Ceramicx Products Guide by Frank Wilson

W W W.C E R A M I C X . C O M

The Guide to Ceramicx Infrared Heating Products Welcome to the Ceramicx Product Guide. Who is this Product Guide for ? Our publication outlines the complete range of Ceramicx infrared heating products for industry, commerce and consumers. The Guide is intended for buyers and users of our infrared heating components and equipment. The Guide will also be useful to stockists, distributors and agents around the world and to general readers who wish to gain an understanding of the world of infrared heating. Ceramicx has also published a sister publication – the Guide to Infrared Heating in Applications Engineering and research. This gives detail of how the Ceramicx products are used in industry. Full details of how to order the products described here are available at the back of the publication

Frank Wilson Managing Director

It gives me great pleasure to present this Guide to our company’s Infrared heating products. In my view, the general industrial user of infrared heating components and systems today stands in need of a concise reference work about the products, their performance and typical use. Ceramicx has nearly a quarter century in making all three kinds of IR emitters – short, medium and long wave. We have called on all of this experience and expertise to put this Guide before you. Ceramicx is an innovator. In other words, we are a company that seeks to renew and re-establish the standards for the industry. We have developed many new IR heating products for the needs of today’s manufacturer, who seeks superior performance and return from process heating. We hope you enjoy our Guide. Full details about ordering products are at the back of the publication.

For further details see page C E R A M I CX I N F R A R E D F O R I N D U S T R Y

For further details see page

CONTENTS

Contents

Dust press Herschel test instrument Getting the best from your infrared General principles of infrared Index of Infrared terms Ceramicx product Guide Ceramicx products and competences Designed for optimum performance Reflector and housing design World class performance Total quality assurance Ceramic hollow for flexible performance Quartz element design and production Quartz tungsten/halogen elements Cerix NG thermocouples Spot heaters for focus and accuracy Panel heaters custom built for your needs Furnace heater

For further details see page

Ceramic trough elements Ceramic hollow elements Ceramic flat elements Edison screw elements Quartz elements Panel heaters Quartz tungsten/halogen tubes Reflectors and projectors Fast IR Accessories

36 38 40 42 44 46 48 50 52 54

02 04 06 08 10 12 14 How to order 16 18 20 22 24

For further details see page

52 Ceramicx

26 28 30 31 34 35

For further details see page

Product Guide

56 01

W W W.C E R A M I C X . C O M

Ceramicx Products and Competences The following gives details of the core competences and products made by Ceramicx.

If your needs are for something more bespoke please consult directly with Ceramicx about the possibility for its manufacture. Ceramicx is an innovator throughout its product range. Should there be a market for your IR heat component we will be happy to help you.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

THE GUIDE

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Ceramic Elements – Designed for Optimum performance World class production methods* at Ceramicx are matched by world class product designs.

The company’s ceramic-based IR heating elements have been refined and redesigned in order to provide the user with best-inclass performance. Ceramic products here provide long wave infrared radiation, used in a diverse range of industrial and engineering applications such as plastics thermoforming, paint curing, printing and drying. Ceramic configurations of these include ceramic trough elements, ceramic hollow elements, ceramic flat elements, and ceramic infrared bulbs.

* World class is defined as being in the top 2% of ceramic-based manufacturers world wide.

User Summary Ceramic-based elements operate in the temperature of 300°C to 700°C (572°F - 1292°F) producing infrared wavelengths in the 2 - 10 micron range. Most plastics and many other materials absorb infrared best in this range, which makes our ceramic heater the most popular infrared radiant emitter on the market. A range of aluminised steel reflectors are also available to ensure the maximum amount of infrared radiation is reflected forward to the target area. To find out more about our ceramic-based IR heaters, please read the technical data in each product page, our application notes and product reports, articles in our HeatWorks magazine – all within the Publications section.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

CERAMIC ELEMENTS

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Reflector and Housing Designs at Ceramicx In order to fulfil a useful service life all three kinds of IR heating elements ceramic, quartz and quartz halogen/tungsten – need heat management in the form of optimum mounting, housing and heat reflection.

Failure to provide a reflector will create in-service problems, not only for the component itself but also for the user’s whole operating system. Ceramicx therefore researches all of these issues and integrates the manufacture of all housings, mounts and reflectors into its finished IR heating components. Ceramicx customers therefore purchase all IR heating components with complete peace-of-mind, knowing that Ceramicx has designed and engineered the build quality for optimum performance and complete safety.

User Summary Ceramicx machines and fabricates all IR emitter housings, mounts and reflectors for the optimum performance and safety of every component supplied. Ceramicx researches and sources the optimum grades of steel, aluminium, gold, copper, wiring and other materials in order to support the optimum performance of all components. Ceramicx supports Ph.D. level research in these matters and publishes a number of studies online. (Please see the White Papers area of www.ceramicx.com for further details) Ceramicx research and product development in this area is supported by the company’s unique machine test instrument – the Herschel – able to empirically assess the performance of metals and other materials under all kinds of IR radiation and temperature.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

REFLECTORS AND PROJECTORS

See page 50 for further details of standard reflectors and projectors

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Ceramicx Production â&#x20AC;&#x201C; world class performance* for discerning users Continuous improvement methods at Ceramicx have created a world class production environment that guarantees superior product performance and customer peace-of-mind.

The Ceramicx factory provides a blend of automated, semi-automated and craft skilled manufacturing, together with substantial research and development teams, staffed at Ph.D. level. Innovation and new IR product development are key to Ceramicx growth. The Ceramicx factory and facilities are accordingly set for significant expansion in the period 2016-19.

* World class is defined as being in the top 2% of ceramic-based manufacturers world wide.

User Summary Your IR heating products are designed and built at Ceramicx to the most rigorous and most effective systems of manufacturing and quality assurance.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Ceramicx elements - Total Quality Assurance Nothing less than total quality assurance will do in today’s business-to-business world. Manufacturers worldwide need complete peace of mind and fail-safe performance from all their heating components. This they receive from Ceramicx.

Every ceramic and quartz element made at Ceramicx is positively tested and passed fit for purpose as part of the company’s semiautomatic quality assurance system. Each element is then shipped to the customer with its own unique technical ‘thumbprint’, birth certificate and product specification available on line. Assisted by Trinity College Dublin (TCD) Ceramicx is now in its fourth generation of semi-automated QC systems, adding super computing power and Industry 4.0 methods to bring customers the infrared heating of the future. The Big Data approach supplements a worldclass array of sensing and measurement capabilities at Ceramicx - hardware and software which takes the form of a number of custom-designed testing stations and cradles. This new QC (quality control) capability is called CIRCLE – Ceramicx InfraRed Characterisation Laboratory Equipment infrastructure. And CIRCLE now gives Ceramicx a worldclass edge in creating new IR products, both standard and customized. CIRCLE also provides Ceramicx customers with a unique, unrivalled and growing body of IR heating data allowing for design of new products. When you purchase a component from Ceramicx you immediately reap the benefit of these world-class testing and QC services.

User Summary World-class quality of ceramic and quartz components is guaranteed and specified for each element supplied to customers The Ceramicx partnership with Trinity College Dublin (TCD) underwrites and future proofs the quality development of future ceramic products and the use of Big Data in the process

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

QUALITY ASSURANCE

CERAMIC ELEMENT TYPE FTE

REFERENCE IMAGE

RATED VOLTAGE

230

UNIQUE SERIAL NUMBER

COIL WATTS 650

COIL INTEGRITY

PASS

MASS 192.32g 06161337510 Under test

DI-ELECTRIC TEST <5mA@1500Vac PASS

THERMOGRAPHIC IMAGE

Dimensions

timestamp 14.20.04

x244.92 y59.81

COIL LOADING Ohms â&#x201E;¦

PASS

81.4

APPROVALS

CER

AR ED

RANDOM SUB SAMPLE

AMICX I NF R

LABORA

Product Guide

Ceramicx

CHAR AC T

UIPMENT

Additional lab mode long term testing to validate existing product performance and characterise new product design prototypes.

W/cm2

HEAT FLUX

W W W.C E R A M I C X . C O M

Ceramic hollow options – for flexible performance Ceramicx designs and supplies a number of ceramic hollow elements for use in industrial, commercial and domestic applications.

The hollow constructed ceramic elements have the primary advantage of having a shorter heat up time. It also provides remarkable energy efficiency. If demand is sufficient Ceramicx can create hollow ceramic designs to order, in quantity and for particular marketplaces, according to culture, practice and geography. Recent examples include the redesign of the Ceramicx Square Flat Hollow IR heating (SFEH) element for the important Chinese marketplace. The Ceramicx SFEH-LN is the result – supplied in 2 wattages, 400W and 650W with ring terminals.

See page 38 for further details of ceramic hollow elements

User Summary Ceramicx hollow constructed products typically consist of a high temperature FeCrAl resistance alloy embedded in a specially formulated lightweight hollow cast ceramic body. This is then filled with a high density insulating material. Typical operating temperatures for hollow designs run up to a maximum of 750ºC and with a maximum power of 800W (FFEH Model Only). Performance-wise, Ceramicx hollow elements boast a significant reduction in rear heat loss, together with increased radiant output from the front of the element.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

HOLLOW CERAMIC ELEMENTS

ENERGY INTENSITY AS A FUNCTION OF DISTANCE SFEH 600W / 230V Square Flat Element Hollow with white glaze

Percentage of Heat Flux [%]

CHANGE IN RADIATIVE HEAT FLUX AS A FUNCTION OF DISTANCE comparison between black and white glaze SFEH 600W /230V 70 60 50

SFEH White 600W/230V SFEH Black 600W/230V

40 30 20 10 0

100 200 300 Distance from heater [mm]

400

SFEH long neck designed for the Chinese market

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Quartz element design and production Ceramicx product innovation and redesign is continuous as regards its quartzbased IR heaters; providing medium wave IR radiation and ideal for faster heat response.

Ceramicx is the only supplier to offer quality IR heating products across the three major IR product types – short, medium and long wave emitters Major new improvements, for example, were recently incorporated into the end cap of one of the Ceramicx quartz cassettes. A one piece “flat bridge” now eliminates four other components per cassette end, thus enabling customers to achieve even greater efficiencies in their heat work. The new Ceramicx dust press production capacity plays a key role in the success of quartz-based projects, helping create new components and sub assemblies. The Ceramicx IR test instrument, the Herschel, is also frequently called upon to measure the performance of the company’s quartz-based heaters and innovations therein. Recent times have seen Ceramicx innovate in curved quartz heaters and in quartzbased solutions for drying and curing materials.

User Summary Ceramicx offers bespoke and standard IR quartz heating systems and components All Ceramicx quartz components and systems are manufactured and rigorously tested in-house. Ceramicx research on quartz designs and quartz testing is available in the White Papers section of www.ceramicx.com Quartz heaters are particularly effective in systems where rapid heater response and/or zone controlled heating is required. Quartz heaters have a broad emission spectrum from around 1.4 to 8 microns, slightly shorter in wavelength than ceramic elements. Pillared quartz elements have the same mounting fixture as ceramic elements allowing easy replacement. This easy change pillar is ideal for design alterations involving the use of materials with different absorption characteristics.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

QUARTZ ELEMENTS

Ceramicx standard quartz element range

Energy intensity as a function of distance HQE 600W / 230V Half Quartz Element

above; Curved Quartz Heaters

See page 44 for further details of standard quartz elements

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Quartz Tungsten/ Halogen – for fastest performance Ceramicx makes extremely high intensity infrared heaters using quartz tungsten, or quartz halogen.

Ceramicx selects and manufactures all materials and components to the highest quality, supplying a wide variety of manufacturers worldwide. The tungsten filament used, for example, is the porcupine or star type coil. This can be operated at temperatures up to 1500°C (2732°F), with a peak wavelength emission of approximately 1.6 microns. It reaches top temperatures within seconds. Halogen heaters are filled with a halogen gas to allow the supported tungsten filament to reach temperatures as high as 2600°C (4712°F). Peak emission for these tubes is around 1 micron.

User Summary Ceramicx quartz tungsten emitters heat up and cool down within seconds, making them particularly suitable for systems requiring short cycle times. Heat output is also very high. This factor makes quartz tungsten heaters very useful in high heat demand or in fast moving processes such as paper Tubes can be supplied individually, in bulk, or as part of the Ceramicx Fast IR system.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

QUARTZ TUNGSTEN / HALOGEN

See page 48 for further details of standard quartz tungsten/ quartz halogen tubes

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Cerix NG thermocouples – the key to measurement & control In order to ensure the best possible performance for its customers Ceramicx designs and manufactures its own thermocouples.

The current model is named Cerix Next Generation (NG). Prior to creating Cerix NG, Ceramicx looked at all of the leading thermocouple types on the market today; researched issues in their usage, and then invested in its own patented thermocouple solutions. Ceramicx found it necessary to introduce a better product to the market since tests on various models had revealed a number of possible deficiencies in the IR heating context. For example: The ceramic pillar can often act as a heat sink causing slow response in thermocouples An improved thermocouple response can be given by re-positioning the thermocouple junction inside a rib section away from the pillar. The design of the measuring bead (hot junction) has a major effect on the thermal response. Many other factors were also considered in the design and manufacture of the Cerix NG, including placement in element; thermal and kiln firing effects; thermocouple signal outputs; issues of electrical noise; terminations and connections; thermocouples and heat flux outputs.

User Summary Ceramicx recommends the use of Cerix NG thermocouples for customers – and all across its product range The Cerix NG design uses two strands of triple wound thermocouple wire, which are spot-welded on top of each other to form the thermocouple junction. After the spot weld is made, two excess strands are trimmed, and the remaining single strands of each leg are then tied around a quartz glass tube to fix the thermocouple in relation to the heating coil. Full details of Ceramicx thermocouple technology - including the research data and the rationale behind the new design(s) - are available in the company’s White Paper on the topic, available from www.ceramicx.com

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

THERMOCOUPLES

Type K Thermocouple (Nickel-Chromium / NickelAlumel): is the most common type of thermocouple. It’s accurate, reliable, and has a wide temperature range. The type K is Maximum continuous temperature is around 1,100°C. Type K Accuracy (whichever is greater): Standard: +/- 2.2C or +/- .75% Special Limits of Error: +/- 1.1C or 0.4%

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Ceramicx spot heaters â&#x20AC;&#x201C; for focus and accuracy In response to recent customer demand Ceramicx builds and supplies a number of spot heaters, mainly for industrial users.

The heater is of a barrel shape and comprises of a main body, heater holder and reflector head. It is fitted with a 100W halogen heater which provides short-wave radiation with a peak in the 1-2 micron range. This ensures rapid heat up during operation and leads to low cycle times. The entire unit is manufactured from lightweight aluminium and features either a highly polished aluminium or gold-coated reflector head for maximum infrared delivery to the target area. The low profile design and high efficiency gold coated parabolic reflector maximises the infrared delivery to the target material. An inbuilt cooling system prevents overheating of the bulb, and allows the unit to be mounted in arrays without fear of overheating.

User Summary The Ceramicx spot heater finds many uses in processes such as fabric joining, polymer welding, localised drying or heating, localised softening and forming. The heater was initially designed by Ceramicx for the infrared heating of small polymer parts requiring an intermediate thermal processing step. However, the spot heater has multiple uses and can be used for local heating and softening of small polymer components such as rivets or weld-able lugs for the joining of sub assemblies as found in automotive or medical parts. Ceramicx is developing a range of spot heaters to be used across all sectors including, automotive, aviation, textiles, inks and dyes, coatings, medical, glass and ceramics, electronics and packaging among others.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

SPOT HEATERS

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Panel Heaters â&#x20AC;&#x201C; custom built for user needs Ceramicx manufactures custombuilt IR panel heaters which typically operate at the long wave end of the radiation spectrum.

The Ceramicx design embeds the heating coils in a special ceramic fibre-board. This provides insulation, adds durability and shock resistance. The panel board is located behind an emitting surface of either anodised aluminium or glass ceramic. The unit is then placed inside a 75mm high aluminised steel housing which normally contains some 50mm of thermal insulation in order to reduce heat loss via the rear of the unit.

See page 46 for further details of panel heaters

User Summary Panel heaters find application in thermoforming ovens and in a number of curing and drying applications. The Ceramicx design and construction makes the panel heater a very robust and cost-effective option, with an operating life often in excess of 20,000 hours in many applications.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

PANEL HEATERS

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Furnace elements highest temperature performance Ceramicx has extensive experience in building high temperature furnaces for the manufacture of materials such as toughened glass and high-value composites.

The performance of such furnace elements is key – and Ceramicx has developed its own unique product for use in such applications. The ribbon surface enables a radiant emissivity of 0.60 which is the same as steel. The background surface of ceramic insulation provides a value of 0.95. Due to the High Watt density of the product it’s possible to provide a great deal of energy within a short space, The heat transfer capability of this heater is therefore best utilised when the energy output is contained in a ‘hot box’. The furnace platen control is dependent on the control of the radiant IR energy. The exposed materials on the surface of the heater allow for high ambient operational conditions. Ceramicx does not recommend this heater for close control values with the application of radiant energy.

User Summary Ceramicx furnace elements are ideal for manufacturing that demand high temperature, high energy performance systems

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

FURNACE HEATER

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Electrical Insulation/ Steatite Products from Ceramicx Buyers of electrical steatite connectors need look no further than the competitive manufacturing and service offered by Ceramicx

A full manufacturing service is available: It includes consultancy, design, tooling and the manufacture of specialized steatite ceramic dust press components on the Ceramicx 6 Ton, 15 Ton and 30 Ton Dorst presses. These capabilities are also deployed in making mainstream Ceramicx products. Steatite â&#x20AC;&#x201C; commonly known as ceramic dust - has proven itself to be the materialof-choice for the manufacture of electrical insulators. It has good mechanical strength with good dielectric properties and a high temperature resistance of up to 1000Â°C. Current Ceramicx steatite production include beads, connector blocks and additional components for high-temperature Infrared heating applications. Ceramicx global commercial expertise and services can be included in the steatite and machining services. The company can ship steatite orders directly to the specifier or to the specifierâ&#x20AC;&#x2122;s customers worldwide

User Summary Ceramicx will be introducing Alumina products in 2017

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

FURNACE HEATER

Ceramicx recently made this specially made-to-measure steatite block in order to help qualify its Far Eastern customer for medical-based manufacturing. The previous component was part of a fibrebased holding mechanism within quartz medium wave IR heating cassette.

Steatite beads

Steatite blocks

Steatite grommets

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

The Ceramicx Herschel Test Instrument – Bringing the IR heat spectrum to life Ceramicx The Herschel – a world-first IR heat test instrument – is at the heart of everything Ceramicx does.

Ceramicx can now provide itself and its clients with a new tool and an automated way to measure and map the previously invisible IR heat spectrum. The Herschel comprises a heat flux sensor, guided by an ABB robot. The sensor coordinates can be cubic grid, or spherical. The cubic grid is ideal to sense the heat flux outputs from arrays or larger elements. The spherical coordinates are used to gain an idea of the precise amount of heat emitted by the device under test, and compare it against other emitters. In this way all product development and all heat work consultancy at Ceramicx IR is based upon a fully predictive and fully documented science.

User Summary The performance of any IR heater can be tested and mapped in 3D space by the Ceramicx Herschel Most IR heat process work - i.e. IR heat/materials combinations can also be tested and mapped in the same way Client programmes of materials testing under IR heat are undertaken Herschel test instruments are also being built for users under the Ceramicx/Trinity College Dublin partnership. Full details from Ceramicx.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

THE HERSCHEL TEST INSTRUMENT

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Getting the best from your IR heat system

If in doubt with any aspect of your IR heating system – remember that Ceramicx is here to help. Please contact us directly and we will do our very best with your heating issues.

The Ceramicx website – and our Heat Works Magazine series – also contains much useful information, with case studies of IR heat use and with more detailed White Papers on the science and application of IR heat, the workings or Planck’s law and many other topics. The key point to always bear in mind is that the IR radiation spectrum is not the same as the heat temperature scale. Understanding and applying this key principle will save much time and cost.

User Summary Use the Ceramicx resources – website, magazine, IR heat training – to become educated in IR heat. Consult Ceramicx directly with specific issues of equipment and IR heating.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

INTRODUCTION TO INFRARED

An introduction to the fundamentals of heat transfer and infrared Infrared is a form of electromagnetic radiation or wave. Electromagnetic radiation can take many forms such as gamma rays, ultraviolet light or radio waves. These have similar properties, but differing energies. Visible light lies in the wavelength range of 0.38-0.78 microns. Infra means below or beyond, therefore, infrared lies just “beyond red” from 780 nanometres or 0.78 microns to 1000 microns (1000 microns = 1mm). Wavelength

Electric Field Direction Magnetic Field

Thermal energy is transferred by virtue of a temperature difference. It moves in only one direction; flowing from regions of higher temperature to regions of lower temperature. The energy will flow from one location to another until the two substances have the same temperature. Temperature is therefore a measure of the total amount of energy in a system. Any surface at a temperature greater than 0 K (-273.15°C) will radiate infrared energy. Similarly, surrounding objects will also radiate infrared energy. If both objects are at the same temperature, then they both emit and receive the same amount of energy, and will not change in temperature. When one object is hotter than the other, infrared energy will be transferred from the hot object to the cold object. 0.78 μm 1.5 μm 3 μm Short Medium Wave IR Wave IR

Gamma Rays

Long Wave IR Infrared

Increasing Energy

10-7 μm 10-5 μm

1000 μm

0.01 μm 1 μm X-Rays

100 μm 104 μm 106 μm 108 μm

Visible Light 0.4 μm 0.5 μm

Increasing Wave length

Radio Waves

Definitions used in measurement of heat Heat is a form of energy and can be measured in Joules, calories or BTUs. Mechanical equivalent: it is equal to the energy expended (or work done) in applying a force of one Newton through a distance of one metre (1 Newton metre or Nm), Electrical equivalent: the energy expended in passing an electric current of one ampere through a resistance of one ohm for one second. Temperature can be measured using several scales. Celsius (°C) is the most common unit in industry; Kelvin (K) is a more scientific unit (absolute scale) or Fahrenheit (°F) which is used mostly in USA Heating power is measured in Watts (W): Watt = 1 Joule / second

Three heat transfer mechanisms. 1. Conduction Conduction is the transfer of energy from one region to another without movement of the substance. It occurs as a result of interactions between particles. Thermal conductivity (k) is a measure of how well a substance conducts heat. The rate of energy transfer ( q’’ ) through a surface depends on the temperature difference (ΔT), the surface area (A), the material thermal conductivity (k) and its thickness (Δx). The energy must flow from higher to lower temperatures; therefore a negative sign is included. Thermal conductivity (Watts/m.°C)

Cross sectional area (m2)

A ( q˝ = -k — T2 -T1 ) x

Heat transfer rate (Watts)

Length (m)

Temperature difference (°C)

x q˝

0.7 μm

2. Convection Convection is the transfer of heat by the movement of a fluid (liquid or gas). It includes the random movement of molecules (diffusion) and also the macroscopic movement of the bulk (advection). The heat transfer rate ( q’’ ) depends on the temperature difference (ΔT), the surface area (A) and the heat transfer coefficient (h) which is calculated based on the fluid’s physical properties. Heat transfer coefficient (Watts/m2.°C)

Fluid contact area (m2)

q˝ = hA (T2 -T1 ) Heat transfer rate (Watts)

0.6 μm

Фq

Heat flux ( Φq ) is the rate of thermal energy transfer through a given surface per unit time. Its symbol is and unit is W/m2. In industry it is common to use W/cm2.

Temperature difference (°C)

Convection can take two forms: free and forced Free convection occurs in the absence of an external force. A fluid is heated by a surface, becomes less dense and rises. The moving molecules therefore carry energy away from the hot surface. Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Forced convection occurs when the fluid is moved by an external force (e.g. a pump) over a heated surface which causes the energy transfer. 3. Radiation Radiation is heat transfer by electromagnetic waves (including light) produced by objects because of their temperature. Thermal radiation, emitted by any matter with temperature above 0 K (-273 °C), does not require a medium as electromagnetic waves, which travel at the speed of light, can permeate a vacuum. The higher the temperature of an object the more thermal radiation it gives off and the shorter the wavelength of the radiation. Shorter wavelengths are more energetic and contain more energy. Generally, the electromagnetic radiation wavelengths are longer than the visible spectrum and therefore described as beyond red (infrared in Latin) in the wavelength range of 0.78µm and 1mm. Radiative heat transfer only occurs when the emitted radiation wave strikes another body and is absorbed.

Classes of infrared radiation 0.78 μm

1.4 μm

SHORT WAVE

3 μm

1000 μm

MEDIUM WAVE

This is for a theoretically ideal emitter, one that reflects nothing and emits pure thermal radiation. Such an emitter is describes as a perfect “black body” which has an emissivity (ε) of 1. Allowing for the surface area of the emitter (A) and emissivity (ε) of real materials, the Stefan-Boltzmann law becomes:

P = ε σ AT 4

Emissivity (ε = 1 for a perfect black body)

Stefan-Boltzmann law – emissivity explained Within the definition of Kirchhoff’s law, for an arbitrary body emitting and absorbing thermal radiation in thermodynamic equilibrium, the emissivity is equal to the absorptivity. This means that emissivity is useful to determine how much a surface will absorb as well as emit. Back body (matt) 1.00 0.22   Brass plate dull Aluminium foil 0.04 Brass plate polished 0.03   Radiation in W/m2

P = ε σ AT 4

LONG WAVE Far - infrared(FIR)

Near - infrared Mid - infrared (NIR) (MIR)

Radiated power versus temperature up to 100W/cm2

Infrared heating is non-contact, it does not require a medium for heat transfer. Upon hitting a surface all infrared emissions will be either reflected (ρ), absorbed (α) or transmitted (τ). Reflected radiation

Absorbed

radiation Transmitted radiation

Reflectivity

1=ρ+α+τ

Transmissivity

3500

ε = 0.1 ε = 0.2 ε = 0.3 ε = 0.4 ε = 0.5 ε = 0.6 ε = 0.7 ε = 0.8 ε = 0.9

3000 Temperature ( °C )

Radiation

2500 2000 1500 1000 500 O

Absorptivity

Emission of Radiation Infrared emitters can emit in all directions although some design can help in this regard. Infrared is line of sight, so the product geometry determines how much infrared energy will reach the material surface.

A. Stefan-Boltzmann law The Stefan-Boltzmann law gives the total power radiated at a specific temperature from an infrared source. That is, the entire amount of infrared radiation emitted from a given source (at a specific temperature) over all wavelengths for a black body.

P = σT 4

Absolute temperature (K)

Stefan-Boltzmann constant 5.67 x 10-8 Watts/m2.K4

30 40 50 60 70 Radiated power ( W/cm2 )

100

Using this law means we can now calculate the net heat transfer between two emitting surfaces at T1 and T2 .

P1 = ε1 σ A1T1 4 T2 P2 = ε2 σ A2T2 4

There are three main laws that govern radiative heat transfer.

E = α σ AT 4

Stefan-Boltzmann constant 5.67 x 10-8 W/m2.K

Absorption of Radiation

Power (Watts)

Absorption

Pnet = P2 - P1 Pnet = ε2 σ A2T2 4 - ε1 σ A1T1 4 As both are emitting the net power transfer will be the difference between both emitted power outputs

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

INTRODUCTION TO INFRARED

B. Planck’s law

C. Wien’s displacement law

This mathematical relationship, formulated in 1900 by German physicist Max Planck, Wien’s law follows from Planck’s law and predicts the wavelength at which the gives the spectral distribution of radiation from a black body source. That is, a source spectral distribution of the radiation emitted by a black body is at a maximum. that emits 100% infrared radiation at a specific temperature. The spectral distribution Wiens displacement constant 2898 μm. K shows the amount of power emitted at a particular wavelength. spectral emissive power

λmax = b T peak wavelength in μm

the speed of light in the medium

2 1 2hc Bλ (T) = 5 λ exp (λkhcT )-1

absolute temperature

Black body spectrum

Plank’s constant Boltzmann’s constant

14000

Spectral emissive power ( W/cm2.μm )

1500°C 1200°C 1000°C 700°C

15 10

Spectral emissive power ( W/cm2.μm )

Spectral intensity distribution of a source at various temperatures (ε = 0.9)

1000 K 900 K 800 K 700 K 600 K 500 K 400 K

12000

Notice at 700°C the bandwidth is 9 - 1.2 = 7.8 microns. At 1500°C the bandwidth is now 10 - 0.4 = 9.6 microns

temperature in Kelvin

10000 8000 6000 4000

5 0

2000

4 5 6 Wavelength ( μm )

10 0

Radiation is a continuous function of wavelength whose power increases with temperature

900 K visable 400 600 800 ( nm )

40 50 60 Wavelength ( µm )

100

Notice the dotted red line formed when we connect the maximum points of each temperature curve on Planck’s distribution and connect them.

Source temperature versus peak emission wavelength

900 K 10

A O

Infrared 2000 4000 6000 Wavelength ( nm )

For a ‘red hot’ object the extreme short wavelength end of the blackbody curve encroaches into the red end of the visible spectrum as is the case with solar radiation Planck’s law leads us into the third law that concerns radiative heat transfer

Peak wavelength ( μm )

1000 K

Spectral emissive power ( W/cm2.μm )

1000 K

8 6 4 2 0

500

1000 1500 Temperature ( °C )

2000

2500

Radiation A perfect black-body is a surface that reflects nothing and emits pure thermal radiation. The graph of power versus wavelength for a perfect black-body is called the black-body spectrum. A white-hot filament of a bulb is a good example of a black-body because almost all electromagnetic radiation from the filament is absorbed by surrounding objects and virtually none reflected.

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

Power versus wavelength

104 10

10-2 10

-4

Emitter: An object that acts as a source for infrared radiation. Otherwise referred as IR heater or element in this manual. Heat flux/Heat output: Energy distribution on a unit area per second. Unit is W/cm2 Infrared thermometer: A non-contact temperature measuring equipment, which uses laser beams, at a specified emissivity value Lead wire: Termination wire at the ends of the resistance coil wire Maximum power density: Electrical power distribution on a unit area. Mean surface temperature or average surface temperature: Average of the temperatures measured at different locations on the face of the emitter. Radiant watt density: Radiated power distribution on a unit area. Resistance coil wire: Coil of wire embedded inside the emitter meant for production of heat while resisting the current flow Thermocouple: A temperature measuring equipment which consists of a junction of two dissimilar metals that creates electrical signal when encounters a change in temperature.

600°C Stove 20°C Rock

105

104 103 Wavelength (nm)

102

106

900

Mean surface temperature (°C) FFEH Mean surface temperature (°C) FTE Element power density (W/cm2)

800

710

700 600 500 400 300 200 100 0 0

602

596 624 497 5.4 515 5.1 480 390 4.4 405 4.1 351 3.4 2.7 2.0 1.7 548

200

400

600 800 Power (W)

726 6.8

9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0

1000

1.0 0.0 1200

Power density (W/cm2)

Emissivity: Ratio of the radiation emitted by an emitter (body) at certain temperature to the radiation emitted by a perfect emitter (black body) at the same temperature level. In other words, it is a measure of the emissive nature of an emitter.

Visible light

Variation of surface temperature and power density for FQE (Full Quartz Elements, standard range 150W - 1000W 230V)

900

Mean surface temperature (°C) Element power density (W/cm2)

800 700 600 500 400 300 200 100 0 0

542

593

664 690

438

4.4

343 2.7 1.0 200

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

772 6.8 5.1

600 800 Power (W)

8.0 7.0 6.0 5.0 4.0 3.0 2.0

3.4

1.7 400

9.0

1000

1.0 0.0 1200

Power density (W/cm2)

Infrared heating: Heating an object using infrared radiation. Unlike the other two forms of heating such as conduction and convection, this mode of heating does not require a medium for the heat transfer.

Mean surface temperature (°C)

Classes of Infrared Radiation Class Spectral Range Short-wave (Near-infrared (NIR)) 0.75 – 1.4μm Medium-wave (Mid-infrared (MIR)) 1.4 - 3 μm Long-wave (Far-infrared (FIR)) 3 - 10 μm

2,600°C Light bulb

Variation of surface temperature and power density for FFEH (Full Flat Elements Hollow, standard range 250W - 800W 230V) and FTE (Full Trough Elements, standard range 250W - 1000W 230V) elements

Mean surface temperature (°C)

Infrared (IR) radiation: A part of electromagnetic radiation between the visible light and the microwave spectrum.

Infrared light

5,500°C Sun

10-6 10-8

Summary of terms used

Ultraviolet

106

Relative Power

From the graph, we can see how a light bulb produces a certain quantity of energy with only a small part in the visible spectrum. As temperature increases and the peak wavelength becomes shorter, the greater amount of radiated energy. The graph also shows that a rock at room temperature will not ‘glow’ as the curve for 20°C does not extend into visible spectrum. As objects heat up they start to give off visible light, or glow. At 600°C objects glow dull red, like the element on an electric stove.

Ceramic elements Ceramic trough elements Ceramic hollow elements Ceramic flat elements Ceramic edison screw elements

36 38 40 42

Ceramic Elements

Quartz elements Quartz elements Panel heaters Single tube quartz heaters Quartz Elements

Quartz tungsten / halogen tubes

44 46 46 48

Reflectors and projectors 50 Fast IR 52 Accessories 54

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

CERAMIC TROUGH ELEMENTS Useful wavelength range 2 to 10Âľm (FTE/HTE/QTE) are industry standard curved ceramic infrared heaters used in a wide range of industrial, commercial and domestic applications. These solid cast elements consist of a high temperature FeCrAL resistance alloy embedded in a specially formulated ceramic body allowing operating temperatures up to 750oC and a maximum power of 1000W (FTE Model Only).

FTE Full Trough Element, Standard Wattages 150W 250W 300W 400W 500W 650W 750W 1000W. Standard Voltage 230V. Average weight 192g. 245

100

60 22*

15.5

HTE Half Trough Element, Standard Wattages 125W 150W 200W 250W 325W 400W 500W. Standard Voltage 230V. Average weight 105g. 38

122

100

22*

15.5

QTE Quarter Trough Element, Standard Wattages 125W 250W. Standard Voltage 230V. Average weight 65g. 38

100

15.5

22*

QCE Quarter Curved Element

LFTE Large Full Trough element,

Standard Wattages 150W 250W. Standard Voltage 230V. Average weight 70g

Standard Wattages 1000W 1500W. Standard Voltage 230V. Average weight 356g 245

110

100

38.5

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

28*

CERAMIC ELEMENTS

HEATING UP CURVES

°C

Heating up cooling down curves based on FTE tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 ( element mounted in an aluminised steel reflector, RAS )

COOLING DOWN CURVES

800 700

FTE

1000W 750W 650W 500W 400W 250W 150W

600 500 400 300

HTE

QTE

500W 1250W 325W 250W 125W 200W 125W

LFTE 1500W LFTE 1000W QCE 250W QCE 150W FTEL-LN 1000W

200 100 0

FTE 1000W 750W 650W 500W FTEL_LN 1000W QCE 250W... 150W..... LFTE 1500W- - - 1000W- - - -

400W

15 Time min

250W 150W

Wattage

150W

250W

300W

400W

500W

650W

750W

1000W

Mean surface temperature

272 °C

351 °C

405 °C

480 °C

515 °C

596 °C

624 °C

726 °C

Max power density

9 kW/m2

15 kW/m2

18 kW/m2

24 kW/m2

30 kW/m2

39 kW/m2

45 kW/m2

60 kW/m2

Radiant Watt density at 100mm

0.10 W/cm²

0.48 W/cm²

0.69 W/cm²

0.26 W/cm²

1.14 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

150W

200W

250W

325W

500W

Mean surface temperature

351 °C

405 °C

480 °C

515 °C

596 °C

726 °C

Max power density

15 kW/m2

18 kW/m2

24 kW/m2

30 kW/m2

39 kW/m2

60 kW/m2

0.69 W/cm²

1.14 W/cm²

0.26 W/cm²

Radiant Watt density at 100mm

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

250W

Mean surface temperature

515 °C

726 °C

Max power density

30 kW/m2

60 kW/m2 1.14 W/cm²

Radiant Watt density at 100mm

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

FTEL-LN Full Trough Element Long - Long Neck, Standard Wattage 1000W. Standard Voltage 230V.

200

285 60

62 16

52*

All dimensions mm Tolerances apply Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

CERAMIC HOLLOW ELEMENTS Useful wavelength range 2 to 10Âľm Ceramic Hollow Elements (SFEH, FFEH, HFEH, QFEH) are industry standard ceramic emitters used in a wide range of industrial, commercial and domestic applications. The hollow constructed ceramic element has the advantage of having a shorter heat up time combined with increased energy efficiency. These hollow constructed products consist of a high temperature FeCrAl resistance alloy embedded in a specially formulated light weight hollow cast ceramic body which is subsequently filled with a high density insulating material. This results in a significant reduction in rear heat loss and increased radiant output from the front of the element, the operating temperature is up to a maximum of 750Â°C and a maximum power of 800W (FFEH Model Only)

FFEH Full Flat Element Hollow, Standard Wattages 250W 400W 500W 600W 800W. Standard Voltage 230V. Average weight 250g. 245

120

60 26*

HFEH Half Flat Element Hollow, Standard Wattages 125W 200W 250W 300W 400W. Standard Voltage 230V. Average weight 117g.

122

120

38.5

14.5 22

26*

37.5

QFEH Quarter Flat Element Hollow, Standard Wattages 125W 200W. Standard Voltage 230V. Average weight 75g. 60

120

38.5 60 14.5 26*

37.5

SFEH Square Flat Element Hollow, Standard Wattages 250W 400W 500W 600W 800W. Standard Voltage 230V. Average weight 239g. 122

38.5 122

120

14.5

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

26*

37.5

CERAMIC ELEMENTS

HEATING UP CURVES

°C

COOLING DOWN CURVES

Heating up cooling down curves based on FFEH tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 ( element mounted in an aluminised steel reflector, RAS )

800 700 600 500 400

FFEH

HFEH

800W 600W 500W 400W 250W

400W 1200W 800W 300W 125W 600W 250W 500W 200W 400W 125W 250W

QFEH

SFEH

300 200 100 0

SFEH/FFEH 800W

600W

500W

400W

15 Time min

250W

Wattage Mean surface temperature Max power density Radiant Watt density at 100mm

250W

400W

500W

600W

800W

390 °C

497 °C

548 °C

602 °C

710 °C

15 kW/m2

24 kW/m2

30 kW/m2

36 kW/m2

48kW/m2

0.25 W/cm²

0.44 W/cm²

0.73 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

200W

250W

300W

400W

Mean surface temperature

390 °C

497 °C

548 °C

602 °C

710 °C

Max power density

15 kW/m

24 kW/m

30 kW/m

36 kW/m

48kW/m2

0.31 W/cm²

Radiant Watt density at 100mm

0.49 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

200W

Mean surface temperature

548 °C

710 °C

Max power density

30 kW/m

48kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

250W

400W

500W

600W

800W

Mean surface temperature

390 °C

497 °C

548 °C

602 °C

710 °C

Max power density

15 kW/m

24 kW/m

30 kW/m

36 kW/m

48kW/m2

Radiant Watt density at 100mm

0.28 W/cm²

0.81 W/cm²

1.18W/cm²

0.51W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

CERAMIC FLAT ELEMENTS Useful wavelength range 2 to 10Âľm Ceramic IR Flat Elements (FFE/HFE/QFE) are industry standard ceramic emitters used in a wide range of industrial, commercial and domestic applications. These solid cast ceramic elements consist of a high temperature FeCrAl resistance alloy embedded in a specially formulated ceramic body allowing operating temperatures up to 750Â°C and a maximum power output of 1000W (FFE Model Only). The solid cast heater body is flat, producing a diffuse radiant output to target distance in some applications.

FFE Full Flat Element, Standard Wattages 150W 250W 300W 400W 500W 650W 750W 1000W. Standard Voltage 230V. Average weight 182g. 245

100 60 15*

HFE Half Flat Element, Standard Wattages 125W 150W 200W 250W 325W 500W. Standard Voltage 230V. Average weight 105g. 122

100

15*

QFE Quarter Flat Element, Standard Wattages 125W 250W. Standard Voltage 230V. Average weight 65g. 38

100

14 15*

SFSE Full Flat Solid Element, Standard Wattages 250W 400W 500W 600W 800W . Standard Voltage 230V. Average weight 192g. 122 38

122

150

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

15*

CERAMIC ELEMENTS

HEATING UP CURVES

°C

COOLING DOWN CURVES

Heating up cooling down curves based on FFE tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 ( element mounted in an aluminised steel reflector, RAS )

800 700

FFE 1000W 750W 650W 500W 400W 250W 150W

600 500 400 300

HFE QFE SFSE 500W 1250W 750W 650W 325W 250W 125W 500W 400W 200W 250W 125W 150W

LFFE 1400W 750W 350W 150W

200 100 0

FFE 1000W LFFE 1400W

750W 750W

650W

500W

350

150W

400W

15 Time min

250W 150W

Wattage

150W

250W

300W

400W

500W

650W

750W

1000W

Mean surface temperature

272 °C

351 °C

405 °C

480 °C

515 °C

596 °C

624 °C

726 °C

Max power density

9 kW/m

15 kW/m

18 kW/m

24 kW/m

30 kW/m

39 kW/m

45 kW/m

60 kW/m2

Radiant Watt density at 100mm

0.10 W/cm²

0.25 W/cm²

0.47W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

150W

200W

250W

325W

500W

Mean surface temperature

351 °C

405 °C

480 °C

515 °C

596 °C

726 °C

Max power density

15 kW/m2

18 kW/m2

24 kW/m2

30 kW/m2

39 kW/m2

60 kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95 (element mounted in an aluminised steel reflector, RAS)

Wattage

125W

250W

Mean surface temperature

515 °C

726 °C

Max power density

30 kW/m

60 kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.95(element mounted in an aluminised steel reflector, RAS)

Wattage

150W

250W

300W

400W

500W

650W

750W

Mean surface temperature

272 °C

351 °C

405 °C

480 °C

515 °C

596 °C

624 °C

Max power density

9 kW/m

15 kW/m

18 kW/m

24 kW/m

30 kW/m

39 kW/m

45 kW/m2

0.71 W/cm²

0.81 W/cm²

Radiant Watt density at 100mm

0.23 W/cm²

0.39 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 (element mounted in an aluminised steel reflector, RAS)

All dimensions mm Tolerances apply

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

LFFE Large Flat Solid Element,

Standard Wattages 150W 350W 750W 1400W.

245

Standard Voltage 230V.

150

Average weight 342g. 15*

CERAMIC EDISON SCREW ELEMENTS Useful wavelength range 2 to 10Âľm Ceramic Edison Screw Elements (ESEB, ESES, ESER, ESEXL) are industry standard infrared bulbs used primarily in the area of reptile/animal/pet health care. These ceramic bulbs provide the infrared heat required without any of the negative effects of a light output that can disturb the day/night sleeping cycle of the reptile/animal. Ceramicx hollow cast bulbs consist of a high temperature FeCrAl resistance alloy embedded in a specially formulated ceramic body allowing operating temperature up to 530Â°C and a maximum power of 400W (ESEXL Model Only). The face of the ESE is circular and convex in design, producing a circular outward trending radiant output.

ESES Edison Screw Element Small,

ESER Edison Screw Element Regular,

Standard Wattages 60W 100W. Standard Voltage 230V. Average weight 113g

Standard Wattages 150W 250W. Standard Voltage 230V. Average weight 165g 28

112 82

ESEB Edison Screw Element Bulb, Standard Wattages 60W 100W. Standard Voltage 230V. Average weight 112g

ESEXL

Edison Screw Element Large, Standard Wattages 300W 400W. Standard Voltage 230V. Average weight 253g

35 109

112

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

140

CERAMIC ELEMENTS

Wattage

150W

350W

750W

1400W

Mean surface temperature

204 °C

338°C

501 °C

667 °C

Max power density

5.4 kW/m

12 kW/m

27 kW/m

50 kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 (element mounted in an aluminised steel reflector )

°C

HEATING UP CURVES

COOLING DOWN CURVES

Heating up cooling down curves based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9 ( element mounted in an aluminised steel reflector, RAS )

800 700

ESES

600

ESEB ESEXL 1 400W

ESER 250W

500

300W

150W

400

100W 60W

300

100W 60W

200 100 0

400W ESEXL

250W ESER

300W ESEXL

15 Time min

150W ESER

100W ESES/ESEB

ESES

60W ESES/ESEB

ESER

ESEB

Wattage

60W

100W

150W

250W

Mean surface temperature

300°C

426 °C

441°C

516 °C

Max power density

7.3kW/m2

12 kW/m2

15kW/m2

25 kW/m2

ESEXL

60W

100W

300W

400W

300°C

426 °C

450°C

530 °C

13.5kW/m

22.5 kW/m

22.5kW/m2

30 kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.9

UNIT CONVERSION Celsius ( °C) - Fahrenheit ( °F ) °F = (°C x 1.8 ) + 32.0 FTE 1000W, mean surface temperature 726°C = (726 x 1.8) + 32.0 = 1338.8 °F Millimetres ( mm ) - inches ( in ) in = mm x 0.039370 FTE 1000W, dimensions 245 x 60 mm = (245 x 0.039370) x (60 x 0.039370) = 9.65 x 2.36 in Grams ( g ) - ounces ( oz ) oz = g x 0.035274 FTE 1000W, average weight 192g = 192 x 0.035274 = 6.77 oz Watts per meter square ( W/m2 ) - Watts per inch square ( W/in2 )

W/in2 = W/m2 x 0.000645

FTE 1000W, max power density 60 W/m2 = 60 x 0.00645 = 0.387W/in2

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

QUARTZ ELEMENTS Useful wavelength range 1.5 to 8Âľm Quartz infrared heating elements provide medium wave infrared radiation. They are favoured in industrial applications where a more rapid heater response is necessary, including systems with long heater off cycles. Quartz infrared heating elements are particularly effective in systems where rapid heater response and/or zone controlled heating is required. They have a broad emission spectrum from around 1.4 to 8 microns, slightly shorter in wavelength than ceramic elements. Pillared quartz elements have the same mounting fixture as ceramic elements allowing easy replacement.

FQE Full Quartz Element, Standard Wattages 150W 250W 300W 400W 500W 650W 750W 1000W. Standard Voltage 230V. Average weight 403g. 247

100

187 62.5

29 22.5

HQE Half Quartz Element, Standard Wattages 150W 250W 400W 500W. Standard Voltage 230V. Average weight 210g. 123.5

63.5

100

62.5

22.5

QQE Quarter Quartz Element, Standard Wattages 150W 250W. Standard Voltage 230V. Average weight 144g. 62.5

37.5

100 29

62.5

22.5

SQE Square Quartz Element, Standard Wattages 150W 650W, 1000W. Standard Voltage 230V. Average weight 401g. 123.5

93.5

123.5

100

80 28 22.5

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

QUARTZ ELEMENTS

HEATING UP CURVES

°C

COOLING DOWN CURVES

Heating up cooling down curves based on FQE tests of average surface temperature with an infrared thermometer set at an emissivity of 0.7 ( element mounted in an aluminised steel reflector, RAS )

800 700

FQE 1000W 750W 650W 500W 400W 250W 150W PFQE

600 500 400 300 200

HQE 500W

QQE 250W

325W 250W

SQE 1000W 750W 650W 500W 400W 250W 150W

PHQE

100 0

0 FQE 1000W

5 750W

10 650W

500W

15 Time min

400W 250W 150W

Wattage

150W

250W

300W

400W

500W

650W

750W

1000W

Mean surface temperature

343 °C

438 °C

477 °C

542 °C

593 °C

664 °C

690 °C

772 °C

Max power density

9 kW/m

15 kW/m

18 kW/m

24 kW/m

30 kW/m

39 kW/m

45 kW/m

60 kW/m2

Radiant Watt density at 100mm

0.10 W/cm²

0.26 W/cm²

0.48 W/cm²

0.69 W/cm²

1.14 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.7 (element mounted in an aluminised steel reflector, RAS)

Wattage

150W

250W

325W

400W

500W

Mean surface temperature

477 °C

493 °C

644 °C

709 °C

772 °C

Max power density

18 kW/m

30 kW/m

39 kW/m

48 kW/m

60 kW/m2

Radiant Watt density at 100mm

0.26 W/cm²

0.69 W/cm²

1.14 W/cm²

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.7 (element mounted in an aluminised steel reflector, RAS)

Wattage Mean surface temperature Max power density

150W 642 °C 36 kW/m2

250W 772 °C 60 kW/m2 1.14 W/cm²

Radiant Watt density at 100mm

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.7 (element mounted in an aluminised steel reflector, RAS)

Wattage

150W

250W

300W

400W

500W

650W

750W

1000W

Mean surface temperature

343 °C

438 °C

477 °C

542 °C

593 °C

644 °C

690 °C

772 °C

Max power density

9 kW/m

15 kW/m

18 kW/m

24 kW/m

30 kW/m

39 kW/m

45 kW/m

60 kW/m2

Based on tests of average surface temperature with an infrared thermometer set at an emissivity of 0.7 (element mounted in an aluminised steel reflector, RAS)

All dimensions mm Tolerances apply Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

PFQE Pillared Full Quartz Element, Standard Wattages 150W 250W 400W 500W 650W 750W 1000W. Standard Voltage 230V. Average Weight 403g

73.5

247

13.5

39.5

26.5 62.5

10 22.5

STQH Single tube Quartz Heaters, STQH 100

Standard Wattage Range 150W - 400W.

STQH 112

Standard Wattage Range 150W - 400W.

Standard Voltage 230V

Standard Voltage 230V 100

100

112

100 56

Unheated area 100

Unheated area 112

PANEL HEATERS Useful wavelength range 4 to 6µm They are a neat, easily mounted and readily expanded heating solution. Infrared panel heaters are custom built infrared heaters operating primarily in the long wave range. The basic construction consists of a resistance coil embedded into a ceramic fibre board which is then located behind an emitting surface of either anodised aluminium or glass ceramic. This is then placed inside a 75mm high aluminised steel housing which normally contains 50mm of thermal insulation to reduce heat loss through the rear of the unit.

STANDARD OPTIONS

( Other options available on request. Please contact us for further details.)

Emitting surface Electrical terminations Fixing studs

Glass ceramic face - Very good radiant efficiency, high percentage transmission of radiant output in medium to short wave range, surface can be easily cleaned. Anodised aluminium face - Good radiant efficiency, very robust, surface sheet can be easily cleaned or replaced if damaged by molten material. Open 2P terminal block, Terminal block with cover, M6 or 1/4” threaded stud, Type K thermocouple with fixed high temperature socket and removable plug M5/M6/M8/0.25” x 25mm long

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

QUARTZ ELEMENTS

PHQE Pillared Half Quartz Element, Standard Wattages 150W 250W 400W 500W. Standard Voltage 230V. Average Weight 268g

73.5

124

13.5

39.5

26.5 62.5

10 22.5

STQH 140

STQH 150

Standard Wattage Range 150W - 650W.

Standard Voltage 230V

Standard Voltage 230V 100

100

150

140 70

Unheated area

Unheated area 150

140

Sample panel heater, black anodised aluminium face, 270 x 135mm, 500W, 230V, with open 2P terminal block connection. 270

135

25 M5 mounting studs

Interchangable anodised aluminium face

Watts: Volts: Serial no: www.ceramicx .com

Stainless steel clips (x4)

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

QUARTZ TUNGSTEN/ QUARTZ HALOGEN TUBES The tungsten filament used in these quartz tungsten heaters is the porcupine or star type coil, which can be operated at temperatures up to 1500째C (2732째F), with a peak wavelength emission of approximately 1.6 microns. It reaches top temperatures within seconds. Halogen heaters are filled with a halogen gas to allow the supported tungsten filament to reach temperatures as high as 2600째C (4712째F). Peak emissions for these tubes is around 1 micron. These emitters heat up and cool down within seconds making them particularly suitable for systems requiring short cycle times.

QTS Quartz Tungsten Short,

QTM Quartz Tungsten Medium,

Standard Wattage 750W. Standard Voltage 240V.

Standard Wattage

1000W. Standard Voltage 240V. 277

244

7.2

7.2 225 Heated Length

170 Heated Length

QHS Quartz Halogen Short,

QHM Quartz Halogen Medium,

Standard Wattage 750W . Standard Voltage 240V.

Standard Wattage 1000W. Standard Voltage 240V. 277

224 10

7.2

7.2 225 Heated Length

170 Heated Length

Bespoke sizes are also available but a minimum order of 25 pieces applies. Quartz tungsten tube, 450W, 120V, 342mm, terminal R7s, Gold reflective coating. Twin tube medium wave heater, 750W, 240V, 400 x 23.3 x 11.7mm, terminal type B, 3,000 mm leads, Gold reflective coating.

Quartz halogen tube, 2,000W, 240V, 473mm, terminal R7s, Ruby coating.

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

Quartz tungsten tube, 450W, 120V, 342mm, terminal RCB, 100mm leads. Ceramic coating.

QUARTZ TUNGSTEN/HALOGEN TUBES

Tube Sizes

ELEMENT TYPE QTS QTM QTL QTL QTL QHS QHM QHL

WATTS 750W 1000W 1500W 1750W 2000W 750W 1000W 2000W

MAX COIL TEMPERATURE

Single Tube

1450°C 1450°C 1270°C 1470°C 1500°C 2410°C 2410°C 2250°C

Coil Type Twin Tube

23 Twin Tube

TTF Fast Medium Wave Quartz Tungsten

Termination Type Single Tube TTS Short Wave Quartz Halogen R7s (Standard)

FCB Flat Ceramic base

TTL Long Wave Quartz Coil Type twin tube

MT Metal Tab

Coatings

Type B Single Sided Connection SL Sleeve

Ceramic

RCB Round Ceramic Base

Termination Type

Type C Double Sided Connection

Gold R7s Ring (Standard) M4/M5

Ruby

Fork M4/M5

QTL Quartz Tungsten Long, Standard Wattage 1500W 1750W 2000W. Standard Voltage 240V. 473 10 7.2 415 Heated Length

QHL Quartz Halogen Long, Standard Wattage 1000W 1750W 2000W. Standard Voltage 240V. 473 10 7.2 415 Heated Length

Short wave heater, 1000W, 240V, 250 x 20 mm, terminal type SL Sleeve with 500 mm leads,

Twin tube short wave heater, 900W, 120, 400 x 11 x 23mm, terminal type TTS, 100 mm leads. Short wave heater, 450W, 120V, terminal type RCB, 100 mm leads, Ceramic reflective coating.

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

REFLECTORS AND PROJECTORS Highly reflective aluminised steel projectors and reflectors At Ceramicx, our reflectors are designed to cater for a wide range of ceramic and quartz infrared emitters. units can be mounted individually or side-by-side forming infrared heat panels. Our projectors are designed to cater to a wide range of ceramic elements and are the ideal solution where positional heat is required economically, efficiently and quickly.

RAS 5 Suitable for FTE, FFEH and FFE elements. Overall length A = 1,254 mm Distance between fittings B = 1,028 mm

RAS Reflector Aluminised Steel Reflector material 0.75mm polished aluminised steel. Mounting studs with M6 internal thread. 300mm, high temperature leads.

250mm x 4

RAS 4 Suitable for FTE, FFEH and FFE elements. Overall length A = 1,004mm Distance between fittings B = 778 mm 100 250mm x 3

RAS 3 Suitable for FTE, FFEH and FFE elements. Overall length A = 754 mm Distance between fittings B = 528 mm B 250mm x 2 60

RAS 2 Suitable for FTE, FFEH and FFE elements. Overall length A = 504 mm Distance between fittings B = 278 mm 250 mm

RAS 1 Suitable for FTE, FFEH and FFE elements. Overall length A = 254 mm Distance between fittings B = 172 mm

RAS 0.5 Suitable for HTE, HFEH and HFE elements.

Overall length A = 160 mm Distance between fittings B = 96 mm

30 30

RAS 1 shown as example

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

REFLECTORS AND PROJECTORS

QTR Quartz Tungsten / Halogen Reflectors 62

Reflector manufactured from 0.75 mm polished aluminised steel. 2 x M5 fixing bolts R7s holders with 200mm leads Ø 0.75mm with PTFE-insulation

QTSR Quartz Tungsten Halogen Short Reflector

Suitable for QTS/QHS tubes with R7s terminations Overall length A = 250mm Distance between fittings B = 153mm

QTMR Quartz Tungsten Halogen Medium Reflector

Suitable for QTM/QTL tubes with R7s terminations Overall length A = 300mm Distance between fittings B = 203mm

QTLR Quartz Tungsten Halogen Long Reflector

Suitable for QTL/QHL tubes with R7s terminations Overall length A = 497mm Distance between fittings B = 400mm 48

QTSR shown as example

PAS 5 Suitable for FTE, FFEH and FFE elements. Overall length A = 1,258 mm B = 1,200mm C = 1,140mm

PAS Projector Aluminised Steel Reflector material 0.75mm polished aluminised steel. Ø16 mm metal conduit, length 1.5m

250mm x 4

PAS 4 Suitable for FTE, FFEH and FFE elements. Overall length A = 1,008 mm B = 950mm C = 890 mm 96 250mm x 3

PAS 3 Suitable for FTE, FFEH and FFE elements. Overall length A = 758 mm B = 700mm C = 640mm

B C

250mm x 2

PAS 2 Suitable for FTE, FFEH and FFE elements. Overall length A = 508 mm B = 450mm C = 390mm 250mm

PAS 1 Suitable for FTE, FFEH and FFE elements. Overall length A = 258 mm B = 200mm C = 140mm

33.5

92.5

PAS 1 shown as example

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

FAST IR These compact robust systems form an ideal installation for quartz heating elements - quartz tungsten/halogen glass tube emitters. Optimum efficiency is achieved by highly polished aluminium steel reflection and rear mounted axial flow fans, which eliminate rear convection losses and keep the reflectors cool for better directional quality on the infrared output. The external body which manufactured from aluminium can be maintained at â&#x20AC;&#x153;touch safeâ&#x20AC;? temperature.

500

450

500

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

450

FAST IR HEATERS

FAST IR 305 Suitable for 1000W Quartz tungsten/Halogen heaters QTM or QHM. Standard FastIR 305 designed to hold 4 tubes (4kW), also available as 5 tube (5kW). 20 305

255

150

255

305

4 x Aluminium stand off with M6 threaded screw with fixing nut. Electrical termination made via 1.5m of 16mm diameter flexible metal conduit with additional 0.5m of glass fibre insulated NPC conductors. 2 rear mounted axial flow fans. Suitable for heater type QTM (Quartz Tungsten Medium) or QHM (Quartz Halogen Medium) tubes with R7s termination, 240V (1000W maximum) See page 48 for details of tubes. 20 150

FAST IR 500

Suitable for 1500W, 1750W, 2000W Quartz Tungsten heaters QTL or 2000W Quartz Halogen heaters QHL . Standard FastIR 500 designed to hold 6 tubes (12kW) also available as 7 tube (14kW). 4 x Aluminium stand off with M6 threaded screw with fixing nut. Electrical termination made via 1.5m of 25mm diameter flexible metal conduit with additional 0.5m of glass fibre insulated NPC conductors. 6 rear mounted axial flow fans. Suitable for heater types QTL (Quartz Tungsten Long) or QHL (Quartz Halogen Long) tubes with R7s termination, 240V (2000W maximum) See page 49 for details of tubes Please note other configurations are available on request.

Products

I N F R A R E D

Solutions

F O R

Research and development

I N D U S T R Y Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

ACCESSORIES Ceramicx manufactures a range of accessories, including steatite press components. Steatite ceramic dust has proven itself to be the material-of-choice for the manufacture of electrical insulators thanks to its good mechanical strength, ideal dielectric properties and high temperature resistivity of up to 1000oC

2P Ceramic terminal block Stainless steel fittings Maximum voltage: 500V Maximum temperature: 450°C Maximum current: 20A* Maximum cable CSA (solid): 4.0mm sq. Maximum cable CSA (stranded/with ferrule) 2.5mm sq. *Up to 30A permissible at lower temperatures.

41 M4 x 8

32.5 19.5

2P Mini Ceramic terminal block

TB2 Ceramic terminal block

Nickel galvanised brass inserts. Zinc plated steel screws. 21 x 18 x 15mm

Plated brass inserts. Nickel galvanised screws. 34 x 30 x 22mm

Ceramic beads beads strung Ø 2.0

TB3 Ceramic terminal block

Plated brass inserts. Nickel galvanised screws. 51 x 30 x 22mm

Material: Steatite C-221

Ø 4.0

4.5

6.0

Ø 5.0

2P Terminal block no fittings 40 x 32 x 20mm

Grommet set Ceramic grommet and star-lock fastener set, used as insulator in sheet metal with 6mm hole 9.5 x 7.5 mm

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

Ceramic tubes Ø5 x 11.5 mm Material: Steatite C-221

ACCESSORIES

High temperature NPC cable

Continuous working temperature: -60°C to +280°C Peaks at 350°C Working voltage: 300/500V

3 2 2 1

1. Flexible nickel plated copper core 2. Multiple silicone-impregnated glass lapping 3. Silicone - coated fibreglass braid

Nominal core cross -section

Nominal core stranding

Outer cable diameter

Linear weight approx

0.75 mm2

11 x 0.30 21 x 0.30 35 x 0.30 56 x 0.30

2.4 mm 2.8 mm 3.2 mm 4.0 mm

11.9 kg/km 20.5 kg/km 32.2 kg/km 50.1 kg/km

1.50 mm2 2.50 mm2 4.00 mm2

Fibre glass braided sleeving

Fibre glass braided sleeving non-impregnated Continuous working temperature: -60°C to +450°C

Stainless steel buss bar

Nominal Inner diameter

Min. wall thickness

Linear weight approx

2 mm 4 mm 6 mm

0.20 0.30 0.30

3.10 kg/km 7.60 kg/km 12.00 kg/km

R7s ceramic holder

Used with the ceramic terminal block to produce a flexible power distribution system 8 x 2 x 1000 mm

Steel wave and spring clip

For standard quartz tungsten/halogen tubes

Used in the mounting and instillation of all Ceramic and pillared quartz elements

For further details of our products see our website

w w w.ceramicx.com

CERAMIC ELEMENTS - Trough elements FTE, HTE, QTE, QCE, LFTE. Hollow elements FFEH, HFEH, QFEH, SFEH. Flat elements FFE, HFE, QFE, SFSE, LFFE. Ceramic bulbs ESEB, ESES, ESER, ESEXL QUARTZ ELEMENTS - Standard quartz elements FQE, HQE, QQE, SQE. Pillared quartz elements PFQE, PHQE. Quartz square tube elements STQH100, STQH112, STQH140, STQH150. QUARTZ TUNGSTEN/HALOGEN TUBES - Quartz tungsten tubes QTS, QTM, QTL. Quartz halogen tubes QHS, QHM, QHL. REFLECTORS AND PROJECTORS - Reflectors RAS0.5, RAS1, RAS2 , RAS3, RAS4, RAS5, RAS6. Projectors PAS , PAS2, PAS3, PAS4, PAS5. QTS reflectors QTSR, QTMR, QTLR. EQUIPMENT - Fast IR systems Fast IR 305, Fast IR 500. Panel Heaters. Spot heaters. Furnace heaters. Test ovens. Clam shell ovens. ACCESSORIES - High temp connectors, 2P terminal block, 2P mini, TB2, TB3, Buss bar. Mounting components Flat ceramic base holder, R7s holder, Steel wave and spring set, Dust press components Ceramic beads, Grommet and star lock, Ceramic tubes, 2P block. High temperature cable O.75, 1.5, 2.5, 4.0 , Fibre glass sleeving.

w w w.ceramicx.co.uk

w w w.ceramicx.com.tr

Ceramicx

Product Guide

W W W.C E R A M I C X . C O M

CERAMICX SALES BY COUNTRY

Registered address

I NF R A R E D

FOR

I N DU ST RY

Ceramicx Ltd. Gortnagrough, Ballydehob, Co. Cork, P81 HO26, Ireland. Tel: +353 28 37510 Fax: +353 28 37509 sales@ceramicx.com www.ceramicx.com Ceramicx Ltd. 20 Station Road, Cambridge, CB1 2DJ, U.K. Tel: +44 1223 653159 sales@ceramicx.co.uk www.ceramicx.co.uk Ceramicx İnfrared Teknolojileri Sanayi ve Tic. Ltd. Şti. İkitelli O.S.B. Giyim Sanatkarlari İş ve Tic. Mrkz.3. Ada A Blok No:102, Başakşehir, Istanbul / Türkiye. Tel: +90 212 549 4839 Mobile:+90 544 237 2649 satis@ceramicx.com www.ceramicx.com.tr

C E R A M I CX I N F R A R E D F O R I N D U S T R Y

Ceramicx Ltd. Gortnagrough, Ballydehob, Co. Cork, P81 HO26, Ireland. Registered in Ireland No. 183040 Directors. Mr. F. Wilson, Mrs. G. Wilson, Dr. C. Wilson. VAT No. IE6583040T

www.ceramicx.com

Product Guide

I N F R A R E D

F O R

I N D U S T R Y

Ceramicx Ltd. Gortnagrough, Ballydehob, Co. Cork, P81 HO26, Ireland. Tel. +353 28 37510 Fax. +353 28 37511 e.mail. sales@ceramicx.com www.ceramicx.com