8" G 1/2" G 1/2" G 3/4" 285 bar 285 bar 270 bar 240 bar 6.0 mm 7.5 mm 10.0 mm 12.5 mm 85 mm 110 mm 150 mm 175 mm 140 W/m 160 W/m 200 W/m 260 W/m Other fittings and nominal diameters are available in our fittings table. Temperature control using our controllers, in chapter Control technology. 22
® Industrial heating hoses H 900 series 550 °C High temperature heating hose with T5 stainless steel pressure hose Applications: Heating or heat loss free transport of: oil, grease, resin, tar, paint, water, carbon dioxide, plastic, moulding compounds etc. The pressurised hose made of stainless steel, corrugated version, allows very high temperatures up to 550 °C. It is also diffusion sealed. Operating temperature 350 °C / 450 °C / 250 °C / 550 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power Watt/metre, see type codes Pressure hose type T5 stainless steel, see Pressure hoses Connection fitting see Fittings Heating heating conductor, structure according to DIN, glass insulated with PE conductor Thermal insulation textile glass Outer protective braiding textile glass black Hose end caps elastomer with strain relief and kink protection Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT100 Connecting cable 1.5 m Plug connection round connector Production lengths from 0.3 to 10 m depending on DIN Protection type up to IP20 (EN 60529), protection class I Tolerance Operating temperature ±20 °C Temperature control using our control equipment, in chapter Control technology. Extended applications are possible with special equipment. Connection fitting Elastomer cap Outer protective braiding (textile glass) Thermal insulation (multilayer textile glass) Connecting cable Temperature sensor Heating conductor T5 pressure hose Inner core (corrugated stainless steel) Plug connection 23
Industrial heating hoses ® Series H200A / H800A 200 / 250 °C Heated Hose with Replaceable Pressure Hose The heated hose with exchangeable pressure hose features a flexible stainless steel corrugated hose that serves both as the heating carrier and as the housing for the PTFE pressure hose. Previously, the entire heated hose had to be replaced in case of wear – for example due to abrasive media. This design enables a cost-effective and environmentally friendly replacement of only the damaged pressure hose. Applications: Heat-loss-free transport of: oil, grease, wax, resin, tea, paint, water, carbon dioxide, plastics, potting compounds, etc. Technical Specifications: Usable PTFE pressure hoses: DN8 Pressure rating depending on hose type and temperature: ◾ up to max. 394 bar (H200A) ◾ up to max. 285 bar (H800A) Operating temperature H200A: 200 °C / H800A: 250 °C Rated voltage Rated output 230 V AC/DC (Other voltages up to 500 V available) (W/m) See type code Pressure hose type PTFE DN8 as T1, T2 or T3 Carrier hose Fittings Heating system Flexible stainless steel corrugated hose Upon request; possible fittings are limited due to design Heating conductor, design in accordance with DIN, moisture-protected with protective braid Thermal insulation Heat-stabilized, closed-cell silicone foam Outer protective braid Black polyamide braid (options available) Hose end caps PA hard caps or elastomer caps Temperature sensor Fe-CuNi Type J, NiCr-Ni Type K, PT100 Connection cable 1.5 m Connector Circular connector Manufactured lengths 0.5 m to 20 m Protection rating Up to IP54 (EN 60529), Protection Class I Temperature control via our controllers (see Control Technology section). 24
® Industrial heating hoses H500 with pressure hose HIF series (H500) 100 / 150 °C Heating hose with inner heater Temperature control using heating conductor with HTI controller Applications: Heating low viscosity and gaseous media, such as water, oils, lyes, paints, acids or air. The heating element inside the hose has direct contact with the media. This ensures optimum heat transfer. This configuration means the heating hose has a small outer diameter and is very flexible. No thermal insulation is required up to an operating temperature of 60 °C. Operating temperature max. 150 °C (H500 max. 100 °C) Rated voltage Rated power Pressure hose type Connection fitting Connector head Heating Outer protection Temperature sensor 230 V AC Depending on length and design PTFE DN 10 to 12 mm, T1 and T2 Male thread or union nut (ÜBW) ³⁄8”, ½” or ¾” stainless steel or galvanised steel / 100 bar pressure Heating conductor, PTFE / PFA or FEP insulated Stainless steel braid of the pressure hose or without hose Integral HTI control system; optional temperature sensor (PT100, Fe-CuNi) Connecting cable 1.5 m Plug connection Fuse protection 7-pin standard plug or HTI on-site circuit breaker (optional ex works) Production lengths up to 60 m Protection type up to IP54 (EN 60529), protection class I Temperature control from our HTI-16 controller, see chapter Control technology. Other pressure hoses can be offered on request. HIF without pressure hose 25
Industrial heating hoses ® HIE-06 / HIE-16 series 100 °C HIE inner heater for hoses and pipes The HIE inner heater is very well suited for pre-installed pipes and hoses – the customer can simply insert the single wire heating con- ductor into them via a screw system and seal it with a brass compres- sion fitting. A T-junction is required. Two versions of the HIE are available. HIE-6 with mini controller on the screw fitting for max. 1500 W / 230 V. HIE-16 for a separate controller HTI-16 up to 3600 W / 230 V. Operating temperature max. 100 °C Rated voltage 230 V AC/DC (other voltages 115 to 400 V) Rated power depending on configuration 5-70 W/m Heating conductor outer diameter 2 - 5 mm Brass connector head ½" internal thread Pressure-resistant up to 15 bar HIE-16 type with plug (for HTI-16 controller) Temperature setting 0 - 100 °C on controller Temperature measure- ment integral heating conductor HTI control system Plug connection HIE-06 HIE-16 German "Schuko" mains plug plug for HTI-16 Production lengths from 7 m - 100 m Connecting cable 1.5 m Protection type IP42, cast IP44, protection class I Operation of the HIE inner heater has to be protected with a residual current circuit breaker (RCD). Temperature measurement using an integral controller, see chapter Control technology. The HIE inner heater with mini controller can be used up to a length of max. 30 - 35 m. The HIE-16 up to max. 100 m HIE-6 type (with HTI-6 mini controller) Integral temperature controller HTI-16 26
® Industrial heating hoses HWI 19/25 series 80 °C Compact heating hose with integrated inner heat- er for waste water. Frost protection hose for mobile water supplies in winter and under cold ambient conditions. Applications: Container settlements, stables, washing and cleaning plants, Christmas markets, catering, agriculture, road construction, construction sites. The heating element of the HWI hose is located directly in the medium. This direct heating technique consumes a low level of energy. This hose no longer differs visibly or in its usage from an unheated hose. A mini- controller in its main cable keeps the temperature in the hose con- stant above freezing point. The hose heater is to be connected by way of a fault current circuit breaker. Operating temperature Rated voltage Rated power Outer hose Structure -20 to +80 °C 230 V AC depending on configuration 10 - 20 W/m EPDM - waste water hose without KTW smooth inside, outer surface is ozone and weather resistant Production lengths 10 / 15 / 20 / 30 / 35 / 40 / 45 / 50 and 60 m Connector fittings GEKA-plus in brass Pressure rating max. 10 bar Smallest bending radius 200 mm Dimensions ø 19 or 25 mm, wall thickness approx. 4-5 mm Connecting cable Regulation 1.5 m with German "Schuko" mains plug Optional: German "Schuko" mains plug with inte- grated fault current circuit breaker Control HTI-6 mini-controller set to +20 °C, other temp 0-80 °C on customer request, see chapter Control technology Protection type up to IP44 (EN 60529), protection class I 27
Industrial heating hoses ® HDM 95 / 200 series 95 °C / 200 °C Double-jacket heating hose / heat transfer medium Applications: Explosion hazard areas. Dosing equipment, food industry, filling lines. The HDM hose can be used as a HEATABLE ELEMENT, as a COOLABLE ELEMENT and as a SAFETY ELEMENT. A temperature regulating unit which works with water or heat-transfer oil in a circulating system is required to operate HDM as a heating hose. Operating temperature 95 °C / 200 °C Pressure hose T1 – T3, see Pressure hoses Connection fitting RSL pipe connector stainless steel / inner hose Heat transfer medium connection AGR 3/8" to 1/2" Heat transfer hose Elastomer hose, PTFE hose, Viton hose Heat transfer fluid* water (70 °C), oil (95/200 °C), max. 8 bar Outer diameter Bending radius DN DN DN DN DN DN 4 – 10 approx. 35 mm 12 – 16 approx. 45 mm 20 – 25 approx. 55 mm 4 – 10 12 – 16 20 – 25 200 mm 400 mm 500 mm Production lengths from 1 to 25 m Option thermal insulation with 10 mm foam insulation and PA external braiding, end caps on both sides, special pressure hose TA / DN 2 mm * The pressure specification is valid for the heat transfer medium in the outer hose when the inner hose is filled and is under operating pressure. There must be no negative pressure difference between the outer hose and the inner hose, i.e. the pressure in the inner hose must always be higher than in the outer hose. A negative pressure difference (e.g. during filling) can cause the inner hose to collapse. If a negative pressure difference is unavoidable, the inner hose can be provided with an outer jacket. The outer jacket distributes the pressure over the stainless steel braiding and prevents the inner core collapsing. In the case of an integrated inner pressure hose T3, only use oil or an- other heat transfer media. No water! Braiding rusts! Heat transfer medium connection Heat transfer medium hose Pressure hose Hose connection Gap for heat transfer medium 28
® Industrial heating hoses HDM 60 / 62 / 68 series 60 °C / 200 °C / 250 °C Heat transfer medium hose Applications: Plastics equipment, PU equipment, 2-component equipment, adhesive equipment. The HDM hose can be used as a HEATING or as a COOLING ELEMENT and as an antistatic version is also suitable for use in explosion hazard areas. A temperature regulating unit which works with steam, water or heat-trans- fer oil in a circulating system is required to operate HDM as a heating hose. A heat transfer hose is tightly coiled around the pressure hose, in which the heat transfer fluid flows in order to heat the material in the material hose. This construction precludes the type of fault which would allow an intrusion of heated material from the material hose into the heat transfer circulation system to destroy the temperature regulating unit. Operating temperature 60 °C / 200 °C / 250 °C Pressure hose T1 – T4, see Pressure hoses Connector fittings material hose Execution See fittings HDM 60: PUR 6 mm Ø HDM 62: PTFE 6 mm Ø HDM 68: PTFE 6 mm Ø 60 °C 200 °C 250 °C heat transfer medium hose Single or double ended extending 1.0 m out of the material hose Heat transfer fluid water (70 °C), oil (60/200/250 °C), steam (164 °C) 8 bar max. Production lengths 1 – 25 m Connector fittings heat transfer hose AG ¼", ¼" union nut special fittings possible Thermal insulation fleece of foam hose Outer protective braiding polyamide black Hose end caps PA hard cap or elastomer cap Connection fitting Hose end cap Outer protective braiding (polyamide) Thermal insulation (foam hose or fleece) Heat transfer medium hose Heat transfer hose Material hose Inner core PTFE 29
Industrial heating hoses HR series Heated pipes ® 600 °C Applications: Filters, valves, measuring gas distributors, cold zones and tanks. The HR series is manufactured in consultation with the customer and is specially matched to the respective application. Pre-formed pipes can be provided by the customer. They are heated and insulated as straight pipe systems or in various shapes. With a multitude of heat transfer materials in stock, the pipes can be optimally matched to the different operating temperatures ranging from frost protection to 600 °C. Optimal outside protection and end caps round off the system. Operating temperature from frost protection to 600 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power depending on the configuration Nominal diameters 4 – 100 mm Pipe materials metal, glass, quartz, plastic, etc. End caps PA hard cap, elastomer or aluminium cap Built-on accessories heated, thermally insulated with outer jacket Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT100 and integral control system (HTI) possible Connecting cable 1.5 m Plug connection optional Temperature control using our controller equipment, see chapter Control technology. Pipe End cap Outer protective braiding Connecting cable 30 Thermal insulation Temperature sensor Heating conductor Pipe Plug connection
® Industrial heating hoses HFM series – flexible heating jackets 600 °C The flexible heating jackets are constructed from heating tape and in- sulation and are suitable as trace heaters for customer pipes, also pre-shaped pipes. Heating of bundles of pipes is also possible. The HFM heating jackets are slid onto the pipes to be heated, so the customer has a heating system that is easy to install and can be replaced. Operating temperature from frost protection to 600 °C Rated voltage Rated power Heat insulation Heating jacket Temperature sensor 230 V AC (other voltages up to 500 V) depending on configuration up to 250 °C silicone up to 450 °C textile glass up to 600 °C silicate fibre lengths 0.3 m up to approx. 10 m; optionally can also be split into individual segments, so that greater lengths or complete installations can be incorporated in the system. Fe-CuNi type J, NiCr-Ni type K, PT100 and integral control system (HTI) possible Pipe diameter from capillary to 50 mm outer diameter (larger diameters on request) Inner hose flexible metal corrugated hose Bending radius adaptable to the heating system Connecting cable Plug connection 1.5 m optional Temperature control using controller equipment, see chapter Control technology. SIM series 150 °C Clip attachment tracer heater for heating thin pipes and hoses This tracer heater for thin steel and copper pipes, as well as for hoses, consists of a silicone profile with parallel heating elements. The slotted shape enables pre-installed pipe systems, e.g. in analytical cabinets, to be heated without having to dismantle them. This saves considerable assembly costs. The version presently available covers piping from 4-12 mm OD. The lengths and power ratings are flexibly adapted to customer require- ments. The tracer heaters are therefore very easy to replace. Operating temperature -20 °C to +150 °C Rated voltage Rated power Heating 12 - 230 V AC/DC depending on configuration 50 - 100 W/m heating conductor, structure according to DIN, moisture-proof with protective braiding Thermal insulation heat-stabilised closed-pore silicone hose Outer protection silicone profile smooth Pipe diameter 4 - 12 mm End cap PA hard cap / at the connecting end Temperature sensor Connecting cable Plug connection Production lengths PT100 1.5 m optional max. 5 m Protection type up to IP54 (EN 60529), protection class I 31
Industrial heating hoses ® HDM 90 / 200 series 90 °C / 200 °C Transfer and delivery hoses with large nominal diameters DN > 200 mm HE heating hose has a special structure, which makes it suitable for its special structure makes it suitable for maintaining the temperature of the most diverse types of media, such as chemicals, solvents, oils, greases, and abrasive materials etc. For example, this heated hose can be used for loading and delivery of lorries and ships. An antistatic version is also optional. Operating temperature 90 °C / 200 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power depending on the configuration Nominal diameters 20 to 200 mm Pressure hose type Outer cover Hose end caps Couplings / fittings rubber (NR, NBR, EPDM, SBR), plastic hose (PTFE, PUR, PA, PE), stainless steel corrugated hose Optional: steel spring spiral / suction hose abrasion resistant, weather resistant PA hard cap, elastomer or aluminium cap flange, couplings: Storz, TW, Kamlok, external thread special fittings: on request Temperature sensor Connecting cable PT100 1.5 m Production lengths up to max. 40 m Protection type up to IP44 (EN 60529), protection class I A range of devices is available for temperature control. The line ex- tends from the HT 54 integral mini-controller with fixed temperature setting to convenient microprocessor controlled devices. See chapter Control technology for more detailed information. PTFE smooth hose T46 Lever arm coupling (Kamlock) Flange Tank truck coupling 32
® Industrial heating hoses H100 HL series 80 °C Heating hose with foodstuff approval The H100 HL heated hose has an NBR suction and pressure hose with electrical heating and is equipped with milk pipe fittings as standard. A silicone hose is used as outer protection. A range of devices is available for temperature control. The line ex- tends from main cable integrated mini-controller to convenient mi- croprocessor controlled devices. Operating temperature max. 80 °C Rated voltage 230 V AC/DC (other voltages up to 500V) Rated power see table below Suction and pressure hose structure white odourless, toxin-free special NBR rubber, generally suitable for use with foodstuffs, Outer protection silicone hose or rubber hose for large nominal widths Outer protection color blue or white Fittings dairy coupling fittings RD - DIN 11851 Optional fittings aseptic-connection – DIN 11864, Clamps – DIN 32676, other fittings in request Temperatur sensor PT100 as standard, other sensors on request Main cable Cleaning 1,5m silicon cable short-term steam cleaning max. 130 °C, suitable for CIP and conventional cleaning Protection type up to IP 54, protection class I Production lengths up to 10 m The used NBR hose suits regulation (EG) Nr. 1935/2004, BfR XXI Kat. 2 and FDA CFR §177.2600 DN (mm) Fitting (RD) Working pressure / vacuum (bar) Bending radius (mm) Rated power (W/m) 20 25 32 40 50 60 80 44 x 1/6" 52 x 1/6" 58 x 1/6" 65 x 1/6" 78 x 1/6" 95 x 1/6" 110 x 1/4" 10 / 0.9 10 / 0.9 10 / 0.9 10 / 0.9 10 / 0.9 10 / 0.9 10 / 0.9 60 85 115 150 210 265 320 130 160 190 220 260 350 380 33
Industrial heating hoses H 400 series ® 80 °C Heated twin-hose for PU foam installations Applications: Polyurethane foam processing. epoxy resin systems, paint spraying, dual-component casting systems. Heating two separate pressure hoses prevents the components from cooling down during transportation from the machine to the working site and therefore not reacting together properly. A pneumatic hose made of PVC, with 6 mm inner diameter and rated for 8 bar pressure, is housed under the outer protection. Special designs will be fabricated to your specifications. Custom designs based on the H 100 / 200 hose series are available on request. Operating temperature max. 80 °C Rated voltage 230 V AC/DC (other voltages up to 500 V) Rated power Watt/metre depending on configuration Pressure hose type T1 – T4, see Pressure hoses Connection fitting stainless steel / steel, see Pressure hoses Heating heating conductor, structure according to DIN, moisture-proof with protective braiding Thermal insulation inner protective hose and elastomer foam Outer protective braiding polyamide black, optional: Textile glass braiding Outer diameter Hose end caps Temperature sensor approx. 70 mm / depending on DN PA hard caps Fe-CuNi type J, NiCr-Ni type K, PT100 and integral control system (HTI) possible Connecting cable 1.5 m Plug connection one plug / coupling per hose Production lengths 7.5 m / 15 m / 30 m / 60 m, other lengths on request Protection type up to IP54 (EN 60529), protection class I Tolerance Operating temperature ±10 °C Temperature control using our control equipment, see chapter Control technology Pressure hose Connecting cable Marking Multi-pin connector Air hose Outer jacket Connecting cap 34
Type codes Analytical heating hoses ® Heating hose Sensor Outer protection Fitting Temperature 3 = H 300 0 = Fe-CuNi 0 = polyamide standard 0 = without 1 = Fe-CuNi + limiter braiding 6 = RSL/V4 A 2 = PT 100 1 = stainless steel braiding A = H 300 A 3 = PT 100 + limiter 2 = galv. steel braiding B = H 300 B 4 = NiCr-Ni 5 = NiCr-Ni + limiter 6 = limiter 7 = without sensor 8 = HTI controller 3 = PA corrugated hose C = H 300 C 4 = metal ring corr. hose 5 = textile glass braiding 6 = PU corrugated hose 7 = silicone outer skin 9 = PT 100 + 2nd PT 100 8 = rubber hose 100 °C 170 °C 200 °C 250 °C 350 °C H Nominal length in dm DN Thermal insulation Heating conductor Connection Inner core Insulation Outer protection Fitting Rated power Watt/metre at 230 V ~ for the H 300 series analytical heating hoses Type H 300 H 300 A+C H 300 H 300 A DN mm 200 °C 200 °C 350 °C 350 °C 4 100 120 200 220 6 120 140 220 250 8 140 160 250 280 10 160 200 280 310 12 200 260 310 400 Tolerances Rated power / rated voltage + 5 % / -10 % Diameter Length ± 10 % ± 2 % Test voltage for heating hoses (230 V measurement voltage) 2000 Volt high voltage test heating conductor – PE conductor 36
® Inner core - Analytical Inner core (or pipe) for the H 300 analytical heating hose series PFA or PTFE Core with 1 mm wall thickness 250 °C DN mm Minimum bending radius / mm*** Pressure / bar** Vacuum 8 mbar 4 200 12 6 250 9 8 300 7 10 350 6 12 400 5 VA stainless steel inner core with 1 mm wall thickness (1.4571) 350 °C DN mm Minimum bending radius / mm* Pressure / bar* Vacuum 50 mbar 4 300 60 6 350 60 8 400 50 10 500 50 12 600 40 PFA or PTFE core type TA with braiding layer of soft steel. Optional with replaceable core 250 °C DN mm Minimum bending radius / mm*** Pressure / bar* with industrial fitting Pressure / bar** without fitting 2 40 20 20 4 50 20 12 6 75 20 9 8 10 12 100 120 130 15 7 15 6 15 5 Vacuum 8 mbar. The braiding layer reduces the risk of the core kinking The inner cores are partly also available in inch dimensions. PTFE = polytetrafluoroethylene PFA = perfluoroalkoxy * ** temperature correction factor 100 °C x 0.9; 200 °C x 0.8; 250 °C x 0.7; 350 °C x 0.6 temperature correction factor 100 °C x 0,68; 150 °C x 0,53; 200 °C x 0,39; 250 °C x 0,28 *** Minimum bending radius in static operation in millimetres Cores made of stainless steel may be used virtually without limi- tation in the range -190 °C to max. +550 °C for liquids and gaseous media in all industries, and are completely diffusion resistant; not suitable for chlorides, bromides and other halogens. All basic hoses are subjected to a pressure test after installing the fitting if technically possible (double the operating pressure). A heater element with a close pitch is mounted or a heating tape (H300B type) depending on the model. Heater elements can be encapsulated with polyolefin, silicone, fluor plastic (FEP, PFA, PTFE...), glass fibre and mineral insulation, and may or may not include earth-wire sheathing. Rigid core TA Replaceable core TA 37
Outside protective hoses - Analytical ® PA standard protective braiding Material PA 6, polyamide Temperature stability Very flexible, available in various colours +150 °C * Metal protective braiding Material steel, galvanised or stainless steel Temperature stability Very flexible, very good protection against abrasion +300 °C to +500 °C * PA corrugated hose / PUR corrugated hose Material polyamide PA6 optional PA12 PUR Temperature stability Very flexible, non-crush, flame-retardant, non-halogen +120 °C * +100 °C +90 °C PUR corrugated hose with steel coil Material PU (polyurethane) Temperature stability Very flexible, non-crush, flame-retardant, non-halogen +90 °C * Metal ring corrugated hose Material steel, galvanised Temperature stability Very flexible, non-crush, very resistant against sharp objects and swarf +250 °C * Textile glass braiding Material textile glass - black Temperature stability Very flexible, very good protection against abrasion, protection against falling glowing swarf etc. +400 °C * Silicone outer skin Material silicone smooth - black/white Temperature stability Very flexible, smooth surface, easy-to-clean, moisture-proof +200 °C * * The temperature stability relates to brief contact with a correspondingly hot environment. In case of prolonged use above the operating temperature of the external protective hose, the structure of the heating hose must also be changed accordingly. Also partly available antistatic 38
® End connections - Analytical For H300 B series heating hoses End cap made of silicone Connection cable 3 m long H 300 B B-Si Ends caps made of polyamide with terminals in the hard cap Available as a self-assembly set H 300 B-Ki Terminal with KV screw connector on the end. H 300 B-KVEi Terminal with sliding KV screw connector. H 300 B-KVi All end connections technologies can be combined with each other. H 300 B On a cable drum 39
Connection cable outlet - Analytical ® Hard cap – made of polyamide PA6 glass-fibre reinforced Soft cap – made of silicone or elastomer bent up forward forward hose sided or frontal hose sided or frontal hose sided (Standard) hose sided (Standard) 40 combined
® Analytical heating hoses H 300 series 350 °C Analytical sample gas lines with RSL fitting Application potential: Maintaining the temperature of motor exhaust, CO2 measurements, industrial exhaust gasses, blast furnace exhaust gasses, air testing, environmental testing, etc. This heated sample-extraction line prevents condensation from forming or a temperature drop below the dew point, thus no gas components are eliminated or lost. Operating temperature 100 °C / 200 °C / 250 °C / 350 °C Rated voltage Rated power Inner core DN 4 – 12 mm Connection fitting Heating Thermal insulation 230 V AC/DC (other voltages up to 500 V) Watt/metre, see type codes up to 250 °C PTFE or PFA above 250 °C stainless steel see Inner cores analytics RSL 1.4571 steel, for cutting ring screw, without transition, see table heating conductor, structure according to DIN, moisture-proof with PE conductor braiding; > 250 °C not moisture-proof depending on the operating temperature heat stabilized, close-pore silicone foam or thermal fleece, elastomer foam Outer protective braiding polyamide black, options - see outer protection Hose end caps PA hard cap or elastomer cap Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT 100 and integral control system (HTI) possible Connection cable 3 m Plug connection according to specification Production lengths up to 100 m Protection type IP54 (EN 60529), protection class I Tolerance Operating temperature ±10 °C Temperature control using our controllers, in chapter Control technology. Fitting (pipe connection) RSL Hose end cap Outer protective braiding (polyamide) Thermal insulation RSL Pipe connection for cutting ring screw DN RSL L (mm) d (mm) 4 6 8 10 12 25 25 26 26 28 6 8 10 12 15 UL Versions UL-compliant hose solutions are available for selected series within defined technical limits. Details available upon request. Connection cable Temperature sensor Heating conductors Main hose Inner core Plug connection 41
Analytical heating hoses H 300 A series ® 350 °C Analytical sample gas lines with replaceable inner core and cable screw fitting. Application potential: Maintaining the temperature of probe lines for motor exhaust, CO2- measurements, industrial exhaust gasses, blast furnace exhaust gasses, air testing, etc. The core of this heating hose runs uninterrupted and unrestricted from the extraction point to the analysis unit. Threaded cable fittings on both ends simplify assembly on housings. This version permits quick on-site replacement of the inner core if the inside walls are contaminated. Operating temperature 100 °C / 200 °C / 250 °C / 350 °C Rated voltage Rated power Inner core DN 4 – 12 mm Heating Thermal insulation 230 V AC/DC (other voltages up to 500 V) Watt/metre, see type codes up to 250 °C PTFE or PFA above 250 °C stainless steel - see Inner cores analytics 100 mm protruding on both sides seamless heating conductor, structure according to DIN, moisture-proof with PE conductor; > 250 °C not moisture-proof depending on the operating temperature heat stabilized, close-pore silicone foam or thermal fleece, elastomer foam Outer protective braiding polyamide black, options - see outer protection End of hose KV screw connector Strain relief from cable screw fitting, bore hole Ø 42 mm DN 4 – 6 bore hole Ø 52 mm DN 8 – 12 bore hole Ø 65 mm DN 16 Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT 100 and inte- gral control system (HTI) possible Connection cable 3 m Plug connection according to specification Production lengths up to 50 m Protection type IP44 (EN 60529), protection class I Tolerance Operating temperature ±10 °C Temperature control using our controllers, in chapter Control technology. Extended applications are possible with special equipment. Diffusion proof on special request. Temperature sensor Thermal insulation Inner core Support hose Heating conductors Outer protective braiding (polyamide) Connection cable Cable screw fitting Inner core (replaceable) Plug connection 42
® Analytical heating hoses H 300 B series 120 °C Analytical sample gas lines, cut to size with PTFE inner core, available on reels of by the metre For user assembly on the construction site: H 300 B heating hoses are available as meter goods up to a length of 150 m. This makes it possible for the customer to determine hose lengths for themself "from the roll". In combination with our H 300 B-K assembly set, the end connections can be fitted on-site. Heating tapes are used for heating. The H 300 B heating hoses with HBR semiconductor heating tapes limit their power on heating. The temperature attained depends on the environ- mental conditions. A temperature controller may be required, depending on the application, as too high temperatures destroy the semiconductor layer. If temperature differences occur along sections of routed heating hoses, the heating power adapts to the environmental temperature from section to section. This ensures uniform heating overall. Operating temperature depending on the selection of heating tape Data relate to an outside temperature of approx. +10 °C - see table below Rated voltage Inner core DN 4 – 12 mm 230 V AC (other voltages on request) PFA, PTFE or stainless steel - see Inner cores analytics, Option: replaceable core Connection fitting cores protruding, seamless Thermal insulation Outer protection Hose end caps thermally stabilised, close-pore foam or thermal fleece PA corrugated hose PA hard cap or elastomer cap separate assembly set optional Temperature sensor Fe-CuNi, PT 100 or HTI optional Outer diameter 42 mm, ±10 % Production lengths up to 150 m - see table below Protection type IP44 (EN 60529), protection class I H 300 B-K assembly set end connection Option Technical data H 300 B Analytical lines at +10 °C outer temperature and 16 A fuse protection: Watt/m can be cut to size at intervals of Holding temp. max. heating circuit length Self-limiting heating tape HBR reduced power on heating 10 17 25 31 45 60 can be cut to size for each length 35 °C 40 °C 50 °C 60 °C 95 °C 120 °C 150 m 148 m 118 m 92 m 66 m 38 m Core protruding Hose end cap Outer protection (PA corrugated hose) Thermal insulation Braiding Connection cable Core Plug connection Heating band 43
Analytical heating hoses H 300 C series ® 250 °C Analytical sample gas lines with replaceable PTFE inner core and screwed fitting Application potential: Maintaining the temperature of probe lines for motor exhaust, CO2 measurements, industrial exhaust gasses, blast furnace exhaust gas- ses, air testing, etc. The special fittings made of 1.4571 steel prevent the movement or kinking of the PTFE core at the end of the analysis heating hose. A clamping ring fitting can be attached. Strain relief is accomplished by way of the outer braid. Operating temperature max. 100 °C, 200 °C, 250 °C Rated voltage Rated power Inner core DN 4 – 12mm Connection fitting Heating Thermal insulation Outer protective braiding Hose end caps Temperature sensor Connection cable Plug connection Production lengths Ingress protection Tolerance 230 V AC/DC (other voltages up to 500 V) Watt/metre, see type codes PFA or PTFE. see Inner cores Analytical RSL special fitting 1.4571 stainless steel, screwed without transition heating conductor, structure according to DIN, moisture-proof with PE conduc- tor heat stabilized, closed-pore silicone foam, thermal fleece or elastomer foam polyamide black, options - see Outer protection PA hard cap or elastomer cap Fe-CuNi type J, NiCr-Ni type K, PT 100 and integral control system (HTI) possible 3 m according to specification up to 100 m IP44 (EN 60529), protection class I Operating temperature ±10 °C Temperature control using our controllers, in chapter Control technology. RSL screwed RSL Pipe connection for cutting ring screw DN RSL L (mm) d (mm) 4 6 8 10 12 25 25 26 26 28 6 8 10 12 15 Screwed connection fitting (pipe connection) Hose end cap Outer protective braiding (polyamide) Thermal insulation Connection cable Temperature sensor Heating conductors Support hose Inner core replaceable Plug connection 44
® Analytical heating hoses HAF series 200 °C Heating hose with integrated filter Application potential: Portable measuring instruments, TÜV (technical inspection agencies) application. Analytical heating hoses with integrated filter are an advanced develop- ment of the previous separated systems of heated hose and heated filter section. This version was preferentially designed for use with portable measuring instruments. For this purpose, special importance was placed on a light and flexible construction. The version shown is designed for this application. HAF specification Test gas pipes (PTFE core DN 2 or DN 4) and control lines can be built into this system as options. The filter housing is made of 1.4571 steel. Versions in Hasteloy or with PTFE coating are also possible. The heating hoses can be connected to all our controller types (see chapter Control technology). Our HTI integral system is preferred. Temperature measure- ment is performed on the filter housing for all other control systems. For general use, the filter housing can be adapted to other filter dimen- sions, other hose diameters and hose lengths so that this new develop- ment can be matched to all our existing analytical heating hose systems and covers the complete range of analytical technology. Filter cartridge D 30 / 15 x 80 mm Inner core PTFE: Nominal diameter fixed replaceable 8 6 4 X X X X Option 2 quick coupling Hexagonal nut wrench size 17 mm Viton sealing ring Stainless steel sealing cap with round thread Filter housing Heating element Thermal insulation Heating hose ¼" connection thread measurement input or quick coupling PTFE seal Filter Outer body Strain relief 45
Analytical heating hoses HMI series ® 200 °C Mini heating hose Applications: In analytical technology for portable measuring systems; connection hoses in medical technology in all application areas; for maintaining the heat of a medium. The HMI mini heating hoses are a miniaturized version of our standard H300 hose series. The structure is similar, only less thermal insulation is used. Operating temperature max. 200 °C Rated power Rated voltage Main hose type individually adaptable low voltage and mains voltage PTFE cores, silicone-Viton hoses, capillaries made of stainless steel and copper, plastic hoses made of PA/PP/PE/PVC/... Outer diameter min. 20 mm possible Available execution self-limiting, with in-built (customer-specific) sensor. with connection to an HTI integral con- troller Depending on the application, the outer jacket consists of an SI hose, red-brown/black or a closed PA corrugated hose. The end connections are silicone moulded parts and tapered or cast shapes. SIM series 150 °C Clip attachment trace heater for heating thin pipes and hoses This trace heater for thin steel and copper pipes, as well as for hoses, consists of a silicone profile with parallel heating elements. The slotted shape enables pre-installed pipe systems, e.g. in analytical cabinets, to be heated without having to dismantle them. This saves considerable assembly costs. The version presently available covers piping from 4 - 12 mm OD. The lengths and power ratings are flexibly adapted to customer require- ments. The tracer heaters are therefore very easy to replace. Operating temperature -20 °C to +150 °C Rated voltage Rated power Heating 12 - 230 V AC/DC depending on configuration 50 - 100 W/m heating conductor, structure according to DIN, moisture-proof with protective braiding Thermal insulation heat-stabilised closed-pore silicone hose Outer protection silicone profile smooth End caps PA hard cap single ended Temperature sensor PT100 chip Connection cable Plug connection 1.5 m according to specification Production lengths max. 5 m Protection type up to IP54 (EN 60529), protection class I 46
® Analytical heating hoses Heated hose junctions 200 °C If you have an unheated fitting and need to keep your medium at the right temperature, then our HIH heating sleeve is the right solution. Application potential: Interconnection of heating hoses, connection of heating hose system, feeders in the heating hose system, or as an adapter between different fittings. HIH heating sleeve Operating temperature 200 °C, maximum Rated voltage Power rating 230 V AC/DC (other voltages 12 to 500 V) Sleeve Ø 22 mm = 12 W Sleeve Ø 40 mm = 24 W The rated power is designed so that heating hoses are set to operating temperatures of up to 200 °C and the temperature in the connector component does not drop. For this reason, in the majority of cases HIH does not need any controller, although it can be fitted with one if required. Type HIH – 08 HIH – 16 Inner Ø Heated length Total length 22 mm 40 mm 70 mm 90 mm 96 mm 120 mm For special applications, the sleeves can be provided with outlets. These permits special feeder types. Other dimensions are available. HI insulation sleeve without heating Type HI – 08 HI – 16 Temperature Inner Ø Total length 200 °C 200 °C 22 mm 40 mm 70 mm 90 mm with loop fastening Other dimensions are available. Hot box Housing with integrated heater for loss-free thermal connection to analysis lines made with robust metal casing. Operating temperature max. 250 °C Rated voltage Power rating Dimensions Insulation 230 V AC/DC (other voltages 12 to 500 V) adapted to design requirements adapted to design requirements 10 mm silicone foam Temperature sensor Connection cable optional 3 m Temperature regulators see chapter Control technology 47
Analytical heating hoses Airtherm air heater ® 100 °C Air heater with highly flexible connection hose The Airtherm air heater was specially designed for heating compressed air. The air in the connection heat is heated, which is equipped with a ceramic heating element and the appropriate sensor. The feed con- nection is via a highly flexible line in which both compressed air and also the electrical connection are integrated. The air and electrics are separated in a connector housing. Airtherm air heater system Components Operating temperature Connection thread 20 to 100 °C G ¼ Manufacturing lengths of the compressed air line 2.5 m, 5.0 m, 7.5 m, 10 m (special lengths on request) Heating cartridge – IP protection type Operating voltage Power rating Airtherm hose (hybrid round cable) Air pressure range IP 65 230 V AC 500 VA 1 – 8 bar Depending on requirements, the air temperature can be set up to max. 100 °C (measured at the pistol nozzle). The compact design permits easy integration into existing systems. Applications Painting technology: automatic paint spraying systems, painting robots, manual spraying, prevention of condensation Breathing air heating (protective wear): Chemical industry, tank cleaning General mechanical engineering For controll purposes, our HAT 85L control unit can be used with specialized air-management software (connection of two Airtherm units possible). 48
Heating cords Type HST ® 250 °C Moisture-proof heating cords of small diameter HST is a PTFE-insulated, inexpensive heating cord for heating pipes of small diameter, area etc. The connecting cables are PTFE insulated. The heating cord is moisture-proof and protective earthed (PE). Operating temperature max. 250 °C (integral controlled HTI 150 °C) Rated voltage 230 V AC/DC (special voltages possible) Minimum bending radius 4 mm Connection cable 1.5 m single-wires at both ends Diameter Ø 2.5 – 3.5 mm Protection type IP54 (EN 60529), protection class I PE conductor braiding copper nickel-plated, moisture-proof With a spacer tape the heating cord can be fixed in place for surfaces and cylindrical heating, see Accessories. Metres Watt Order no. 4.5 5.5 6.0 8.0 9.0 12.0 14.0 14.1 15.0 16.0 17.0 20.0 30.0 35.0 38.0 42.0 48.0 50.0 58.0 125 135 125 220 195 275 235 360 335 315 300 510 700 600 1000 900 790 1200 1400 HST/045 HST/055 HST/060 HST/080 HST/090 HST/120 HST/140 HST/141 HST/150 HST/160 HST/170 HST/200 HST/300 HST/350 HST/380 HST/420 HST/480 HST/500 HST/580 In addition to the listed lengths, larger and intermediate lengths are also available. Heating conductors PTFE / FEP PE conductor braiding (copper galvanised) 50
® Heating cords Type HS 450 °C Heating cord for tight winding radii Glass silk insulated heating cord. Very flexible, especially suitable for tight winding radii and concentrated power. The connecting cables are glass silk insulated. The heating cord has no PE conductor and is not moisture-proof Operating temperature max. 450 °C Rated voltage Minimum bending radius 230 V AC 4 mm Connection cable Diameter Protection type 1.5 m single-wires at both ends Ø 3 – 4 mm IP20 (EN 60529), protection class I PE conductor braiding none, not moisture-proof Type HSS 450 °C with additional PE conductor braiding. Construction is the same as type HS. Operating temperature max. 450 °C Rated voltage Minimum bending radius 230 V AC 6 mm Connection cable Diameter Protection type 1.5 m single-wire both ends Ø 3.5 – 4.5 mm IP20 (EN 60529), protection class I PE conductor braiding nickel, not moisture-proof Metres Watt Order no. 0.6 1.0 2.0 3.0 4.0 5.0 6.0 8.0 10.0 15.0 75 100 250 350 500 600 800 900 1250 1500 HS/006 HS/010 HS/020 HS/030 HS/040 HS/050 HS/060 HS/080 HS/100 HS/150 HSS/006 HSS/010 HSS/020 HSS/030 HSS/040 HSS/050 HSS/060 HSS/080 HSS/100 HSS/150 In addition to the listed lengths, longer lengths and powers, as well as intermediate lengths, are also available. Please state the length and power of the heating cord, as required. Temperature control using our controllers, in chapter Control technology. Heating conductors Glass yarn insulation Heating conductors Glass yarn insulation PE conductor braiding (nickel) 51
Heating cords Type HSQ ® 900 °C High temperature heating cord Quartz glass insulated heating cord for very high temperatures. It is very flexible and especially suitable for tight winding radii and concentrated power. The connecting cables are glass silk insulated. This heating cord has no PE conductor and is not moisture-proof. Operating temperature max. 900 °C Rated voltage Minimum bending radius 230 V AC 10 mm Connecting cables Diameter Protection type 1.5 m single-wire both ends Ø 3.5 – 4.5 mm IP20 (EN 60529), protection class O PE conductor braiding none, not moisture-proof Metres 1.0 2.1 3.0 4.0 5.0 6.0 Watt 170 370 500 700 850 1000 Order no. HSQ/010 HSQ/021 HSQ/030 HSQ/040 HSQ/050 HSQ/060 In addition to the listed lengths, longer lengths and powers, as well as intermediate lengths, are also available. Please state the length and power of the heating cord, as required. Temperature control using our controllers, in chapter Control technology. Heating conductor Quartz insulation 52
® Heating tape configuration sets for parallel and self-limiting heating tapes Sold by the metre Type HKS and HBR heating tapes Examples of configuration ex works Configuration ex works Self-configuration set KFE-80 KF-80 For heating tapes: HBR-ILLw and HKSP 20 up to max. 90 °C; configuration with 1.5 m connecting cable; (shrink fit technology) KFE-90 KF-90 For heating tapes: HBR-ILLw and HKSP 20 up to max. 90 °C; configuration for direct connection in junction box; (shrink fit technology) KFE-120 KF-120 For heating tapes: HBR-ILS and HBR-ILH up to max. 200 °C; configuration with 1.5 m connecting cable; (shrink fit technology) KFE-180 KF-180 For heating tapes: HKSI 70 NI and HKSI 40 up to max. 200 °C; configuration with 1.5 m connecting cable; (silicone adhesion technology incl. 25 g silicone tube) KFE-190 KF-190 For heating tapes: HKSI 70 NI and HKSI 40 up to max. 200 °C; configuration for direct connection in junction box; (silicone adhesion technology incl. 25 g silicone tube) KFE-130 KF-130 For heating tapes HBR-ILLw, HBR-ILH and HKSP 20 up to max. 130 °C Screw connection technology; protection type IP65, terminal cross section 2.5 mm2,, connector length 125 mm, termination length 58 mm. Also suitable for HBR-ILS, HKSI-40 and HKSI70 if connection is installed out- side the insulation, with 1.5 m connecting cable 53
Parallel heating tapes Type HKSI 70 Ni ® 150 °C High-Tech-Integral; HTI heating tape with the heating conductor as sensor / on a reel With HTI parallel heating tape, the entire length of the heating tape is used for temperature measurement with the (integral) HTI controller, so even temperature measurement over the entire length is achieved. Further advantage: The parallel heating tape can be cut to size in-situ and can be specifically adapted to the existing system on installation. Holding temperature Rated voltage Rated power at 20 °C Rated power at 150 °C Surface temperature Heating circuit length Contact clearance Minimum bending radius 150 °C depending on the insulation thick- ness on the pipe max. 230 V AC approx. 70 W/m approx. 30 W/m max. 200 °C max. 60 m 2 m 50 mm Outer dimensions approx. 8 x 11 mm (oval) Outer jacket Protection type FEP IP65 (EN 60529), protection class I PE conductor braiding yes Heating tape connection, see Configuration sets Temperature control using our HTI integral controller, in chapter Control technology. Outer connector (Cu strands 2 mm2) Silicone insulation PE conductor braiding Heating coil Silicone insulation FEP outer jacket Contact clearance HKSI 70 NI / 2 m contact clearance 54
® Parallel heating tapes Type HKSP 20 Type HKSI 40 60 °C 120 °C Parallel heating tape by the metre for self-configuration / on a reel The HKS heating tapes were specially developed for heating industrial plants, gutters, pipes, tanks and for similar uses outdoors and in damp rooms. They can be supplied by the metre, so the tape can be routed in-situ, as required, and can be configured ready for connection using an addi- tionally available configuration set. On request, the quoted length can be supplied ex works configured ready for connection. Holding temperature approx. 60 °C depending on the insulation thickness on the pipe HKSP 20 Rated voltage Power rating 230 V AC approx. 20 W/m Surface temperature Heating circuit length max. 90 °C max. 150 m Contact clearance 0.7 m Minimum bending radius 50 mm Outer dimensions approx. 8 x 11 mm (oval) Outer jacket Protection type PVC IP65 (EN 60529), protection class I PE conductor braiding yes Holding temperature approx. 120 °C depending on the insulation thickness on the pipe HKSI 40 Rated voltage Power rating 230 V AC approx. 40 W/m Surface temperature Heating circuit length max. 200 °C max. 100 m Contact clearance 0.6 m Minimum bending radius 50 mm Outer dimensions approx. 7 x 10 mm (oval) Outer jacket Protection type FEP IP65 (EN 60529), protection class I PE conductor braiding yes Heating tape connection, see Configuration sets HKSP / 0.7 m contact clearance HKSP 20 Outer connector (Cu strands 2 mm2) PVC outer jacket PVC insulation Silicone insulation Heating coil PE conductor braiding HKSI 40 Outer connector (Cu strands 2 mm2) FEP outer jacket Silicone insulation Silicone insulation Heating coil PE conductor braiding HKSI / 0.6 m contact clearance 55
Parallel heating tapes ® Type HBR-ILLw / ILH / ILS 120 °C Self-limiting heating tape / on a reel reduced power on heating The HBR self-limiting heating tapes regulate their heating power according to the respective temperature level, so that after attaining the final temperature it is maintained. If temperature differences arise between sections, the heating power adapts from section to section. This ensures uniform heating. The tapes can be laid overlapping; this is especially suitable for uneven surfaces, such as on pumps, valves and branches. HBR heating tape is sold by the metre with the appropriate heating tape connector, see Configuration sets for individual adaptation of the length in situ or the available preconfigured length ex works. Heating tape versions Max. permissible temperature Outer jacket Rated voltage ILLw ILH ILS ILLw ILH ILS 85 °C / 85 °C switched off 200 °C / 225 °C switched off 220 °C / 250 °C switched off Polyolefin (CT) Fluoropolymer (CF) PTFE (NF) 230 V AC / other voltages on request Minimum bending radius 35 mm Protection type IP 65 (EN 60529), protection class I Heating tape technical data Type Temp.* Watt/m** Heating circuit length* Outer dimensions Width x thickness (mm) HBR-ILLw-10 HBR-ILLw-17 HBR-ILLw-25 HBR-ILLw-31 HBR-ILH-45 40 °C 50 °C 55 °C 60 °C 95 °C 10 17 25 31 45 60 188 m 134 m 108 m 84 m 64 m 30 m 12.95 x 5.95 12.95 x 5.95 12.95 x 5.95 12.95 x 5.95 11.45 x 5.25 12.1 x 5.4 W/m I L L w 3 1 IL L w 2 5 ILLw17 ILLw10 40 35 30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 85 HBR-ILS-60 120 °C Pipe temperature in °C W/m** 60 ILH / ILS ILS60 ILH45 50 40 30 20 10 0 20 40 60 80 100 120 140 Pipe temperature in °C 56 * at +0 °C outside temperature, 16 A fuse protection, approx. hold- ing temperature depending on mounting position, insulation thick- ness and outside temperature on the pipe. ** Rated output power at 230 V AC if the heating tape is installed on insulated metal pipes. Insulation thermoplastic elastomer copper conductor 2 x 1.1 mm2 Self-limiting heating element PE conductor braiding Outer covering
® Heating tapes Type HSTD 250 °C Narrow version heating tape With this very narrow heating tape, two PTFE insulated heating conductors with a PE conductor are wrapped in a common braiding and resistant to splashing water. Operating temperature max. 250 °C / HTI max. 150 °C Rated voltage Power rating 230 V AC/DC (special voltages possible) approx. 50 W/m Minimum bending radius 6 mm Outer dimensions approx. 4 x 9 mm (thickness x width) Outer jacket Connection Protection type braiding, copper galvanised 1.0 m cable at one end IP 54 (excluding connection area; EN 60529), protection class I Option Sensor integrated in tape For temperature control, we can recommend our HTI integral control, which is controllable without a sensor via the heating conductor. Further information, see chapter Control technology. Metres 0.5 1.0 1.5 2.5 4.0 6.0 8.0 10.0 15.0 20.0 Watt 30 50 90 150 220 275 400 500 700 1100 Order no. HSTD/005 HSTD/010 HSTD/015 HSTD/025 HSTD/040 HSTD/060 HSTD/080 HSTD/100 HSTD/150 HSTD/200 In addition to the listed lengths, larger and intermediate lengths are also available. Heating conductors PTFE PE conductor braiding (copper galvanised) 57
Heating tapes Type HSTP ® 250 °C Heating tape with high performance With this narrow heating tape, two PTFE insulated heating conductors are wrapped in a common braiding and resistance to splashing water. Due to the high performance large pipes and containers can be heated with relatively short heating tapes. Operating temperature max. 250 °C / HTI max. 150 °C Rated voltage Power rating 230 V AC/DC (special voltages possible) approx. 200 W/m, 300 W/m Minimum bending radius 30 mm Outer dimensions approx. 6 x 20 mm (thickness x width) Outer jacket Connection Protection type braiding, copper galvanised 1.0 m cable at one end IP 44 (excluding connection area; EN 60529), protection class I Option Sensor integrated in tape For temperature control, we can recommend our HTI integral control, which is controllable without a sensor via the heating conductor. Further information, see chapter Control technology. Metres 1.2 1.8 2.7 4.0 6.0 9.0 11.0 15.0 21.0 Metres 1.5 2.3 3.3 5.0 7.5 9.0 12.0 17.0 Watt 250 370 580 820 1250 1900 2400 2700 4200 Watt 440 680 1000 1500 2350 3000 3400 5000 Order no. HSTP/200012 HSTP/200018 HSTP/200027 HSTP/200040 HSTP/200060 HSTP/200090 HSTP/200110 HSTP/200150 HSTP/200210 Order no. HSTP/300015 HSTP/300023 HSTP/300033 HSTP/300050 HSTP/300075 HSTP/300090 HSTP/300120 HSTP/300170 In addition to the listed lengths, larger and intermediate lengths are also available. 58 Heating conductor PTFE PE conductor braiding (copper galvanised)
® Heating tapes Type HSTDD 250 °C Wide version heating tape With this heating tape, four PTFE insulated heating conductors are laid parallel with the PE conductor and are wrapped in common Cu braiding and are resistant to splashing water. This structure makes the heating strip very flexible and the outer braiding ensures very good heat transfer to the pipe or container to be heated. Operating temperature max. 250 °C / HTI max. 150 °C Rated voltage Power rating 230 V AC/DC (special voltages possible) approx. 100 W/m Minimum bending radius 10 mm Outer dimensions 4 x 20 mm (thickness x width) Outer jacket Connection Protection type braiding, copper galvanised 1.0 m cable at one end IP 54 (excluding connection area; EN 60529), protection class I Option Sensor integrated in tape For temperature control, we can recommend our HTI integral control, which is controllable without a sensor via the heating conductor. Further information, see chapter Control technology. Metres 0.5 1.0 1.5 3.0 4.0 6.0 8.0 10.0 15.0 20.0 Watt 50 100 125 275 420 430 660 1100 1250 1740 Order no. HSTDD/005 HSTDD/010 HSTDD/015 HSTDD/030 HSTDD/040 HSTDD/060 HSTDD/080 HSTDD/100 HSTDD/150 HSTDD/200 In addition to the listed lengths, larger and intermediate lengths are also available. Heating conductor PTFE PE conductor braiding (copper galvanised) 59
Heating tapes Type HBS Type HB ® 350 °C / 450 °C High temperature heating tape with glass fabric Only suitable for a dry environment, very flexible version. Multiple glass silk insulated with additional PE conductor above the heating conductor. One-ended connection. For diverse use in the lab, technical education institutions and industry, not moisture-proof. The HB version has no PE conductor. This makes it even thinner and more supple than the HBS series. HBS Operating temperature Rated voltage Power rating max. 450 °C max. 350 °C up to 7.0 m from 10.0 m 230 V AC/DC approx. 250 W/m PE conductor braiding Outer dimensions approx. 5.5 x 30 mm (thickness x width) Minimum bending radius 10 mm Glass fabric Outer jacket Glass fabric Heating conductors Glass yarn insulation Heating conductor Glass yarn insulation Glass fabric 60 Connection cable Protection type 0.5 m with connection box IP20 (EN 60529), protection class I PE conductor braiding Nickel HB Operating temperature Rated voltage Power rating max. 450 °C max. 350 °C up to 7.0 m from 10.0 m 230 V AC/DC approx. 250 W/m Minimum bending radius 6 mm Outer dimensions Outer jacket Connection cable Protection type approx. 3.5 x 30 mm (thickness x width) glass fabric 0.5 m with connection box IP20 (EN 60529), protection class I PE conductor braiding none Metres 0.5 1.0 1.5 2.0 2.5 3.0 4.0 5.0 7.0 10.0 15.0 Watt 100 250 350 500 600 800 900 1250 1550 2000 3000 Order no. HB/005 HB/010 HB/015 HB/020 HB/025 HB/030 HB/040 HB/050 HB/070 HB/100 HBS/005 HBS/010 HBS/015 HBS/020 HBS/025 HBS/030 HBS/040 HBS/050 HBS/070 HBS/100 HBS/150 Temperature control using our controllers, in chapter Control technology.
® Heating tapes Type HBQ 900 °C High temperature heating tape with quartz fabric Very flexible heating tape, with high temperature stability and high power concentration, not moisture-proof. The heating conductor is integrated in the quartz fabric and has no PE conductor. Operating temperature Rated voltage Power rating max. 900 °C 230 V AC approx. 350 W/m Minimum bending radius 10 mm Outer dimensions Outer jacket Connection cable Protection type approx. 5 x 30 mm (thickness x width) quartz fabric 1.0 m with connection box IP20 (EN 60529), protection class O PE conductor braiding none Metres 0.5 1.0 1.5 2.0 2.5 3.0 4.0 Watt 170 350 500 700 850 1000 1400 Order no. HBQ/005 HBQ/010 HBQ/015 HBQ/020 HBQ/025 HBQ/030 HBQ/040 Temperature control from our controllers, see chapter Control technology. Heating conductor Quartz insulation Quartz fabric 61
MI Heating cables Type HIL-SS ® 800 °C Heating cable with metal jacket stainless steel 1.4541 Applications: immersion heaters, tanks, valves, pump, mould, plate heaters. This mineral-insulated heating cable with a jacket of stainless steel 1.4541 can also be used in extremely corrosive and damp environments. The HIL heating cable is extremely robust and easy to bend. The stain- less steel jacket is watertight, oil-tight and gas-tight. Its deployment tem- perature up to 800 °C opens up a multitude of applications. The cold end of the heating cable can be fed into a terminal box and con- nected using a M20 X 1.5 screw connection. Operating temperature max. 800 °C Metres 100 Order no. Rated voltage 230 V AC Power rating Outer jacket 100 / 200 / 250 W/m stainless steel 1.4541 Length cold ends 0.5 m Protection type IP67 (EN 60529), protection class I PE conductor yes Temperature control in chapter Control technology. Watt/m 720 910 1150 1450 1800 2300 2900 3600 4600 5750 7.2 9.1 11.5 14.5 18.0 23.0 29.0 36.0 46.0 57.5 HIL-SS/10007 HIL-SS/10009 HIL-SS/10011 HIL-SS/10014 HIL-SS/10018 HIL-SS/10023 HIL-SS/10029 HIL-SS/10036 HIL-SS/10046 HIL-SS/10057 Ø mm Heating con. OD 3.2 3.2 3.2 3.6 3.8 4.1 4.5 5.0 5.6 6.5 Metres 200 Order no. Watt/m Ø mm Heating con. OD Heating conductors MgO 1.4541 Jacket 5.1 6.5 7.7 10.3 12.7 15.5 20.3 25.5 32.5 40.0 1020 1300 1540 2060 2540 3100 4060 5100 6500 8000 HIL-SS/20005 HIL-SS/20006 HIL-SS/20008 HIL-SS/20010 HIL-SS/20012 HIL-SS/20015 HIL-SS/20020 HIL-SS/20025 HIL-SS/20032 HIL-SS/20040 Also available in Ex Metres 250 Order no. Watt/m 4.6 7.3 9.2 12.0 14.0 18.0 23.0 29.0 1150 1825 2300 3000 3500 4500 5750 7250 HIL-SS/25004 HIL-SS/25007 HIL-SS/25009 HIL-SS/25012 HIL-SS/25014 HIL-SS/25018 HIL-SS/25023 HIL-SS/25029 3.2 3.2 3.2 3.6 3.8 4.1 4.5 5.0 5.6 6.5 Ø mm Heating con. OD 3.2 3.2 3.6 3.8 4.1 4.5 5.0 5.6 Heating conductor Bending radius Ω/m 10.0 6.3 4.0 2.5 1.6 1.0 0.63 0.4 0.25 0.16 > 15 > 15 > 15 > 15 > 15 > 20 > 20 > 30 > 30 > 30 Heating conductor Bending radius Ω/m 10.0 6.3 4.0 2.5 1.6 1.0 0.63 0.4 0.25 0.16 > 15 > 15 > 15 > 15 > 15 > 20 > 20 > 30 > 30 > 30 Heating conductor Bending radius Ω/m 10.0 4.0 2.5 1.6 1.0 0.63 0.40 0.25 > 15 > 15 > 15 > 15 > 15 > 20 > 20 > 30 62
® MI heating cables Type HIL-IC 1000 °C Heating cable with metal jacket Inconel 2.4816 Applications: radiation heaters, vacuum technology, immersion heaters, containers, valves, pumps, forms, process and plate heaters. This mineral-insulated heating cable with a jacket of Inconel 2.4816 can also be used in extremely corrosive and damp environments. The HIL heating cable is extremely robust and easy to bend. The Inconel jacket is watertight, oil-tight and gas-tight. It deployment temperature up to 1000 °C opens up a multitude of applications. The cold end of the heating cable can be fed into a terminal box and connected using a M20 X 1.5 screw connection. Metres 100 Order no. Watt/m Ø mm Heating con. OD 7.2 9.1 11.5 14.5 18.0 23.0 29.0 36.0 46.0 57.5 720 910 1150 1450 1800 2300 2900 3600 4600 5750 HIL-IC/10007 HIL-IC/10009 HIL-IC/10011 HIL-IC/10014 HIL-IC/10018 HIL-IC/10023 HIL-IC/10029 HIL-IC/10036 HIL-IC/10046 HIL-IC/10057 3.2 3.2 3.2 3.6 3.8 4.1 4.5 5.0 5.6 6.5 Metres 100 Order no. Watt/m Ø mm Heating con. OD 5.1 6.5 7.7 10.3 12.7 15.5 20.3 25.6 32.5 40.0 1020 1300 1540 2060 2540 3100 4060 5100 6500 8265 HIL-IC/20005 HIL-IC/20006 HIL-IC/20008 HIL-IC/20010 HIL-IC/20012 HIL-IC/20015 HIL-IC/20020 HIL-IC/20025 HIL-IC/20032 HIL-IC/20040 3.2 3.2 3.2 3.6 3.8 4.1 4.5 5.0 5.6 6.5 Metres 100 Order no. Watt/m Ø mm Heating con. OD 4.6 7.3 9.2 12.0 14.0 18.0 23.0 1150 1825 2300 3000 3500 4500 5750 HIL-IC/25004 HIL-IC/25007 HIL-IC/25009 HIL-IC/25012 HIL-IC/25014 HIL-IC/25018 HIL-IC/25023 3.2 3.2 3.6 3.8 4.1 4.5 5.0 Heating conductor Bending radius Ω/m 10.0 6.3 4.0 2.5 1.6 1.0 0.63 0.4 0.25 0.16 > 16 > 16 > 16 > 18 > 20 > 21 > 23 > 25 > 28 > 33 Heating conductor Bending radius Ω/m 10.0 6.3 4.0 2.5 1.6 1.0 0.63 0.4 0.25 0.16 > 16 > 16 > 16 > 18 > 20 > 21 > 23 > 25 > 28 > 33 Heating conductor Bending radius Ω/m 10.0 4.0 2.5 1.6 1.0 0.63 0.25 > 16 > 16 > 18 >20 > 21 > 23 > 25 Operating temperature max. 1000 °C Rated voltage 230 V AC Power rating Outer jacket 100 / 200 / 250 W/m Inconel 2.4816 Length cold ends 0.5 m Protection type IP67 (EN 60529), protection class I PE conductor yes Temperature control in chapter Control technology. Heating conductors MgO 2.4816 Jacket Also available in Ex 63
Practical examples ® Practical examples Heating cable length Cold end length Flexible strands approx. 150 mm Connector socket M20 screw connection approx. 500 mm 64
® Mounting accessories / tapes IP65 connection housing Both housings are provided with KV cable glands. Order no. Length x width x height HZ-G HZ-K 94 x 65 x 56 mm 94 x 94 x 56 mm Terminal 5 x 4 mm2 8 x 4 mm2 KSP Heat-stabilized plastic tie to secure heating cables and heating tapes up to 130 °C Order no. KSP/200 KSP/360 KSP/450 Length x width Delivery unit 200 mm x 4.8 mm 360 mm x 4.8 mm 450 mm x 7.8 mm 100 pcs. 100 pcs. 100 pcs. AB Spacer tape to fix HST heating conductors for area and cylindrical heating systems. Smallest layout spacing 15 mm Order no. Delivery unit AB/015 Sold by the metre ABF Spacer tape made of stainless steel 1.4301 for routing heating tapes and heating cables on tanks. The spacer tape can be attached by spot- welding or with straps. Order no. Delivery unit Routing spacing ABF/030 ABF/040 ABF/045 5 m 5 m 5 m 30 mm 40 mm 45 mm 65
Mounting accessories / tapes ® GKB up to 160 °C Adhesive tape. Glass fabric with acrylate adhesive (hardening) to attach heating tapes and temperature sensors. Order no. GKB/160 Width 15 mm Delivery unit 50 m roll GKB High-grade adhesive tape, glass fabric with silicone adhesive. up to 140 °C Order no. GKB/180 Width 19 mm Delivery unit 33 m roll GAB up to 160 °C Heavy duty aluminium foil tape with acrylate adhesive (hardening) to bond plastic insulating heating tapes, cables and conductors. The aluminium ensure very good heat distribution. Order no. GAB/160 Width x thickness Delivery unit 50 mm / 0.13 mm 50 m roll GAB up to 450 °C Thin, supple glass tape for binding and wrapping heating conductors. Order no. Width x thickness Delivery unit GB/25 GB/16 25 mm x 0.15 mm 16 mm x 0.15 mm 50 m roll 50 m roll GBB up to 500 °C Wide glass silk tape for bandaging heating conductors. Also suitable for thicker pipes and tanks. Order no. GBB/75 Width x thickness Delivery unit 70 mm x 0.7 mm 100 m roll GBW up to 450 °C Fleecy, around 3 mm thick glass fabric tape for insulating heated routes. Order no. GBW/25 Width x thickness Delivery unit 25 mm x 3 mm 30 m roll KSV up to 100 °C Simple to handle Velcro fasteners to bind and fix insulation sleeves on pipes. Order no. KSV/25 Width 25 mm Delivery unit 10 m Velcro, 2 m fleece KSV Velcro tape, Velcro one side, fleece the other (sold by the metre) up to 80 °C Order no. KSV/20 Width 20 mm Delivery unit Sold by the metre 66
® Mounting accessories / tapes SJ up to 250 °C Closed-pore, water-tight silicone foam hose to insulate pipes and hoses. Order no. SJ/15 SJ/20 SJ/25 SJ/30 SJ/40 SJ/50 Inner Ø 15 mm 20 mm 25 mm 30 mm 40 mm 50 mm SJ/80 80 mm Other dimensions on request Silicone foam mat Outer Ø 30 mm 40 mm 45 mm 50 mm 60 mm 80 mm 104 mm Length up to 25 m up to 25 m up to 25 m up to 25 m up to 25 m up to 20 m up to 20 m Order no. Thickness SJ/05 SJ/10 5 mm 10 mm Width 1000 mm 1000 mm AF Polymer foam hoses for insulation Order no. AF 18 AF 22 AF 28 AF 35 Inner Ø 18 mm 22 mm 28 mm 35 mm AF 42 42 mm Other dimensions on request Polymer foam mat Outer Ø 38 mm 42 mm 49 mm 57 mm 64 mm Order no. Thickness AF 13 AF 19 13 mm 19 mm Width 1000 mm 1000 mm up to 200 °C Length 1000 mm 1000 mm up to 150 °C Length 2 m piece 2 m piece 2 m piece 2 m piece 2 m piece up to 150 °C Length up to 11 m up to 7 m MG Needle-punched fibreglass mat for insulating pipes and tanks. up to 550 °C Order no. MG/12 Width 1000 mm Thickness 12 mm Length per metre MQ + 1000 up to 1000 °C High-grade flexible ceramic fibre mat for insulating in the temperature range up to 1000 °C. Order no. MQ/10 Width 1000 mm Thickness 13 mm Length per metre 67
Mounting accessories / tapes ® GS Glass fabric hoses to insulate electrical conductors. (sold by the meter) max. 450 °C GSH GSI with outer coating silicone max. 250 °C Order no. Order no. GSH/03 GSH/06 GSH/08 GSH/12 GSI/04 GSI/06 GSI/08 GSI/12 Inner Ø 4 mm 6 mm 8 mm 12 mm GSK High-grade quartz fabric hoses to insulate electrical conductors. up to max. 900 °C Order no. GSK/04 GSK/30 Inner Ø 4 mm 30 mm Delivery unit 10 m 5 m FIL up to 260 °C Connection wires of Cu-nickel with PTFE insulation for wiring in different colours. Order no. Cross section Delivery unit FIL/075 FIL/150 FIL/250 0.75 mm2 1.50 mm2 2.50 mm2 10 m 10 m 10 m KF-SILT 25 Tube of silicone adhesive 25 g Silicone adhesive in tubes to produce self-configuration connections for HKSI heating tapes (silicone adhesive technology). You need 10 to 15 g of adhesive per heating tape. KF-SILT 85 Tube of silicone adhesive 85 g AA Porcelain terminals, for use up to 250 °C. Cross section Delivery unit 1 x 2.5 mm2 2 x 2.5 mm2 3 x 2.5 mm2 4 x 2.5 mm2 10 pcs. 10 pcs. 10 pcs. 10 pcs. Spring terminals / mounting rails Description Spring terminal, 4 mm2, grey Spring terminal, 4 mm2, blue Spring terminal, 4 mm2, gr-ye End plate, 4 mm2, grey Mounting rail, 35 mm End bracket for mounting rail Residual current circuit breaker (RCD) For permanent connection to equipment or extension cables, all-pole disconnection, plug in accordance with DIN VDE 0661. Technical data Rated tripping current 30 mA (residual current) Undervoltage trip 16 A, 230 V ~ IP44 Housing dimensions B 50 x H 130 x T 45 mm 68
® Mounting accessories / tapes Thermoswitch For the simplest control tasks and temperature monitoring. Technical data Switching power max. 10 A (2300 W) Switching frequency approx. 10000 switching cycles Switch-off point ±5 K to rated switching temperature Re-switch-on point approx. 30 ±15 K below the switching off point Rated switching temper- ature 80 °C / 100 °C / 120 °C / 140 °C / 160 °C / 200 °C Thermocouple flat sensor with 1.5 m long silicone-insulated compensating cable Order no. Sensor type Max. temperature HT/FF HT/NF Fe-CuNi (J) NiCr-Ni (K) 450 °C 450 °C Thermocouple rod sensor Mineral-insulated, sensor tip bendable, for soldering-in, preferably for use at high temperatures, in fluids and aggressive atmospheres, dia- meter 1.5 mm, length 250 mm, silicone-insulated, 2 m long, compen- sating cable Order no. Sensor type Max. temperature Jacket material HT/FM HT/NM Fe-CuNi (J) NiCr-Ni (K) 600 °C 1000 °C 1.4571 2.4816 (Inconel) PT100 sensor Also available in Ex version +250 °C +250 °C, +350 °C +500 °C Jacket material 1.4571 Jacket material 1.4571 Jacket material 1.4571 Diameter 4 mm Diameter 4 mm Diameter 5 mm Length 30 mm Length 40 mm Length 40 mm PTFE insulated PTFE/glass insulated Glass silk insulated 2 m long conductor 2 m long conductor 0.5 m long conductor Order no. HTI/VA Order no. HTI/PM HTI/PH Order no. HTI/PT Compensating cables For extending the connecting cables for the thermoelements above. Structure: Silicone / silicone-insulated, 2 x 0.25 mm2, diameter 5 mm Order no. Sensor type Max. temperature AG/F AG/N Fe-CuNi (J) NiCr-Ni (K) 200 °C 200 °C Self-adhesive sign Electrically heated 50 x 200 mm 69
Surface heating elements Aluminium electrical heating plates Type HAP ® 250 °C Aluminium electric heating plate Applications Heating of parts and moulds, wood and paper industry, automobile industry, mould-making, plastics industry, bookbinding. The HAP aluminium heating plates cover a temperature range up to 250 °C and can handle extreme pressure loads and are impact resist- ant. Their shapes can be individually fabricated – whether round, oval or L-shaped. Special designs with cut-outs, bore holes and bolt threads can be manu factured. Even combinations with liquid and air channels for cooling can be implemented. Operating temperature max. 250 °C Rated voltage Rated power Heating plate material up to 500 V AC/DC (1 – 3 phases) up to 10 kW/m2 Aluminium (AlMg3 EN-AW-5754) (AIMg4.5 EN 573-3) Dimensions up to 1450 x 2400 mm Heating plate thickness 10 – 20 mm, special dimensions possible Weight Surface for thickness: 10 mm approx. 26 kg/m2 rolled aluminium, finely milled etc. Pressure rating 80 N/mm2 Expansion 0.24 mm 1°K / over 1000 mm length Temperature sensor PT100 / Fe-CuNi (J) Connection cable 1.5 m long, with or without plug Plug connection Protection type optional IP40 - IP65 (EN 60529), depending on heating conductor, protection class I Temperature control from our temperature controllers Option insulation plate silicone, silicate, Pertinax, PTFE Optional cooling plate on request We manufacture special designs of our heating plates to customer requirements, for example: • Aluminium heating plates for heating electronic components, to reduce soldering times • Aluminium heating plates to heat CDs and solar cells during manu- facture and final inspection • Aluminium heating plates for pressing in the wood and paper industry for laminates and hot adhesives • Aluminium heating plates for moulding PU foam and GRP prefabricated components • Aluminium heating plates for catering requirements, keeping food and drinks warm • Heating and cooling plates with pipe system for heat transfer fluids, also for use in Ex areas (separate temperature regulating unit necessary) Self-limiting HAP aluminium heating plates holding temperatures approx. 80 °C, 60 °C, 40 °C with +10 °C ambient temperature. For use without controller. 72
® Surface heating elements Heating and cooling tables Type HA-HT / HA-HKT / HA-SHT 100 °C Heating/cooling table Applications Form-making, automobile construction, wood and paper industry, book binderies, plastics industry. Various materials, such as plastics and metals can be kept or heated to an even temperature on the mobile heating/cooling table. The tempera- ture of the aluminium heating plate is continuously adjustable up to 100 °C using an built-in electronic controller. The special HTI16 integral controller detects temperature across the entire surface of the heat plate, thereby ensuring a much more uniform surface temperature than would be possible with conventional sensor control. Optionally, the heating table can be equipped with an additional built-in cooling plate. This feature permits cooling processes to be accelerated with liquids or even compressed air. This feature requires a separate cooling unit or compressed air source (provided by customer). Operating temperature max. 100 °C Rated voltage 230 V AC Heating plate material Aluminium (AlMg3 EN-AW-5754) (AIMg4.5 EN 573-3) Height Pressure rating Connection cable Protection type Frame colours approx. 90 cm up to 400 kg 3.5 m long with German "Schuko" mains plug with integrated fault current circuit breaker IP54 (EN 60529), protection class I green RAL 6011, light grey RAL 7035, red RAL 3003, blue RAL 5007 Temperature control HTI 16 on the heating table The heating table is available in four sizes (other sizes on request) Type L x W mm Power Area Type with cooling plate Load capacity HA-HT-1 approx. 900 x 550 HA-HT-2 approx. 1050 x 750 HA-HT-3 approx. 1250 x 850 HA-HT-4 approx. 1550 x 850 1200 Watt 0.47 m2 HA-HKT-1 375 kg 1800 Watt 0.79 m2 HA-HKT-2 365 kg 2800 Watt 1.06 m2 HA-HKT-3 350 kg 3400 Watt 1.31 m2 HA-HKT-4 340 kg Warm-up time from +20 °C to 100 °C, approx. 45 - 60 minutes Option: The HTI controller can be supplied with an additional controller module and with a separate sensor (PT100), which serves for tempera- ture monitoring of the applied component. This avoids overheating of the component on the table. Special sizes, heavy duty version or higher temperatures on request. HTI 16 Integral temperature controller HA-SHT Heavy-duty heating table 73
Surface heating elements Heating tarpaulin Type HP 60 ® 80 °C Robust heater tarpaulin for large surfaces Applications Heating or temperature regulation of large surfaces and containers up to 80 °C, e.g. IBC containers, silos, lorries. The heater tarpaulin is heated with electric heater elements sealed in coated polyester fabric. The tarpaulin surface is washable and spray waterproof. The heating tarpaulin has a 5 mm thick foam thermal insulation. The shape of the HP 60 heater tarpaulin can be individually adapted to container sizes; this includes both round and square openings. Options for fastening, by way of hooks, eyes and Velcro, make attachment easy. The HP 60 heater tarpaulin is rated to produce up to 500 Watt of heat per m²; depending on ambient temperature, this ensures a short warm-up time for the tarpaulin. Operating temperature max. 80 °C Rated voltage up to 500 V AC/DC (one, two, or three phase) Rated power up to 500 W/m2 Min. ambient temperature -20 °C, installation temp. min. +5 °C Material Dimensions polyester fabric with PVC coating max. 5 x 10 m Heater element thickness ca. 10 mm, with 5 mm insulation foam Fastening options Temperature sensor Connection cable Plug connection Protection type hooks, eyes, Velcro PT100 / HTI control 3.0 m optional IP44 (EN 60529), protection class I Sensors can be placed either in or on the heater tarpaulin to monitor or control temperature. Especially effective is our HTP 16 integral electronic controller/monitor combination which allows the tarpaulin's heating conductors to also act as probes; thus the heater tarpaulin's limit temperature can be monitored while simultaneously regulating the temperature of the medium in the container precisely with a separate PT100 sensor. Heating tarpaulins for IBC containers Heating tarpaulins for tanks 74
® Surface heating elements Heating mats Type HSI 200 °C Flexible silicone heating mats Applications Heating of complicated surfaces, parts and moulds. The silicone heating elements are characterised by their very uniform heat distribution. They are very flexible and are available in different designs. As mats or shaped parts, they are used as an economical solution in countless applications. The HSI silicone heating mats are always manufactured specifically for the respective applications. Operating temperature Rated voltage Rated power max. 200 °C 230 V AC/DC 6500 W/m2 (standard) and more Minimum ambient tempera- ture -60 °C Material Dimensions silicone, silicone-coated textile glass fabric max. 3.0 x 1.2 m Heater element thickness approx. 3 mm without mains cable Fastening options Temperature sensor adhesives, binding, hooks, eyes, Velcro, self-adhesive coating vulcanised or in sensor pocket PT100, FeCuNi Over-temperature protection with 2nd PT100 or thermoswitch (option) Connection cable Plug connection Protection type various connection technologies possible according to specification IP4x (EN 60529), protection class II or III Temperature control using our controllers, in chapter Control technology. 75
Surface heating elements Heating mats ® HM series The HM heating mats are very flexible so they can not only be used on flat surfaces, but also on cylindrical tanks and pipes. A NiCr-Ni sensor is incorporated in each mat for temperature control. The temperature- stable connecting wires have a length of 1 m. up to 250 °C Type HMST This heating mat is reinforced with a PTFE lattice. The heating conduc- tors are PTFE insulated and have PE conductor braiding. The maximum operating temperature is 250 °C. The heating mat can be stretched over tanks and pipes with Velcro fastenings (accessories). Type HMSG up to 450 °C HMSG is a very flexible heating mat made of textile glass fabric with a maximum operating temperature of 450 °C. The fibreglass insulated heating conductor is incorporated in textile glass fabric on both sides. The heating mats have longitudinal eyes with which they can be fastened with fibreglass fabric tape (accessory). Type HMSQ up to 900 °C This flexible heating mat made of quartz garn has a maximum operating temperature of 900 °C. It is fastened to pipes or tanks with high tem- perature stable cords (accessory). Standard heating mats Technical data Width (mm) Length (mm) HMST Power HMSG Power HMSQ Power 135 236 355 515 659 820 500 500 500 500 500 500 50 W 150 W 250 W 350 W 500 W 690 W 250 W 500 W 1000 W 1200 W 1600 W 2000 W 500 W 1000 W 2000 W 2400 W 3200 W Special dimensions and power ratings available 76
® Surface heating elements Heating mats Type HMG up to 250 °C This heating mat is reinforced with a metal lattice. The heating conduc- tors are PTFE insulated and have PE conductor braiding. The maximum operating temperature is 250 °C. The heating mat can be stretched over tanks and pipes with Velcro fastenings (accessory). Operating temperature max. 250 °C Rated voltage Rated power up to 500 V AC/DC (one, two, or three phase) up to 2000 W/m2 Min. ambient temperature -40 °C Design Dimensions PTFE heating conductor on VA lattice or galvanised lattice max. 1000 x 5000 mm / Lattice separation 10 x 10 mm Heater element thickness approx. 5 mm Temperature sensor PT100 (Optional: NiCr-Ni, Fe-CuNi, HTI) Connection cable Plug connection Protection type Thermal insulation (optional) 1.5 m optional IP54 (EN 60529), protection class I Polymer foam (150 °C), Silicon foam (200 °C) The HMG heating mat can also be used as an underfloor heating system. HGM lattice mat incorporated in a housing to heat a distributor with a geometrically difficult surface. 77
Surface heating elements Heating sleeves Type HMM ® 250 °C Hinged heating sleeves with metal jacket The HMM heating sleeve is a complete heating element consisting of heating, thermal insulation and closed outer metal jacket. The metal jacket encloses all edges and the inside surface of the sleeve, which consists of two half shells. One side has a hinge, on the other side there are adjustable turnbuckles. This means that tolerances in the outer diameter can be compensated. The length, inner diameter and insu- lation thickness are designed for your special applications. Longer built-on accessories can consist of several segments. Operating temperature max. 250 °C with moisture-proofing of the heating element. Rated voltage Rated power Material Height Inner diameter Temperature sensor Connection cable Plug connection Protection type 230 V AC (other voltages on request) designed for special applications aluminium or stainless steel max. 2000 mm 100 to 2000 mm Fe-CuNi type J, NiCr-Ni type K, PT 100 and integral control system (HTI) possible 1.5 m optional IP40 (basic version), IP54 (on request), protec- tion class I Type HFH 450 °C Heating sleeve with glass silk fabric jacket The structure is similar to type HMM. However, the entire heating sleeve consists of glass silk material that clings effectively and closely to the heated object. The sleeves are specifically adapted and manufactured to the object to be heated. Operating temperature up to 250 °C with PTFE heating conductors up to 450 °C with glass heating conductors Rated voltage Rated power Material Dimensions 230 V AC (other voltages on request) designed for special applications glass silk coated depending on requirements Temperature sensor Fe-CuNi type J, NiCr-Ni type K, PT 100 and integral control system (HTI) possible Connection cable Plug connection Protection type 1.5 m optional IP40 (basic version), IP54 (on request), protection class I The HFH heating sleeve is also available with aluminium and Teflon coating (optional). 78
® Surface heating elements Heating sleeves Example of HFH custom fabrications Heating systems for vacuum systems These high vacuum pumps are heated to 350 °C with a removable split heating sleeve. The requirement was uniform heat distribution over the entire surface. Removable insulating heating sleeve The complicated geometry could be insulated against heat losses and heated in a cost-effective and service-friendly way by splitting into several segments. All parts are quick and easy to seal and remove with Velcro fasteners. Heating mobile tanks Here the removable heating sleeve is adapted with thermal insulation and temperature control to the mobile tank. Pressure sensor heating This high-grade capacitative pressure sensor is heated to the required 160 °C with the removable heating sleeve. Heating sleeve on a support Simple surfaces, as well as a group of several components, for example a pump with valve and manometer, can be heated by means of an enclosed cage consisting of heating sleeves on supports made of a perforated stainless steel plate. Heating for reactors A temperature of 600 °C was required for a pilot plant for recycling plastic- coated aluminium in this reactor, so as to thermally separate the plastic and aluminium in this reactor with a conveyor screw. With several individually controlled heating circuits, the heating system achieved a precisely adapted heat distribution. 79
® 80 °C Surface heating elements Heating sleeves Type HM 10 Flexible barrel heating sleeve PVC-coating for 200 litre barrel Operating temperature 80 °C Rated voltage Rated power Material 230 V AC 1000 Watt PU foam / PVC coating Insulation thickness 5 mm Dimensions Fastener Ø 605 mm, height 890 mm Velcro / fleece Temperature sensor PT100 Connection cable Plug connection Protection type 2.0 m cable optional IP65 (EN 60529), protection class I Temperature control see chapter Control technology Design also available for barrels in other sizes Type HFI 10 80 °C Flexible barrel insulation sleeve with PVC-coating for 200 litre barrels Max. insulation tempera- ture 80 °C Insulation thickness 5 mm Material Inner diameter Outer diameter Height Fastener Design PU foam / PVC coating 605 mm 625 mm 890 mm Velcro / fleece also available for barrels in other sizes Type HFI 20 160 °C Flexible barrel insulation sleeve Robust and high-grade insulation for 200 litre barrels. Simple installation wit Velcro fasteners. Max. insulation temperature Inner diameter Insulation thickness Outer diameter Height Material Insulation material Fastener 160 °C 605 mm 17 mm 640 mm 880 mm glass fabric aluminium coated fibreglass Velcro / fleece 80
® Surface heating elements Barrel heating Type HBR 10 100 °C Mobile barrel heating Almost all 200 litre metal and plastic barrels fit on this practical, heated barrel roller. The built-in heater for maintaining the temperature of the barrel's medium has a range from frost protection to 100 °C and can also be used outdoors. Various controller versions are available for temperature control of the HBR 10 barrel base heating system, see chapter Control technology. The polyamide steering rollers (Ø 100mm) have a load bearing capacity of 450 kg Operating temperature up to 100 °C (mechanical limiter) Rated voltage Rated power Material Inner Ø Total height Temperature sensor Connection cable Protection type 230 V AC 1200 Watt Aluminium and steel 610 mm 175 mm PT100 2.0 m IP44 (EN 60529), protection class I Type HB 20 110 °C Heavy, stable barrel base heating plate The design of aluminium and galvanised steel ensures functionality and safety, also under difficult installation conditions. The temperature con- troller is located on the underside, protected in an aluminium housing. The heating surface temperature can be varied between 30 °C and 110 °C. Operating temperature up to 110 °C Rated voltage Rated power Material Dimensions Connection cable 230 V AC (other voltages on request) 1300 Watt aluminium and galvanised steel Ø 520 x 88 mm HB20 = 2 m HB20K = 5 m Plug connection Protection type German "Schuko" mains plug IP65 (EN 60529), protection class I Order no. HB 20 HB 20 K without control with controller Option: PT100 sensor setting range 30 – 110 °C 81
Barrel heating Type HM 20 ® 110 °C Robust barrel heating sleeve The HM 20 is a jacket heater to heat segments of 200 litre DIN barrels. Both the inner and the outer jacket of the barrel jacket heater are manu- factured from aluminium, which ensures maximum protection of the electrical components against mechanical damage. A hinge with adjustable turnbuckle that divides the heating surface into two semi-shells permits convenient installation without having to bend the heating element; the barrel can be completely heated by using three sleeves. The integrated thermal insulation increases efficiency and reduces the temperature of the touchable surfaces. The heating surface tempera- ture can be set on the attached aluminium housing using a mechanical thermostat in the range 30 – 110 °C. A 120 °C thermoswitch is also incor- porated in each semi-shell, as well as a 140 °C thermal fuse as protection against overheating. Operating temperature up to 110 °C Rated voltage Rated power Material Dimensions 230 V AC (other voltages on request) 1400 Watt aluminium sheet ø 570 mm, height 230 mm Heater element thickness approx. 17 mm Connection cable 2.0 m Plug connection Protection type Order no. German "Schuko" mains plug IP65 (EN 60529), protection class I HM 20 without control HM 20 K with controller Option: PT100 sensor setting range 30 – 110 °C 82
Explosion protection classification Ex electrical heaters ® Zones – Explosion groups – Temperature classes Introduction Explosion hazard areas are divided into zones, the equipment in device groups and device categories. For a certified device, the marking on the type plate makes it identifiable for which zone the explosion protected equipment may be used. Classification into device groups Devices are divided in Groups into I and II, whereby Group I involves mining "underground" and Group II involves gas and dust explosion protection in all other applications. Classification into zones Explosion hazard areas are divided into six zones, whereby the division is determined by the probability of how often and long it is expected that a hazardous explosive atmosphere occurs. Combustible gases, mists, vapours and com- bustible dusts are distinguished. Zones 0, 1 and 2 arise for gases-mists-vapours, whereby the requirements for the equipment used there ascend from zone 2 to 0. Zones 20, 21 and 22 arise for dusts, whereby the requirements for the equipment used there ascend from zone 22 to 20. Classification into ignition protection categories fillingline explosion flap The ignition protection type does not represent a quality feature, but is a constructive solution to achieve explosion protection for the equipment. For electrical equipment in gas Intrinsic safety Ex i Pressure-proof enclosure Ex d Increased safety Ex e Pressurized enclosure Ex p Oil immersion Ex o Cast enclosure Ex m Powder filling Ex q Ignition protection for For non-electrical equipment Protection by flow restricting enclosure Ex fr Pressure-proof enclosure Ex d Intrinsic safety Ex g Constructional safety Ex c Ignition source monitoring Ex b Pressurized enclosure Ex p Liquid immersion Ex k brown coal dust silo Zone 20 Zone 21 Zone 22 Zone 2 Ex n Special ignition protection Ex s For electrical equipment in dust Pressurized enclosure Ex pD Intrinsic safety Ex iD Cast enclosure Ex mD Dust ignition protection Ex tD M pneumatic conveying R = 1m Ex zone plan for a pulverized lignite silo Example: Filling station with Ex zones (explosion hazard areas) Zone 0 Zone 1 Zone 2 84
® Explosion protection classification Ex electrical heaters Zone 2 Zone 1 Zone 0 Zone 22 Zone 21 Zone 20 Safe area Safe area Typical zone sequence for gases-mists-vapours originating from a petrol drum with filling in a closed room. Typical zone sequence for gases-mists-vapours originating from a grain silo with filling in a closed room. Hillesheim and dusts in zone 21/22. devices and heating systems are approved for gases in zone 1/2 Classification into device categories The device category defines which equipment may be used in which zone. In turn, there are six device categories. Categories 1G, 2G and 3G are classifications for gas explosion protection (G = gas); equipment with 1G is suitable for zone 0, 1 and 2, equipment with 2G for zone 1 and 2 and equipment with 3G for zone 2. The categories 1D, 2D and 3 D are classifications for dust explosion protection (D = dust); equipment with 1D is suitable for zone 20, 21 and 22, equipment with 2D for zone 21 and 22 equipment with 3D for zone 22. II C II B Explosion groups, temperature classes II A The device group and device category defines in which zones an item of equipment can be used. It is defined from the explosion group and temperature class for which media within the zones the equipment may be used. Classification into explosion groups Depending on the ignition type, the explosion protected equipment is sub-divided for gases, mists and vapours in three explosion groups (IIA-IIB-IIC). The explosion groups are split according to how flammable a gas is. The requirements for the equipment rise from II A to II C. T2 T3 T1 T4 T5 T6 400 °C 300 °C 200 °C 135 °C 100 °C 85 °C Classification in temperature classes The explosion protected equipment installed within the explosion hazard area is divided in six temperature classes (T1 to T6). The temperature class is not - as it is often erroneously interpreted - the deployment temperature of the equipment, but rather the maximum permissible surface temperature on the equipment, which, in relation to an environmental temperature of + 40 °C, must not be exceeded at any point on the surface at any time. The maximum surface temperature must always be lower than the ignition temperature of the surrounding medium. The requirements for the equipment rise from T1 to T6. Conformity mark Number of the notified body Temperature class Explosion subgroup Ignition protection type Device category Device group 0045 II 2G Exi IIc T3 Example Labelling of devices for operation in explosion hazard areas according to the ATEX product directive 2014/34/EU 85
Ex electrical heaters HX6 series ® 200 °C Industrial heating hose with constant power The industrial heating hose with HX6 series heating conductors is designed for use in Ex areas. The heating hoses are above all charac- terised by their compact construction with connection configuration. The HX series heating hoses are tested to ATEX standards and with an EC type examination certificate they are certified for the entire heating hose. The specially structured HX6 series heating hoses can be used in tem- perature classes T1 ... T3 depending on the temperature control and are suitable for use in zones 1/2 (gas) and zones 21/22 (dust). Their operation in zones 0 and 20 is not permissible. The HX6 series industrial heating hoses are equipped with two EX-PT100 sensors. PT100 Exi intrinsically safe are also optional. Applications: Heat-loss free transport of: oil, grease, resin, tar, paint, water, carbon dioxide, plastic, moulding compounds etc. in Ex areas. Temperature classes T3=200 °C Ex areas Marking Zone 1/2 (gas) Zone 21/22 (dust) II2G Ex eb IIC T1... T6 II2D Ex tb IIIC T85 °C... T450 °C 2004 EC type examination certificate EPS 11 ATEX 1 341 X Directive 2014/34/EU, EN 60079-0, EN 60079-7, EN 60079-18 Operating temperature 200 °C Rated voltage Power rating 230 V AC depending on the design of the nominal diameter Connecting cable 1.0 m Pressure hose see Industrial pressure hoses Connector fittings steel / stainless steel, see Fittings Thermal insulation thermally stabilised, close-pore foam or thermal fleece Outer protection antistatic, see Outer protection hoses Hose end caps PA hard cap or elastomer cap The temperature must be monitored with controllers dependent upon the temperature class. 86
® Ex electrical heaters HX6B series 120 °C Industrial heating hose with self-limiting power The HX6B series industrial heating hoses is designed for use in Ex areas. The heating hoses are above all characterised by their compact construc- tion with connection configuration. The HX series heating hoses are tested to ATEX standards and with an EC type examination certificate they are certified for the entire heating hose. The specially structured HX6B series heating hoses can be used in tem- perature classes T1 ... T6 depending on the temperature control and are suitable for use in zones 1/2 (gas) and zones 21/22 (dust). Their operation in zones 0 and 20 is not permissible. The HX6B series industrial heating hoses can be deployed, even without temperature regulation, as a consequence of their self-limiting charac- teristic. The maximum final temperature must be monitored with con- trollers dependent upon the application. Applications: Heat-loss free transport of: oil, grease, resin, tar, paint, water, carbon dioxide, plastic, moulding compounds etc. in EX areas. Temperature classes EX areas Marking EC type examination certificate Directive T6 = 85 °C, T4 = 135 °C, T3 = 200 °C Zone 1/2 (gas) Zone 21/22 (dust) II2G Ex mb IIC T3... T6 II2D Ex mb IIIC T85 °C... T200 °C 2004 EPS 11 ATEX 1 341 X 2014/34/EU, EN 60079-0 , EN 60079-7, EN 60079-18 Operating temperature Rated voltage Power rating Connecting cable Pressure hose Connector fittings Thermal insulation Outer protection Hose end caps Option approx. 35 °C... 120 °C 230 V AC see table below 1.0 m see Industrial pressure hoses steel / stainless steel, see Fittings thermally stabilised, close-pore foam or thermal fleece antistatic, see Outer protection hoses PA hard cap or elastomer cap Ex PT100 or PT100 Exi intrinsically safe sensors Data relate to an outside temperature of approx. +10 °C Insulation thermoplastic fluoropolymer Galvanised copper conductor 2 x 1.1 mm2 PE conductor braiding galvanised copper Self-limiting heating element Outer jacket Approx. power per metre up to DN12 pressure hose Holding temperature approx. Permissible temperature switched on Max. heating circuit length at 16 A Temperature classes 10 W/m 35 °C 85 °C 150 m T6 17 W/m 40 °C 85 °C 130 m T6 25 W/m 50 °C 85 °C 100 m T6 31 W/m 60 °C 85 °C 70 m T6 45 W/m 95 °C 200 °C 66 m T3 60 W/m 120 °C 200 °C 40 m T3 87
Ex electrical heaters ® HX3 series 100 °C / 200 °C Analytical heating hose with constant power The HX3 series analytical heating hoses with Ex heating conductor is designed for use in Ex areas. The heating hoses are above all charac- terised by their compact construction with connection configuration. The HX series heating hoses are tested to ATEX standards and with an EC type examination certificate they are certified for the entire heating hose. The specially structured HX3 series heating hoses can be used in tem- perature classes T1 ... T3 depending on the temperature control and are suitable for use in zones 1/2 (gas) and zones 21/22 (dust). Their opera- tion in zones 0 and 20 is not permissible. The HX3 series analytical heating hoses are equipped with two EX-PT100. PT100 Exi intrinsically safe are also optional. Applications: Maintaining temperature and avoidance of frost and condensation (motor exhaust fumes, CO2-measurement, measuring samples, indus- trial gases, air & environmental measurements) in EX areas. Temperature classes T3=200 °C Ex areas Marking Zone 1/2 (gas) Zone 21/22 (dust) II2G Ex eb IIC T1... T6 II2D Ex tb IIIC T85 °C... T450 °C 2004 EC type examination certificate EPS 11 ATEX 1 341 X Directive 2014/34/EU, EN 60079-0, EN 60079-7, EN 60079-18 Operating temperature 200 °C Rated voltage Power rating 230 V AC depending on the design of the nominal diameter Connecting cable 1.0 m Inner core DN 4-12 mm PTFE, PFA or VA, see Inner cores analytics Connector fittings steel / stainless steel, RSL Thermal insulation thermally stabilised, close-pore foam or thermal fleece Outer protection antistatic, see Outer protection hoses Hose end caps PA hard cap or elastomer cap Option replaceable core The temperature must be monitored with controllers dependent upon the temperature class. RSL Pipe connection for cutting ring screw connection DN RSL L (mm) d (mm) 4 6 8 10 12 25 25 26 26 28 6 8 10 12 15 88
® Ex electrical heaters HX3B series 120 °C Analytical heating hose with self-limiting power The self-limiting analytical heating hoses is designed for use in Ex areas. The heating hoses are above all characterised by their compact con- struction with internal connection configuration. The HX series heating hoses are tested to ATEX standards and with an EC type examination certificate they are certified for the entire heating hose. The specially structured HX3B series heating hoses can be used in tem- perature classes T1 ... T6 depending on the temperature control and are suitable for use in zones 1/2 (gas) and zones 21/22 (dust). Their opera- tion in zones 0 and 20 is not permissible. The HX3B series industrial heating hoses can be deployed, even without temperature regulation, as a consequence of their self-limiting charac- teristic. The maximum final temperature must be monitored with con- trollers dependent upon the application. Applications: Maintaining temperature and avoidance of frost and condensation (motor exhaust fumes, CO2-measurement, measuring samples, indus- trial gases, air & environmental measurements) in EX areas. Temperature classes Ex areas Marking EC type examination certificate Directive T6 = 85 °C, T4 = 135 °C, T3 = 200 °C Zone 1/2 (gas) Zone 21/22 (dust) II2G Ex mb IIC T3... T6 II2D Ex mb IIIC T85 °C... T200 °C 2004 EPS 11 ATEX 1 341 X 2014/34/EU, EN 60079-0, EN 60079-7, EN 60079-18 Operating temperature 35 °C ... 120 °C Rated voltage Power rating Connecting cable Inner core DN 4 – -12 mm PTFE, PFA, stainless steel 230 V AC depending on the configuration of nominal diameter 1.0 m Option Thermal insulation Outer protection Hose end caps Option 100 mm protruding, without transition replaceable core thermally stabilised, close-pore foam or thermal fleece antistatic, see Outer protection hoses PA hard cap or elastomer cap Ex-PT100 / PT100 Exi intrinsically safe sensors Data relate to an outside temperature of approx. +10 °C Insulation thermoplastic fluoropolymer Galvanised copper conductor 2 x 1.1 mm2 PE conductor braiding galvanised copper Self-limiting heating element Outer jacket Approx. power per metre up to DN12 core Holding temperature approx. Permissible temperature switched on Max. heating circuit length at 16 A Temperature classes 10 W/m 35 °C 85 °C 150 m T6 17 W/m 40 °C 85 °C 130 m T6 25 W/m 50 °C 85 °C 100 m T6 31 W/m 60 °C 85 °C 70 m T6 45 W/m 95 °C 200 °C 66 m T3 60 W/m 120 °C 200 °C 40 m T3 89
Ex electrical heaters ® Airtherm air heater 100 °C Air heater with highly flexible connection hose The Airtherm air heater was specially designed for heating compressed air. The air in the connection heat is heated, which is equipped with a ceramic heating element and the appropriate sensor. The feed con- nection is via a highly flexible line in which both compressed air and also the electrical connection are integrated. The air and electrics are separated in a connector housing. Operating temperature Connection thread 20 to 100 °C G ¼ Manufacturing lengths of the com- pressed air line 2.5 m, 5.0 m, 7.5 m, 10 m (special lengths on request) Depending on requirements, the air temperature can be set up to max. 100 °C (measured at the pistol nozzle). The compact design permits easy integration into existing systems Applications Painting technology: automatic paint spraying systems, painting robots, manual spraying, prevention of condensation Breathing air heating (protective wear): in fire fighting, chemical industry, tank cleaning General mechanical engineering For control purposes, our HT 40 controllers, the HT 85L with special air software (connection of two Airtherms possible) or an appropriately approved Airtherm controller for the Ex version can be used. Airtherm air heater system Components for the Ex protected area Connection housing Testing and approval – IP protection type – Ignition protection type – Ignition protection type Cable glands PG 16 – testing and approval PG 9 – testing and approval Control line Testing and approval Heating cartridge Testing and approval – IP protection type – Ignition protection type Operating voltage Power rating PTB 07 ATEX 1051 X IP 65 II 2 G EX e II T3 (gas) II 2 D IP65 T 200 °C (dust) EX 80407016 Rose EX 80407090 Rose PTB 07 ATEX 1051 X PTB 07 ATEX 1051 X IP 65 T3 230 V AC 500 VA Airtherm hose (hybrid round cable) Testing and approval Air pressure range PTB 07 ATEX 1051 X 1 – 8 bar 90
® Ex electrical heaters HAPX series 80 °C Aluminium heating plate with self-limiting power Applications: Heating of parts and moulds, wood and paper industry, automobile industry, mould-making, plastics industry, bookbinding. The HAPX aluminium heating plates cover a temperature range of up to 80 °C and can handle extreme pressure loads and are impact resistant. Their shapes can be individually fabricated – whether round, oval or L-shaped. Special designs with cut-outs, bore holes and bolt threads are possible. Even combinations with liquid and air channels for cooling can be imple- mented. Holding temperature Rated voltage Power rating Material Dimensions / max. Heating plate thickness Weight Surface Pressure rating Expansion Connecting cable Protection type Temperature regulation Temperature classes Ex areas Certification Directive Optional cooling plate Optional temperature sensor approx. 80 °C to +10 °C 230 V AC depending on the configuration Aluminium (AlMg3 EN-AW-5754) (AIMg4.5 EN 573-3) 1450 x 2400 mm 20 mm > Thickness: 20 mm approx. 52 kg/m2 rolled aluminium, finely milled etc. 80 N/mm2 0.24 mm 1°K / over 1000 mm length 1.5 m long IP65 (EN 60529), protection class I via our temperature controllers on request depending on the version T1 ... T6 Zone 1/2 (gas) Zone 21/22 (dust) Only the individual components are certified. 2014/34/EU, EN 60079-0, EN 60079-7 on request Ex-PT100 or PT100 Ex i intrinsically safe We manufacture special designs of our Ex heating plates to customer requirements, for example: • Aluminium heating plates for heating electronic components, to reduce soldering times • Aluminium heating plates to heat CDs and solar cells during manu- facture and final inspection • Aluminium heating plates for pressing in the wood and paper industry for laminates and hot adhesives • Aluminium heating plates for moulding PU foam and GRP prefabricated components The maximum final temperature must be monitored with controllers depending on the temperature class. 91
40 35 30 25 20 15 10 5 0 Ex electrical heaters Approval: ATEX Output power Rated output power at 230 V AC if the heating system is installed on insulated metal pipes. W/m I L L w 3 1 IL L w 2 5 ILLw17 ILLw10 HBR-ILLw...(CT) type ® 85 °C Self-limiting heating conductor HBR-ILLw is a self-limiting heating conductor for frost protection or for maintaining temperature in pipes and containers. This heating conductor can be cut to length in-situ for exact adaptation to the workpiece. Under the respective worldwide standards, HBR-ILLw is approved for use in explosion hazard and aggressive environments. As a result of its self-limiting characteristic, the heating conductor cannot overheat even when overlaps exist in its placement. Its output power is limited in depending upon the temperature of the object. HBR-ILLw is quick and simple to install, it can be fit to size and attached without any special tools. Connection, termination and coupling com- ponents are available with explosion hazard area ratings. Max. permissible temperature Switched on 85 °C / Switched off 85 °C Minimum installation temperature -40 °C Voltage supply 220-277 V AC / 110-120 V AC / 12 V, 24 V DC Temperature classification Maximum resistance of the protective braiding T6 ≤ 18.2 Ohm/km Type Nominal dimensions (mm) Weight kg/100m Min. bending radius (mm) Screw connection ILLw...CT 12.95 x 5.95 11.8 35 M20 Max. lengths (m) depending on the fuse protection 0 10 20 30 40 50 60 70 80 85 Pipe temperature in °C Typ ILLw10 Holding* Temp Start Temp. 10 °C Accessories Hillesheim offers a complete range of acces- sory parts, such as controllers, connection/ termination sets, as well as the relevant connection housings. These items are re- commended for trouble-free operation. ILLw17 ILLw25 ILLw31 40 °C 50 °C 55 °C 60 °C 0 °C -20 °C 10 °C 0 °C -20 °C 10 °C 0 °C -20 °C 10 °C 0 °C -20 °C 10 A 16 A 20 A 25 A 136 122 108 92 84 74 74 68 60 58 52 46 198 188 174 148 134 118 118 108 94 92 84 74 198 188 176 152 144 136 124 120 112 112 104 92 198 188 176 162 144 136 124 120 112 112 104 92 Fuse protection characteristic type C in accordance with EN60898 The maximum final temperature must be monitored with controllers dependent upon the application. * approx. holding temperature depending on mounting position, insu- lation thickness and outer temperature on the pipe. Insulation thermoplastic fluoropolymer Galvanised copper conductor 2 x 1.1 mm2 Self-limiting heating element PE conductor braiding galvanised copper Thermoplastic outer jacket 92
® Ex electrical heaters HBR-ILH...(CF) type 200 °C Self-limiting heating conductor HBR-ILH is a self-limiting heating conductor for maintaining temperature in pipes and containers. This heating conductor can be cut to length in-situ for exact adaptation to the particular workpiece. Under the respective worldwide standards, HBR-ILH is approved for use in explosion hazard and aggressive environments. As a result of its self-limiting characteristic, the heating conductor cannot overheat even when overlaps exist in its placement. Its output power is limited in depending upon the temperature of the object. HBR-ILH is quick and simple to install, it can be fit to size and attached without any special tools. Connection, termination and coupling com- ponents are available with explosion hazard area ratings. Approval: ATEX Output power Rated output power at 230 V AC if the heating system is installed on insulated metal pipes. Max. permissible temperature Switched on 200 °C / switched off 225 °C W/m Minimum installation temperature -40 °C Voltage supply 220-277 V AC / 110 V / 120 V AC Temperature classification Maximum resistance of the protective braiding T3 (200 °C) ≤ 18.2 Ohm/km Type Nominal dimensions (mm) Weight kg/100m Min. bending radius (mm) Screw connection ILH...CF 11.45 x 5.25 13.4 35 M20 Max. lengths (m) depending on the fuse protection Type 16 A 10 A Holding* temp Start temp. ILH45 95 °C 10 °C 0 °C -20 °C 42 40 36 66 64 58 20 A 84 80 72 Fuse protection characteristic type C in accordance with EN60898 The maximum final temperature must be monitored with controllers dependent upon the application. * approx. holding temperature depending on mounting position, insu- lation thickness and outer temperature on the pipe. ILH45 60 50 40 30 20 10 0 20 40 60 80 100 120 140 160 180 200 Pipe temperature in° C Accessories Hillesheim offers a complete range of acces- sory parts, such as controllers, connection/ termination sets, as well as the relevant connection housings. These items are re- commended for trouble-free operation. Insulation thermoplastic fluoropolymer Galvanised copper con- ductor 2 x 1.1 mm2 Self-limiting heating element PE conductor braid- ing galvanised cop- per Fluoropolymer outer jacket 93
Ex electrical heaters ® Approval: ATEX Output power Rated output power at 230 V AC if the heating system is installed on insulated metal pipes. W/m ILS 60 60 50 40 30 20 10 0 20 40 60 80 100 120 140 Pipe temperature in °C Accessories Hillesheim offers a complete range of acces- sory parts, such as controllers, connection/ termination sets, as well as the relevant connection housings. These items are re- commended for trouble-free operation. HBR-ILS...(NF) type 200 °C Self-limiting heating conductor HBR-ILS is a self-limiting heating conductor intended for industrial use for maintaining the temperature of e.g. pipes and conductors in which high temperature stability is an important factor. This heating conductor can be cut to length in-situ for exact adaptation to the workpiece. Under the respective worldwide standards, HBR-ILS is approved for use in explosion hazard and aggressive environments. As a result of its self-limiting characteristic, the heating conductor cannot overheat even when overlaps exist in its placement. Its output power is limited in depending upon the temperature of the object. HBR-ILS is quick and simple to install, it can be fit to size and attached without any special tools. Connection/termination and coupling com- ponents are available with explosion hazard area ratings. Max. permissible temperature Minimum installation temperature Voltage supply Temperature classification Maximum resistance of the protective braiding Switched on 200 °C / Switched off 250 °C -40 °C 220-277 V AC T3 (200 °C) ≤ 18.2 Ohm/km Type ILS..NF Nominal dimensions (mm) 12.1 x 5.4 Weight kg/100m Min. bending radius (mm) Screw connection 14.6 35 M20 Max. lengths (m) depending on the fuse protection Type ILS60 Holding* temp Start temp. 10 A 16 A 20 A 120 °C 10 °C 0 °C -20 °C 30 28 20 50 44 32 62 56 40 Fuse protection characteristic type C in accordance with EN60898 The maximum final temperature must be monitored with controllers dependent upon the application. * approx. holding temperature depending on mounting position, insu- lation thickness and outer temperature on the pipe. Insulation thermoplastic fluoropolymer Galvanised copper conductor 2 x 1.1 mm2 Self-limiting heating element PE conductor braiding nickel-plated copper PTFE outer jacket 94
® Ex electrical heaters Heating tape - assembled Type HBR-IAL8 190 °C Connection and termination set for parallel heating systems in terminal technology for use in explosive hazard areas The HBR-IAL8EX system includes a quick and simple to fit connection technology to connect the connecting cable and heating tape and ter- mination based on a screw connection. The dimensions can be selected so the system can be accommodated beneath the thermal insulation. Neither a hot-air gun nor any other special tool is required for confi- guration. • Temperature stability up to +190 °C • Current load capacity up to 20 A • For parallel heating systems HBR-ILLw, ILH, ILS • Very stable, as completely made of nickel-plated brass • Compact dimensions • Alternative: Low temperature version up to 135 °C, only for HBR-ILLw heating tape Self-configuration 190 °C HBR-ILH/ILS 135 °C HBR-ILLw Type HBR-IAL8Ex-HKSS Type HBR-IAL8Ex-MKSS Temperature class Terminal range for supply line T6 / T5 / T4 / T3 7.0 - 10.5 mm Terminal range for heating conductor 4.7 x 10 - 6.5 x 13 mm Max. current load capacity Measurement voltage Terminal cross section Protection type 20 A AC 12...400 V AC 2.5 mm² IP65 Length connection/termination 110 mm / 70 mm Diameter 25 mm Weight connection/termination 168 g / 116 g Material Marking Nickel-plated brass II 2G Ex e IIC T6/T5/T4/T3 Gb II 2D Ex tb IIIC T195 °C Db IP65 Connecting cable Ex (option) by the metre HBR-ALF-25 HBR-ALR-15 3 x 2.5 mm2 200 °C 3 x 1.5 mm2 135 °C Further information Please observe installation instructions! 95
Ex electrical heaters Type HBR-IAL4SS ® 200 °C Connection/termination set in silicone technology for use in explosion hazard areas The connection technology includes easy-to-configuration connection and termination connections in a set. The structure is selected such that the connection can be made directly in a housing approved for Ex areas, e.g. connection housing from the QXEx series or controllers from the IRMBEx series. Additional connecting cables are no longer neces- sary. In addition, the high temperature stability up to 200 °C also al- lows use with high temperature heating conductors, such as the ILH and ILS series. • Compact dimensions • Temperature stability up to 200 °C • Quick and easy to assemble • For various heating systems Self-configuration set Type HBR-IAL4SS Heating tape – assembled ex works Temperature class Connection/termination material Length connecting sleeve Length of termination sleeve For following heating tapes T3 Silicone 125 mm 66 mm HBR-ILLw ... ILS ... ILH Type HBR-IAL3Ex-HQSS 180 °C Connection/termination set in shrink technology for use in explosion hazard areas The system includes a very flexible and space-saving connection tech- nology for use in explosion hazard areas. The use of a special temperature stable FEP connecting cable offers various applications, also at very high temperatures. The set includes the connection and the termination. • Compact dimensions • Continuous temperature stability up to 180 °C • Flexible in use • Used for ILH and ILS heating conductors Configuration ex works Type HBR-IAL3Ex-HQSS-E Self-configuration set Type HBR-IAL3Ex-HQSS Temperature class For following heating tapes Length of connection piece Length of termination Marking T3 HBR-ILH, HBR-ILS 140 mm 55 mm II 2G Ex mb IIC T3 Connecting cable Ex (option) by the metre 200 °C HBR-ALF-25 FEP – connecting cable 3 x 2.5 mm² Further information Please observe installation instructions! Heating tape – assembled ex works 96
® Ex electrical heaters Type HBR-IAL3Ex-MQSS 85 °C Connection/termination set in shrink technology for use in explosion hazard areas The system includes a very flexible and space-saving connection tech- nology for use in explosion hazard areas. A heating conductor is connected with a special connecting cable via an insulated joint connector and is subsequently sealed with a heat shrink hose. The very compact dimensions also enable installation under confined conditions. The installation instructions illustrated allow sources of error to be virtually excluded. The set includes the connection and the termination. • Compact dimensions • Temperature stability up to +85 °C • Quick and easy to assemble • For ILLw... Use of a heating conductor possible Configuration ex works Type HBR-IAL3Ex-MQSS-E Self-configuration set Type HBR-IAL3Ex-MQSS Type HBR-IAL3Ex-MKSS 65 °C Configuration set like MQSS, but for max. 65 °C, with terminal block up to 2.5 mm2 Self-configuration set Type HBR-IAL3Ex-MKSS MQSS and MKSS data Temperature class For following heating tapes Connecting cable cross section Connecting cable length Length of termination Marking T6 HBR-ILLw 1.5 mm² 140 mm 58 mm II 2G Ex mb IIC T4/T5/T6 Connecting cable Ex (option) by the metre 135 °C HBR-ALR-15 Radox connecting cable 3 x 1.5mm2 Further information Please observe installation instructions! Heating tape – assembled ex works 97
Ex electrical heaters ® Type HT-ESTML Electronic controller-limiter combination for use in explosion hazard areas The electronic Ex-controller is a combination of controller and limiter (SIL2). Configuration and monitoring is carried out via Bluetooth interface. The operating parameters can be monitored via LEDs and a 7-segment display on the front cover or a mobile device such as a tablet or smart- phone that supports Bluetooth via pre-installed software. The fiber- glass-reinforced polyester housing is mechanically robust. The cables are connected via spring terminals. The combination of controller and limiter allows easy and space-sav- ing operation of an electrical tracer heater or a heating hose in explo- sion hazard areas. • Compact design • Switching power up to 30 A • Protection type IP65 according ATEX/IEC Ex • 7-segment display • controller status shown via 4 LEDs Controller response two-point controller Marking Sensor type Power supply II 2G Ex eb mb [ib] [60079-30-1] IIC T6…T5 Gb II 2D Ex tb [ib] [60079-30-1] IIICT80 °C Db PT300, 3-wire, intrinsically safe 230 V ±10 %. 50 to 60 Hz, 15 VA Protection type IP 65 according ATEX/IECEx Measuring range -70 °C up to +500 °C in increments of 1 K Temperature range for limiter Set via electronical coding-elements, standard temperature class T3 (others on request) Operating temperature of controller -55 °C to +55 °C Storage temperature of controller -60 °C to +60 °C Units Power output Alarm contact °C / °F 230 V/400 V up to 30 A 230 V, 2 A Housing dimensions 260 mm x 160 mm x 90 mm Weight Display 4,8 kg 7-segment display, 3-digit LED display Display range -70 °C to +500 °C (-94 °F to +932 °F) 4-LED status display Ready for operation Communication (BUS/Bluetooth) Heating status (On/Off) Error (limiter alarm/error message) Setpoint increments 1 K Interface Hazardous area Bluetooth Class 1 Mode RTU Zone 1/21 . Zone 2/22, industrial use 98
® Ex electrical heaters Type HT-D3Ex Digital Ex Controller-Limiter Combination for Use Outside the Ex Zone The HT-D3Ex electronic Ex-controller is a combined unit consisting of a controller and an ATEX-approved limiter. The combination unit come pre-wired, allowing for quick and easy commissioning. The Ex-controller has a switching capacity of 16A and is to be mounted outside the hazardous area. It ensures the safe operation of all types of Ex-heaters and Ex-heated hoses. Ambient temperature 0 °C to 40 °C Voltage 100 – 240 V AC, 50 – 60 Hz Switching capacity 16 A Control types Two-point controller (pre-programmed), PID Measurement accuracy ±1 °C Sensor connection 2 × Ex-PT100 Load output Alarm output Inputs / Outputs Relay 16 A (normally closed contact) Relay 8 A (changeover contact) cable glands for signal outputs, power supply line, and load Terminal cross-section 2.5 mm² Housing Plastic, 250 × 200 × 123 mm Protection rating IP65 (EN 60529), Protection Class II Interface RS485 Modbus RTU 99
Ex electrical heaters ® Type HT-IRM2Ex/AG Mechanical frost protection thermostat in the housing The M2Ex/AG is characterised as a bimetal thermostat through its compact dimensions combined with a high switching power. It is out- standing for frost protection monitoring with a heating tape or also suitable for heating plates. The thermostat is cast into an M20 screw connection, which is installed in a glass-fibre reinforced polyester housing. Up to two heating circuits can be connected in this pre-wired housing. • Compact dimensions • For up to two heating circuits • 16 A switching power • Low switching hysteresis • Protection type IP66 Voltage Switching power 250 V AC 16 A Switching points outside temperature On 4 °C, Off 11 °C Switching accuracy Min. ambient temperature Max. ambient temperature +/- 3K -55 °C +40 °C (T6) +50 °C (T5) Dimensions 122 x 122 x 90 mm (LxWxH) Ex connection housing HBR-QX Glass-fibre reinforced polyester housing for use in explosion hazard areas Ex connection housing made of glass-fibre reinforced polyester for connecting self-limiting heating conductors, single-wire heating conductors and mineral-insulated heating conductors. The connection housings are available in many different versions for all common uses. Usage under extreme environmental conditions, aggressive chemical media and severe mechanical stresses are no problem for these robust distributor housings. • Temperature stable • Chemical resistant • Antistatic • 2 + 6 + 8 terminals 4 mm2 • Corrosion resistant / UV-resistant Dimensions HBR-QX-P1 HBR-QX-P5 Protection type Min. ambient temperature Temperature class 80 x 75 x 55 mm (LxWxH) 122 x 120 x 90 mm IP65 -40 °C (-55 °C on request) T6 at +50 °C T5 at +55 °C T4 at +60 °C Marking II 2G D, II 1G-D, T6 Exe/Exi 100
® Ex electrical heaters Type HT-IR2M Mechanical capillary thermostat for use in explosion hazard areas The IRM series Ex controllers are mechanical 2-point temperature monitors. The black glass-fibre reinforced polyester housing is mechanically robust and serves as a connection for self-limiting heating conductors. The controllers switch the heating circuit directly up to a current of 25 A. If the set temperature is exceeded, the contact opens. • Compact design • 25 A switching power / 230 V • Protection type IP66 • 4 mm sensor thickness • Resistant against chemical influences HT-IR2M...Ex Setting range (°C) Measurement voltage (VAC) Measurement current (A) Switching difference max. sensor temperature (°C) Protection type Capillary length (mm) Sensor diameter (mm) Type 0120 0..120 230 25 7 % 145 IP66 1000 4.0 Housing dimensions L x D x H (mm) 122 x 120 x 90 M25 screw connections M20 screw connections Terminal cross section (mm²) 1x 1x 6 Marking II 2G Ex ed IIC T6 II 2D Ex tb IIIC T80 °C IP66 Further information Please observe wiring instructions! 101
Ex electrical heaters ® Type HT-IRB2M Dual device with mechanical capillary thermostat and mechanical capillary limiter for use in explosion hazard areas The Ex controllers / limiters are mechanical 2-point controllers. The glass-fibre reinforced polyester housing is mechanically robust. The combination of controller and limiter allows easy and space-saving operation of an electrical tracer heater in explosion hazard areas. The sensors with just 4 mm outer diameter are especially well suited for electrical trace heaters. • Compact design • 25 A switching power • Protection type IP66 / 230 V • 4 mm sensor thickness • Resistant against chemical influences Minimum ambient temperature: -55 °C Temperature class T6 at +40 °C Marking II 2G Ex ed IIC T6 II 2D Ex tb IIIC T=80 °C IP66 HT-IRB2M0120/130190Ex HT-IRB2M0190/0719Ex Voltage (VAC) Current (A) Switching difference max. sensor temperature (°C) Protection type Capillary length (mm) Sensor diameter (mm) Control ranges Controller: 0..120 °C Limiter: 130..190 °C Controller: 0..190 °C Limiter: 70..190 °C 0120/130190 0190/0719 230 25 7 % 145/220 IP66 230 25 7 % 220/220 IP66 1000/1000 1000/1000 4/4 4/4 Housing dimensions L x W x H (mm) 220 x 120 x 90 220 x 120 x 90 M25/M20 screw connections 1/2 1/2 Terminal range M25/M20 (mm) 7-13/12-15 7-13/12-15 Terminal cross section (mm2) 6 6 102
® Ex electrical heaters HBR-IRPT 100Ex 200 °C PT100 for use in explosion hazard areas The PT100 temperature sensor has a PTFE connecting cable. It serves to record temperature and is attached directly to the object to be heated. It's flexible design makes it outstandingly well suited to also be attached to small components. • Small design • Very flexible through PTFE cable • Up to 200 °C • 4-wire technology • Latest standards Voltage Measuring range Signal circuit Sensor diameter Sensor length Connecting cable max. 60 V up to 200 °C max. 10 mA AC/DC 6 mm 60 mm length 2.0 m / 5.0 m / 10.0 m Measurement method 4-wire Marking II2G Ex e IIC T6...T1 Gb / II2D Ex tb IIIC T85 °C...T220 °C Db IP68 103
Compact controllers ® HT 63 series Electronic Controller The temperature controller HT 63 is a further development of the HT40 series. Due to its compact design, simple and clear handling, the HT63 is a universal controller in machine, plant and apparatus engineering. The text-controlled menu allows a simple and intuitive operation of the controller. The most important parameters are shown on the LCD display. The contactless switching capacity is 10 A. All heated hoses in our standard series have a 6-pin connector that fits exactly on this controller. Voltage supply 230 V AC 50/60Hz (optional 115 V AC) Switching power 2300 W (10 A) Sensor types PT100, PT1000, Fe-CuNi (J), NiCr-Ni (K), Ni120, Sensor with 3-wire system Tolerance 1 % +/- 1 Digit Controller outputs elect. switch (Triac) 10 A Controller responce PID-Controller Operating modes Inputs and Outputs Functions Option Package Display Operation automatical, manual, input delay, program (optional) Alarm output relay 24 V/1 A Analog output 0-10 V for temperature actual value display Analog input 0-20 mA for external setpoint input (optional) Alarm delay Alarm upper and alarm lower limit Program function External setpoint input 2-line LCD-Display Membrane keyboard 5 pushbuttons Housing dimensions 160 x 80 x 55mm (LxBxH) Mounting plate dimensions Fastening Protection type Load outputs 160 x 100 mm 4 bores for M4 screws IP65 (EN 60529) protection class I Mains cable, 6+PE pole round plug, KV- screw connection for signal output Mains Plug Schuko, 1,2 m long Setting ex works Control range PT100 0 – 100 °C 0 – 200 °C 0 – 250 °C 0 – 500 °C 0 – 800 °C HT 63 - 10P HT 63 - 20P HT 63 - 25P HT 63 - 50P PT1000 HT 63 - 10M HT 63 - 20M HT 63 - 25M HT 63 - 50M FeCuNi HT 63 - 10F HT 63 - 20F HT 63 - 25F HT 63 - 50F HT 63 - 80F NiCr-Ni HT 63 - 10N HT 63 - 20N HT 63 - 25N HT 63 - 50N HT 63 - 80N Ni120 HT 63 - 10C HT 63 - 20C HT 63 - 25C 106
® Compact controllers Series HT 61 / 62 Controller / limiter combination The temperature controllers HT 61/62 are a further development of the HT40 series. Due to their compact design, simple and clear handling, the temperature controllers HT 61/62 are universal controllers in machine, plant and apparatus engineering. The text-controlled menu allows a simple and intuitive operation of the controller The most important para- meters are shown on the LCD display. In addition, the HT61 / 62 have a limiter function with a permanent shutdown. The contactless switching capacity is 16 A. Voltage supply Switching power Sensor types 230 V AC 50/60Hz (Optional 115 V AC) 3680 W (16 A) PT100, PT1000, Fe-CuNi (J), NiCr-Ni (K), Ni120, Sensor with 3-wire system Tolerance 1 % +/- 1 Digit Controller outputs elect. switch (Triac) 10 A Controller responce PID-Controller Operating modes Inputs and Outputs Functions Option Package Display Operation automatical, manual, input delay, program (optional) Alarm output relay 24 V/1 A Analog output 0-10 V for temperature actual value display Analog input 0-20 mA for external setpoint input (optional) Alarm delay Alarm upper and alarm lower limit limiter function with permanent shutdown remote limiter reset Program function External setpoint input 2-line LCD-Display Membrane keyboard 5 pushbuttons Housing dimensions 160 x 80 x 55mm (LxBxH) Mounting plate dimensions 160 x 100 mm Fastening Protection type HT 61 load outputs HT 62 load outputs 4 bores for M4 screws IP65 (EN 60529) protection class I 1.2 m mains cable with Schuko, 8+PE pole plug (HANQ8), KV- screw connection for signal output KV- screw connection for signal output , main cable, consumer, without main cable Setting ex works Sensor type PT100 Typ HT 61 HT 62 Control range 0 – 200 °C 0 – 200 °C These parameters can be reprogrammed by the customer or pre- programmed according to customer requirements. HT61 with 8+PE pole socket HT62 with screw connections 107
Compact controllers ® HT 64 series Power output via SSR, 3-pole, 6900 W The HT64 temperature controller is a universal controller for use in machinery, plant, and equipment construction, thanks to its compact design. During the design of this device, particular emphasis was placed on simple and clear operation. Operation is in accordance with the HT60 series. The HT64 can be used to control 3-phase heated hoses and heating plates. The total power of 6900 W is distributed evenly across all three phases. Power supply SSR switching capacity Control range Sensor types Alarm output Display Inputs / Outputs Operation Protection rating Enclosure dimensions 400 V AC, 50/60 Hz 3 × 2300 W (3 × 10 A), electronic 0 – 800 °C PT100, PT1000, Fe-CuNi (J), NiCr-Ni (K), Ni120 Relay 24 V / 1 A Setpoint / actual value, 2-line LCD Analog output 0 – 10 V for actual temperature display Analog input 0 – 20 mA for external setpoint input (optional) 5-key membrane keypad IP65 (EN60529), Protection Class I 180 × 190 × 70 mm (W × H × D), incl. surface mounted socket Mounting plate dimensions 180 × 160 mm (W × H) Power cable length Plug Output / load connection 1.5 m CEE plug 16 A HAN Q8 socket, 8-pin HT 65 series Power output via SSR, 1-pole, 4600 W The HT65 temperature controller is a universal controller for use in machinery, plant, and equipment construction, thanks to its compact design. During the design of this device, particular emphasis was placed on simple and clear operation. Operation is in accordance with the HT60 series. The HT65 can be used to control heated hoses and heating plates with particularly high power, which, due to local conditions, can only be operated single-phase. Power supply SSR switching capacity Control range Sensor types Alarm output Display Inputs / Outputs Operation Protection rating Enclosure dimensions 230 V AC, 50/60 Hz 4600 W (20 A), electronic 0 – 800 °C PT100, PT1000, Fe-CuNi (J), NiCr-Ni (K), Ni120 Relay 24 V / 1 A Setpoint / actual value, 2-line LCD Analog output 0 – 10 V for actual temperature display Analog input 0 – 20 mA for external setpoint input (optional) 5-key membrane keypad IP65 (EN60529), Protection Class I 180 × 190 × 80 mm (W × H × D), incl. surface mounted socket Mounting plate dimensions 180 × 160 mm (W × H) Power cable length Plug Output / load connection 1.5 m (3 × 2.5 mm²) None Binder 694, 4-pin + PE 108
® Compact controllers HTI 16 / HTP 16 series Integral controller / monitor combination The device impresses with its perfect matching with our trace heating systems with HTI heating conductor and its compact design and simple handling. Easy mounting via the mounting plate serving as a heat sink and modern connection systems are self-evident. The HTI 16 temperature controller controls the temperature of the heating conductor via the change in resistance of the heating wire without further sensors. The integral controller does not measure at one point, but rather the average value over the entire length / surface of the heating system directly from the heating wire and registers a tem- perature change immediately without any delay. The measured value corresponds to the temperature profile over the entire system and not the temperature at a single point, as is the case with a sensor. A special nickel alloy is used as the heating wire. A PT100 is also required as a HTP 16 controller-monitor. Voltage supply Controllable heating power 230 V AC (optional 115 V / 400 V AC), 50 ... 60 Hz 3680 W (max. 16 A resistive load, ED 70 ... 80 %) 230 V 6400 W at 400 V, 1840 W at 115 V Min. output current 1 A resistive load Control range (-20 ... +250 °C in 4 segments) -20 – +40 °C 0 – 100 °C 10 – 150 °C 10 – 250 °C Display actual/target value 3-digit LED display Temperature setting digital via keys Power unit Signal relay triac changeover relay 230 V AC, 6 A Protection type IP65 (EN 60529), protection class I Mounting surface 160 x 122 mm (H x W) Fastening 4 bores for M4 screws Terminal clamps 2.5 mm2 Control Versions Output / load Housing dimensions Option HTP 16 pulse package control with zero passage detection and defined heating pause D – 1.3 m cable with Schuko plug K – terminal clips / KV screw connection 81 x 161 x 65 mm (W x H x D) ABS housing without screw connections 2nd control circuit with PT100 sensor as controller-monitor combination The HTI controller is always calibrated on the corresponding heating circuit. On supply of a heating system with an assigned controller system, the device is factory set. The heating system and the controller are then labelled accordingly. The calibration is stored as a mode and can be performed without great effort. The calibration and matching to different heating systems is performed at the press of a button. 109
Compact controllers ® HT 85 series Self-optimizing 2-zone controller for the Switch cabinet installation on Top-hat rail Thanks to its free configurability and compact design, the HT 85 is a uni- versal controller for machine, plant and apparatus engineering. When designing this appliance, particular emphasis was placed on simple and clear handling. The mounting on standard rails and the removable terminals (plug-in blocks) also guarantee use under difficult installation conditions in the switch cabinet. Power supply Sensor types Error limit 100 – 240 V AC / 48 Hz...62 Hz; approx. 3 VA 24 V DC / ± 20 %; 3 W Pt100, Pt1000, Fe-CuNi (J), NiCr-Ni (K), Ni120, sensor breakage protection, sensor polarity reversal check, short-circuit monitoring Calibration accuracy: < 0.25 %; linearity error: < 0.2 % Target / Actual display 7-segment display; 3+ digits Measuring range -20 ... 999 °C (depending on the sensor type) Output Triac Output Load relay 230 V AC; 600 W/channel; max. total power 1200 W 24 V DC; 65 W/channel; max. total power 130 W Relay NO contact max. 250 V AC, max. 16 A, resistive load Output Logic Voltage, bistable; 0/12 V DC, Ri = 680 Ohm Output Alarm relay Changeover contact, 24 V DC 1 A, no mains voltage permitted Inputs 4 – 20 mA continuous inputs for external setpoint specification Protection class IP 20 (DIN 40050) Controller dimensions 72 x 70 x 90 mm (H x W x D) without clamps Connections plug-in connection terminals Electrical connections Cross-section terminals 1 – 12: 0,2 ... 2.5 mm² cross-section terminals 20 – 38: 0,14 ... 1.5 mm² Special functions Self-optimisation of the controller parameters for quick adaptation to the controlled system. Safety operating mode can be set by connecting the relays upstream of the triac control to switch off in the event of a fault alarm, setpoint limitation and setpoint correction. Installation housing for HT 85 Housing dimensions HZ-EK 2 for 1 unit 125 x 200 x 122 mm Housing dimensions HZ-EK 4 for 2 units 200 x 200 x 122 mm Housing dimensions HZ-EK 6 for 3 units 250 x 200 x 122 mm HT 85 protection type IP65 (EN 60529) in installation housing Design in accordance with VDE 0631 HT 85 110
® Compact controllers HT 85H series HT 85H dual controller Installed in housing Design with socket or screw connections. Ready wired. For controlling two heating circuits Technical data, see HT 85 The HT 85 is illustrated in the HZ-EK2 housing, installed and ready to plug in. HLD 85 series Temperature controller for high load currents Three-phase or deviating voltages can be connected potential-free (floating) via an in-built contactor or SSR relay. The modern wall housing is easy to mount and the integrated micro- processor controller is programmable for every task. HT 85 H Switching power with contactor 3 x 4.6 kW (20 A) with SSR relay 1 x 5.7 kW (25 A) 2-channel double power Panel mounting controller data, see HT 85 Voltage supply 230 V / 400 V AC Inputs KV screw connections Terminal clamps 2.5 – 4 mm2 Protection type IP65 (EN 60529), protection class I Housing polystyrene (with transparent cover), hinged cover Housing dimensions depending on the design HTM 85 series Multi-channel controller Control circuits Switching power Voltage supply 4 – 10 per circuit triac 600 W or relay 1500 W 230 V / 400 V AC Panel mounting controller data, see HT 85 Inputs KV screw connections Protection type IP65 (EN 60529), protection class I Housing polystyrene (with transparent cover), hinged cover Housing dimensions depending on the number of controllers 111
Panel controllers ® HTE 53 series Simple controller for top-hat rail installation 2300 W / 230 V The dimensions of this controller correspond to a conventional built-in fuse and is easy to install in switchgear cabinets and distribution fuse boards. Voltage supply Switching power Control range Sensor type Special features Display actual/target value Operation Protection type Housing material Housing dimensions Connection Fastening 230 V AC 1 x 2300 W, 10 A, mechanical -270 °C ... +1300 °C adjustable PT100 / PT1000 / thermocouple, NTC switchable to Fahrenheit dot-matrix led screen 4 push buttons IP20 (EN 60529) polycarbonate 22.5 x 93.5 x 61.6 mm (W x H x D) spring terminal blocks top-hat rail 35 x 7.5 mm Installation housing for HTE 53 Housing dimensions HZ-EK 2 Housing dimensions HZ-EK 4 Housing dimensions HZ-EK 6 Protection type Design for 4 units 125 x 200 x 122 mm for 8 units 200 x 200 x 122 mm for 12 unit 250 x 200 x 122 mm IP65 (EN 60529), in housing in accordance with VDE 0631 112
® Panel controllers UTR series Temperature controller for wall mounting This is a simple and inexpensive temperature controller with PTC sensor, and internal or external setpoint setting. It is built into a housing and carries out simple temperature control of heating strips and underfloor heating systems. The PTC temperature sensor can be extended up to 50 m. Voltage supply Switching power Display 230 V AC, +6 / -15 %, 50 / 60 Hz 3600 W "Heating on", "Sensor break" LED Perm. ambient temp. -20 °C to +50 °C Switching temperature difference adjustable approx. 10 K Max. perm. switching current 16 A Contact (relay contact) 1 changeover contact, potential- free (floating) Electr. connections Setpoint setting Mounting Protection type Cable entry Housing material Housing dimensions screw connections knob wall mounting IP65 (EN 60529), protection class II 3 x KV screw connectors plastic 120 x 122 x 56 mm (W x H x D) PTC temperature sensor Type: UTR-175-PTC Sensor Cable length Sensor diameter Ambient temp. (PTC) linearised, self-monitoring 1.5 m 8.5 mm -20 °C to +175 °C Type UTR-60 UTR-100 UTR-160 Control range 0 – 60 °C 40 – 100 °C 100 – 160 °C Sensor UTR (optional) 113
Simple mechanical controllers ® AZT series Electronic antifreeze controller This is an inexpensive electronic antifreeze controller, with internal or external setpoint setting. When the outside temperature drops, it switches the heating on for antifreeze protection and switches off again when the outside temperature rises. Voltage supply Display Control range 230 V AC, +6 / -15 %, 50 / 60 Hz "Heater on" control lamp -15 °C to +15 °C Max. perm. switching current 10 A / 250 V Switching power 2.2 kW Contact (relay contact) 1 changeover contact Perm. ambient temp. -20 °C to +40 °C Switching temperature difference approx. 0.5 K Sensor element Protection type Mounting Internal setting External setting Housing material NTC linearised, in the housing IP54 (EN 60529), protection class II wall mounting Type: AZT-I 524 410 Type: AZT-A 524 410 plastic Housing dimensions 91 x 91 x 53 mm (W x H x D) HTL 13 series Interval power controller The Hillesheim HTL 13 is suitable for automatic, continuously adjustable temperature control of electrical heating systems and heating units. The load is connected via an in-built flange socket. The continuously adjustable temperature control is achieved by automatically switching the power supply on and off in precise time intervals. The duty cycle of the power supply can be continuously adjusted with the knob on the power controller. This means that with a low setting the power output cycle is briefly on - long off, with a higher setting the power controller is briefly off - long on. Voltage supply 230 V AC, 50 / 60 Hz Controllable heating power 2990 W (max. 13 A) Temperature setting knob / scale Switching cycle Protection type Connecting cable Plug Socket depending on setting 10 – 80 %, or max. 100 % IP54 (EN 60529) in the connected state 1.3 m Euro 16 A Hirschmann STAKEI 200, 2 + PE Housing material polycarbonate, grey Housing dimensions 80 x 80 x 80 mm (W x H x D) 114
® Mini controllers HTI 6 series Integral mini-controller The HTI 6 is a temperature controller manufactured with highly- integrated electronic components used in nano Watt technology. Tem- perature detection is accomplished directly through the heater wire. The temperature setting is made by way of a DIL switch which permits settings in 2 °C increments up to a maximum of 254 °C. A triac is used in this temperature controller to achieve wear-free switching. 230 V AC +6/-10 %, / 50...60 Hz max. 1500 W, min. load current 1 A integral / without sensor / special heating conductor LED red / green triac in zero-crossing 0 .... 254 °C, +/-5 °C setpoint setting 2 °C steps with a DIP switch IP42 / Cast: IP65 (EN 60529) two-point controller cable glands PA glass-fibre reinforced 62 x 44 mm (D x W) Voltage supply Switching power Controller type Display Power switch Control range Setting Protection type Response Inputs Housing material Housing dimensions HT 54 series SMD miniature controller for PT100 sensor The idea of integrating a temperature controller directly on the relevant heating system failed in the past due to the size of the components. Today's SMD technology only takes up a fraction of the space of earlier electronics. This prompted us to develop a complete temperature con- troller for installation in the upper part of the PA hard cap of our heating hoses. The HT 54 is the final product of this development! We have accommodated the controller board on an area of just 35 x 40 mm. Thanks to this construction, the customer can save on exter- nal control devices. This creates space in the switchgear cabinet. The HT 54 can also be used just as well for control purposes on heating jacket heating plates or heating strips. Its small dimensions open up new fields of application. Voltage supply Switching power Power switch Control range Setting Display Protection type Response Sensor Inputs Housing material Housing dimensions 115 V AC 500 W 24 V DC 720 W (max. 30 A) 12 V DC 240 W (max. 30 A) 230 V AC 1000 W / 5 A triac in zero-crossing 0 .... 254 °C, +/-5 °C setpoint setting 2 °C steps with a DIP switch heating operation yellow LED IP42 / Cast: IP65 (EN 60529) two-point controller PT100 cable glands PA glass-fibre reinforced 62 x 44 mm (D x W) 115
SSR relays ® HE series SSR electronic load relay 30 A / 20 A The HER load relay is a ready-to-install electronic power actuator for electrical heating systems. It is intended for continuous use with high switching frequency. In contrast to an electromechanical relay or contactor, no wear of switching contacts is possible here. The HER is prepared for use on a top-hat rail (TS 35), completely equipped with heat sink and over-voltage protection. Load voltage HER 30 D load current HER 20 D load current Protection type Connection terminals Housing dimensions Type HER Control voltage 4 – 32 V DC 230 V AC 0.2 – 30 A AC 1 at < 40 °C 0.2 – 20 A AC 1 at < 40 °C IP20 (EN 60529), protection class II 2.5 mm2 / 4 mm2 81 x 22.5 x 100 mm (H x W x D) Solid state relay – SSR 25 A This electronic switching relay can be installed anywhere, saving space in the housing. Installation in a metal housing is recommended for high load currents to ensure sufficient cooling for dissipated heat. Load voltage Load current 24 to 230 V AC 25 A AC 1 (max. load) Protection type IP20 (EN 60529), protection class I Connection terminals 2.5 mm2 Dissipated heat sufficient cooling must be ensured for switching power above 5 A (heat sink) Housing dimensions 57 x 45 x 30 mm (H x W x D) Note Type HED HEA Solid state relay pass residual current even in the open switching state. Therefore connect an upstream main switch or contactor. Control voltage 3 – 32 V DC 90 – 280 V DC 116
® Control technology Temperature sensor Thermocouple flat sensor with 1.5 m long silicone-insulated compensating cable Order no. HT/FF HT/NF Sensor type Max. temperature Fe-CuNi (J) NiCr-Ni (K) 450 °C 450 °C Thermocouple rod sensor Mineral-insulated, sensor tip bendable, for soldering-in, preferably for use at high temperatures, in fluids and aggressive atmospheres, diameter 1.5 mm, length 250 mm, silicone-insulated, 2 m long, com- pensating cable Order no. Sensor type Max. temperature Jacket material HT/FM HT/NM Fe-CuNi (J) NiCr-Ni (K) 600 °C 1000 °C 1.4571 2.4816 (Inconel) PT100 sleeve sensor PT100 sensor +250 °C PT100 sensor +250 °C PT100 sensor +350 °C VA diameter 4 mm, length 40 mm, PTFE-insulated, 2 m cable Jacket material 1.4571, diameter 4 mm, length 40 mm, PTFE-insulated, 2 m cable Jacket material 1.4571, diameter 4 mm, length 40 mm, glass silk insulated, 2 m cable Order no. HTI/VA Order no. HTI/PM Order no. HTI/PH PT100 in EExi design also available. Compensating cables For extending the connecting cables for the temperature sensors above. Structure: Silicone / silicone-insulated, 2 x 0.25 mm2, diameter 5 mm Order no. AG/F AG/N Sensor type Fe-CuNi (J) NiCr-Ni (K) 117