Cast-in Heaters

POWERCAST - Model Z.106

Cast-In Heaters, Model Z.106 (POWERCAST) are made up of a tubular element (resistive core) coated with a high heat conduction metal (aluminum or brass alloys). The peculiar working of this Cast-In Heater allows to reach an excellent heat transfer to the adjacent surfaces.

Thanks to its compact structure, POWERCAST is particularly capable of achieving a temperature slightly higher than the working one, with the advantage of having a lower surface load on the tubular element.

Use

• Food equipment manufacturing
• Plastics: extruder barrels, die heads
• Heat transfer presses for T-shirts, hats
• Medical equipment manufacturing
• Semiconductor manufacturing

Advantages of the cast-in heater

• Accelerated life
• Temperature uniformity
• Heating and cooling efficiencies
• Max. temperature capabilities
• Max. wattage
• Temperature ranges for special coatings

Technical features

• Working temperature with aluminum casting: 450 °C
• Working temperature with brass alloy casting: 650 °C
• Max. wattage: 9W/cm2 on the surface

Assembly

The stiff structure of the Cast-In Heaters (POWERCAST) does not allow their application with a single round segment, consequently they are manufactured with two or more round segments.

In any case, Cast-In Heaters should be equipped with a clamping system on the cylinder:

• System with external clamping band (drawing 1)
• Clamping system obtained directly from the casting (drawing 2)

This process allows to build inside the casting a cooling system made up of stainless steel tubes, into which either water or oil flows, according to the different needs.

In the case of water cooling, we have to make sure that water contains the appropriate chemical balance, in order to avoid any corrosion or scaling process taking place more easily in presence of high temperatures.

Testing

• A sophisticated testing equipment (TPC 2000) allows us to guarantee the entire product, because all heaters are hot tested, applying their actual working voltage
• TPC 2000 is complete with a printer certifying testing results
• Testing certificate for each single heater, upon request

Standard measurements

• Ohmic value
• Dielectric strength
• Current loss
• Insulation resistance
• Earth wire efficiency

When ordering, specify:

• Diameter (D)
• Width (L)
• Feeding voltage (V) (max. 550V)
• Wattage (watt)
• Output type
• Output position
• Cable direction
• Cable length
• Protection degree of the housing
• Please provide a drawing, due to the peculiarity of these heaters
• Electric connections are reported as follow
• For further requests, ask our Technical Departement

The heating element comes out of the casting with a threaded stud, upon which feeding cables can be connected by means of a stainless steel eyelet.

Connections are normally protected by aluminum housings, as shown in the drawings.