Clamp Heaters
Clamp Heaters; it is resistance that can be used in environments with high temperatures. These resistors, which are frequently used in different workplaces, are products with high durability up to 800 degrees.
Our Clamp Type Heaters products are produced from alumsinian steel or special galvanized. It is also extremely resistant to expansion and yawning problems. Clamp Heaters models are generally preferred in the heavy industry thanks to their durable structure.
Clamped Heaters, which have a wide range of uses, can be produced in different shapes and models according to their functional characteristics.
Clamp Heaters
Clamp Heaters
Clamp Heaters
Clamp Heaters
Ceramic Air Cooling Heater
Group Clamp Heating with Ceramic Seperator
Group Clamp Heating with Ceramic Seperator
Half Moon Clamp Heating
Techincal Information
High quality Clamp Heaters are manufactured for high heat-requiring working applications and areas. Clamp Heaters, which are also used easily at the highest temperatures, are among the products that manage to appeal to different uses
Clamp Heaters are produced in 3 different models based on working principles:
Mika Insulated Clamp Heaters
Mica insulated Clamp Resistance models are used efficiently in the shaping and projecting of plastic raw materials, especially in extruder, injection type plastic machines in areas with a working temperature of up to 300°C. In addition, it is widely used in heating tanks of different sizes of many pipelines. Mica Insulated Clamp Resistors are frequently used in industrial areas due to their affordable cost.
Ceramic Clamp Heatres
Ceramic Clamp Resistors, one of the most durable types of clamp resistors, can be easily used in applications up to 650°C. The most important feature that allows ceramic resistors to reach such high temperatures are steatite alloy ceramics used to insulate the resistance wire. The main uses of Ceramic Clamp Resistors are; In addition, ceramic Clamp Resistors are frequently used in heating pipelines, various tanks and special projects by spraying from the outside, which requires high temperature and high power. The energy outputs of ceramic clamp resistors are produced with Klemensli – Closed Box Clamp – Wired – Iron plug output.
Clamp Heaters Models
Square type or flat rectangular pipe heaters manufactured with thin cross-section closed circuit production technique applied to stainless steel as an outer sheath can be produced by placing. Since such resistance models include a closed circuit system, they can be easily used in places with moisture, steam, humidity and liquid fluidity. The probability of failure of these products due to the above handicap reasons is very low. In addition, such Clamp Resistance models can be easily used in areas with a maximum thermal environment of 500 °C.
What is Clamp Heating?
Clamp heating element is a heating system powered by electric current. This heating system generates heat by electric current passed through a metal component and spreads the heat to the targeted area thanks to its clamp-shaped structure.
Technical Specifications of Clamp Heaters
Clamp heaters may have the following technical specifications:
Operating Voltage: Typically ranging from 110V to 240V.
Operating Current: The amount of electrical current required for operation.
Heating Area: The size of the area to be heated.
Heat Output: The amount of heat produced relative to the energy consumed.
Dimensions: The length, width, and thickness of the clamp heater.
Mounting Options: How the clamp heater can be mounted (flat, circular, etc.).
Material: The type of material used in the construction of the clamp heater (nickel alloy, brass, etc.).
Temperature: The maximum operating temperature of the clamp heater.
Usage Areas of Clamp Heaters
Clamp heaters can be used in various industrial and residential applications. Some of the areas where clamp heaters are utilized include:
Industrial: Plastic molding, painting and coating, metal processing, mold heating.
Residential: Water heaters, water tanks, water filter heating.
Automotive: Engine temperature control, heating of oil and clutch fluid.
Chemical and Petroleum Industry: Reactor heating, separation of solid-liquid solutions, solution heating.
What is a Ceramic Clamp Heater?
Ceramic Clamp Heaters refer to the electrical resistance of a ceramic material when subjected to mechanical compression or pressure. This term is typically used in the context of electrical engineering and materials science and defines the ability of a ceramic material to resist the flow of electrical current when clamped or compressed.
The resistance of a ceramic material can be influenced by various factors including the composition and microstructure of the material, the type of ceramic, the presence of impurities, and the applied clamping force. The ceramic clamp resistance of a material can be an important factor in determining its suitability for use in electrical and electronic applications such as the production of capacitors, resistors, and other components.
Ceramic Clamp Heaters Technical Specifications
The characteristics of ceramic clamp heaters can vary depending on the manufacturer and the specific product, but some general features include:
Resistance value: The resistance of the heater, typically measured in ohms.
Tolerance: The amount by which the resistance can deviate from the nominal value, expressed as a percentage.
Power rating: The maximum power that the heater can safely dissipate, typically measured in watts.
Operating temperature range: The range of temperatures within which the heater can be safely used.
Temperature coefficient of resistance (TCR): The rate at which the resistance of the heater changes with temperature, typically measured in parts per million per degree Celsius (ppm/°C).
Insulation resistance: The resistance of the insulation surrounding the heater, typically measured in megaohms.
Voltage rating: The maximum voltage that the heater can withstand, typically measured in volts.
Size: The physical dimensions of the heater, typically specified as length, width, and height.
Termination type: The type of connection used to attach the heater to a circuit, such as wire leads or surface-mount pads.
Dielectric strength: The maximum voltage that the insulation surrounding the heater can withstand before breaking down, typically measured in volts.
Uses of Ceramic Clamp Heaters
Ceramic clamp heaters, also known as ceramic clamp heaters, are used in various industrial and commercial applications where a heat source is required. Some common uses of ceramic clamp heaters include:
Plastic processing: Heating molds to create plastic parts.
Packaging industry: Heating surfaces for bonding and cutting packaging films.
Food and beverage industry: Heating tanks, pipes, and other equipment for processing and storing food and beverage products.
Medical industry: Sterilizing medical instruments and equipment.
Printing industry: Heating printing plates and drying ink.
Textile industry: Heating textile machinery and equipment.
Chemical industry: Heating chemical tanks and reactors.
Clamp Heaters
Clamp heaters are effective resistance systems used in environments requiring high temperatures. Widely preferred in industrial areas, these specific heaters can provide high durability up to 800 degrees. Our clamp-type heaters are manufactured from aluminum steel or special galvanized materials, making them highly resistant to issues such as expansion and contraction.
One of the main reasons clamp heaters are frequently used in heavy industrial industries is their robust structure along with their wide range of applications. These heaters can be produced in various shapes and models depending on their functional features. For instance, they are utilized in industrial ovens, plastic processing machines, the automotive sector, and many other fields.
Known for their durable structure, clamp heaters offer reliable performance in high-temperature environments and ensure long-lasting use. Additionally, they are available in various sizes and power options, making them suitable for a wide range of applications to meet different requirements. With these features, clamp heaters have become a preferred solution for many businesses in industrial processes.
Technical Information of Clamp Heaters
High-quality Clamp Heaters are typically specially manufactured for industrial applications and areas requiring high temperatures. These clamp heaters are products that can be safely used even at the highest temperature degrees and can meet various industrial needs.
Clamp Heaters are produced in three different models:
Mica Insulated Clamp Heaters: Mica insulated clamp heaters are commonly used in areas requiring temperatures up to 300°C. They are efficiently used in shaping and molding plastic raw materials, especially in extrusion and injection-type plastic processing machines. Additionally, they are widely preferred for heating various pipeline systems and tanks of different sizes. Due to their cost-effectiveness, mica insulated clamp heaters are frequently used in industrial areas.
Ceramic Clamp Heaters: Ceramic clamp heaters are one of the most durable types of clamp heaters and are generally used in applications requiring temperatures up to 650°C. An important feature that makes ceramic heaters resistant to high temperatures is the steatite alloy ceramics used to insulate the resistance wire. These types of heaters are commonly used in areas where plastic raw materials are shaped and melted. Moreover, they are preferred in pipelines, various tanks, and special projects requiring high temperatures and high power. Energy outputs of ceramic clamp heaters can be produced with terminal block, closed box terminal block, cable, or iron plug outputs.
Clamp Heater Models: Square or flat rectangular tube heaters manufactured by the thin-sectioned closed circuit production technique placed inside stainless steel outer casing can be safely used in environments with moisture, steam, humidity, and liquid flow. These types of heater models offer reliable performance by minimizing the possibility of malfunctions. Additionally, these products, which can be used at a maximum temperature of 500°C, are preferred in various industrial applications.
Usage Areas of Clamp Heaters
Clamp heaters have a wide range of applications and can be effectively used in many industrial and domestic settings. Here are more detailed areas of use for clamp heaters:
Industrial Applications:
– Plastic Molding: Used in plastic injection machines, extrusion machines, and other plastic shaping processes. They provide heating for melting and shaping plastic materials.
– Painting and Coating Industry: Used in paint drying ovens, industrial drying facilities, and other painting and coating applications.
– Metal Processing: Used for shaping, forging, or hardening metal parts.
– Mold Heating: Used for heating molds in molding processes.
Domestic Applications:
– Water Heaters: Used in water heaters for producing hot water.
– Water Tanks: Used for heating the water inside water tanks and storing hot water.
– Water Filter Heating: Can be used to prevent the freezing of water in water filters.
Automotive Applications:
– Engine Temperature Control: Used to prevent engine freezing in cold weather and ensure optimal operating temperature.
– Heating of Oil and Clutch Fluid: Used to reduce the viscosity of oil and clutch fluids in cold weather and facilitate faster engine warming.
Chemical and Petroleum Industry Applications:
– Reactor Heating: Can be used in reactors to accelerate chemical reactions or maintain them at specific temperatures.
– Separation of Solid-Liquid Solutions: Used in industrial filtration and separation processes.
– Solution Heating: Used in chemical processes to heat solutions and carry out reactions.
Clamp heaters, used in these and similar applications, can increase the efficiency of industrial processes while also providing energy and cost savings.
Clamp Heaters
Technical Details of Clamp Heaters
Clamp heaters are heating elements that can be easily mounted on pipes, pipelines, cylindrical surfaces, or various shaped materials. These heaters are widely used in industrial heating systems, including sectors such as metal processing, plastic manufacturing, chemical processing, and food processing. Clamp heaters stand out for their ease of installation and high heating efficiency. Here are the technical details of clamp heaters:
1. Structure and Design
Clamp heaters typically consist of electrical heating elements wrapped around a metal clamp. The clamp section is designed to fit tightly onto the surface to be mounted.
Clamp Material: The clamp is usually made from stainless steel, aluminum, or alloy steel. These materials offer high thermal conductivity and durability.
Heating Element: The heating element is generally made of nichrome (nickel-chromium alloy) or kanthal (iron-aluminum-silicon alloy), which can withstand high temperatures.
Outer Coating: The heating element is often coated with insulating materials such as silicone, mica, or aluminum oxide to minimize heat loss.
2. Electrical Properties
The electrical properties of clamp heaters depend on the type of material used, length, and power capacity in watts. Common electrical characteristics include:
Resistance: The electrical resistance of clamp heaters varies based on the material used. Typical resistance ranges include:
1 ohm – 50 ohms (for various power options)
Power Capacity: Clamp heaters generally come in a wide power range. Common power options include:
100 W – 5000 W (suitable for small applications to large industrial systems)
Voltage: Clamp heaters usually operate on 220V or 380V systems but can be customized to meet specific voltage requirements.
3. Heat Output and Heating Performance
Clamp heaters provide high-efficiency heating. The heat output depends on the size of the heater, the properties of the materials used, and the electrical resistance value. The heat output is typically offered in the following ranges:
Low-Power Clamp Heaters: 100W – 500W
Medium-Power Clamp Heaters: 500W – 2000W
High-Power Clamp Heaters: 2000W – 5000W
High-power clamp heaters are commonly used in large pipelines or industrial equipment.
4. Operating Temperature
The operating temperatures of clamp heaters depend on the materials used and the design. Typical operating temperature ranges include:
Max Operating Temperature: 300°C – 900°C
High-Temperature Resistance: Clamp heaters can be designed to withstand temperatures above 800°C.
This high-temperature resistance allows their effective use in industrial heating systems.
5. Installation Details
Clamp heaters are designed to be easily mounted on pipelines or cylindrical surfaces. Common installation methods include:
Clamp Connection Point: The clamp is tightly placed around the pipe or surface and secured using screws or locking mechanisms.
Connection Cables: Clamp heaters are usually equipped with heat-resistant cables and connected to junction boxes or terminal boxes for electrical connections.
The ease of installation offers a faster and more practical solution compared to flange heaters.
6. Heat Distribution and Insulation
Clamp heaters are designed to provide even heat distribution, ensuring efficient and uniform heating. Additionally, insulation materials help to minimize heat loss and improve energy efficiency. The insulation can be customized according to the type of material and application requirements.
7. Protection and Durability
Clamp heaters offer high durability against environmental factors. Their protective features ensure efficient operation over long periods. The durable outer coating and high-temperature resistance provide protection against extreme temperatures, vibrations, and mechanical damage.
8. Special Application Features
Clamp heaters can be customized for specific applications, including:
Pipe Heating: Used to heat liquids passing through pipes.
Surface Heating: Applied to the external surfaces of pipes for material processing.
High-Pressure Systems: Specially designed durable models for systems operating under high pressure.
Clamp heaters are highly efficient heating solutions that can be customized for various applications. With their electrical properties, ease of installation, high-temperature resistance, and application versatility, they are widely preferred in industrial heating systems. Clamp heaters are commonly used in pipelines, cylindrical surfaces, and liquid/gas heating applications.
Clamp Heaters Dimensional Details
Clamp heaters come in a wide range of sizes depending on the application area and design requirements. These dimensions can be customized according to the size of the surface to be heated and specific needs. The common dimensional details for clamp heaters are as follows:
1. Clamp Diameter (Outer Diameter)
The outer diameter of the clamp heater must match the diameter of the surface where it will be mounted. This dimension varies based on the pipe diameter and surface size.
Standard Diameter Ranges:
20 mm – 100 mm
100 mm – 200 mm
200 mm – 500 mm
500 mm – 1000 mm
The clamp diameter should be compatible with the pipe or cylindrical surface to ensure proper installation.
2. Clamp Height (Clamp Depth)
The height of the clamp is essential for the proper placement of the heating element. This height should provide sufficient space for the heating element to be wrapped securely.
Standard Height Ranges:
15 mm – 50 mm
50 mm – 100 mm
100 mm – 150 mm
The height is determined based on the thickness of the material used and the requirements of the heating element.
3. Clamp Length
The length of the clamp heater depends on the length of the material used and the size of the surface where it will be mounted. The length should be designed to fit the surface precisely.
Standard Length Ranges:
100 mm – 300 mm
300 mm – 600 mm
600 mm – 1000 mm
Clamp length can be customized according to the dimensions of the installation surface.
4. Number of Heater Windings
The number of windings of the heating element directly affects the heating performance. More windings result in higher heating power.
Common Winding Numbers:
5 windings – 10 windings
10 windings – 20 windings
20 windings and above
The number of windings determines the efficiency of the heating element and can be adjusted based on application needs.
5. Connection Terminal Type
Clamp heaters can have different connection terminals for electrical connections. The connection type is determined according to the electrical requirements of the system.
Connection Terminal Types:
Screw terminals
Terminal block connections
Terminal box connections
Cable lead connections
The connection type is chosen based on the ease of installation and the system’s safety requirements.
6. Heating Element Material and Thickness
The heating element material and thickness are also important dimensional details of clamp heaters. Common materials used include kanthal, nichrome, and mica.
Common Material and Thickness Ranges:
Kanthal: 0.5 mm – 3 mm thickness
Nichrome: 0.2 mm – 1 mm thickness
Mica Coating: 1 mm – 3 mm thickness
The thickness of the heating element is crucial for heating performance and safety.
7. Operating Temperature Range
The operating temperatures of clamp heaters vary depending on the materials used and the design.
Standard Operating Temperature Ranges:
100°C – 300°C
300°C – 500°C
500°C – 900°C
The operating temperature is determined according to the requirements of the application.
8. Power Capacity
The power capacity of clamp heaters varies depending on the heating application. The common power capacity options are as follows:
Standard Power Ranges:
100W – 500W
500W – 2000W
2000W – 5000W
The power capacity is directly proportional to the heat output provided by the heater.
The dimensions of clamp heaters can be customized according to the application area and required performance. Details such as diameter, height, length, number of windings, connection terminals, and heating element material can be tailored to meet the specific needs of each application. These dimensional details are crucial for both efficiency and safety.
Operating Principle of Clamp Heaters
Clamp heaters are heating elements that are typically mounted directly onto pipes or cylindrical surfaces. These heaters are widely used in heating applications, especially in liquid and gas heating systems. Their operating principle is based on the conversion of electrical energy into heat. Here is a detailed explanation of the working principle of clamp heaters:
1. Flow of Electrical Current
Clamp heaters contain a heating element that conducts electricity. This element is usually made of a metal wire or a heat-resistant material such as kanthal or nichrome. When electrical current passes through the conductive material of the heater, it is converted into heat due to electrical resistance.
2. Heat Generation
As the electrical current flows through the heating element, the conductive material offers resistance, causing electrical energy to transform into heat. This heat is directly transferred to the surrounding environment. The design of clamp heaters ensures effective heat distribution, allowing for a uniform temperature increase on the surface. Heat transmission is most concentrated near the mounting surface.
3. Installation and Heat Transfer
Clamp heaters are placed around the external surface of the pipe, rod, or other cylindrical structures that need heating. The clamp tightly wraps the heating element around the surface, ensuring efficient heat transfer. Thanks to their design, the heating element comes into direct contact with the surface, allowing for optimal thermal conduction.
4. Thermal Equilibrium
Clamp heaters reach thermal equilibrium once a specific temperature level is achieved. This equilibrium is established when the heat generated by the heater balances with the heat dissipated into the surrounding environment. A well-designed heating element ensures uniform heat distribution, minimizing localized temperature variations.
5. Control and Thermostat Usage
Most clamp heaters are equipped with thermostats or temperature sensors to regulate operating temperatures. These sensors help prevent overheating by automatically shutting down the heater or reducing power levels as needed. This ensures efficient operation and prevents potential damage due to excessive heat.
6. Energy Efficiency
Clamp heaters are designed to deliver and concentrate heat directly, making them highly energy-efficient. A significant portion of the electrical energy is converted into heat and transferred to the surrounding material. This results in lower energy consumption and provides cost-effective long-term operation.
7. Continuous Heat Transfer
Clamp heaters are engineered to provide consistent and continuous heat transfer. During operation, the heating element continuously generates heat and transfers it to the surface, maintaining a stable temperature level. This feature is essential for applications that require constant temperature regulation.
The operating principle of clamp heaters is based on converting electrical current into heat and transferring this heat directly to the mounted surface. Their high energy efficiency and direct heat transfer capabilities make them a preferred choice in industrial heating applications. Additionally, when integrated with temperature control systems, clamp heaters provide safe and efficient heating solutions.
Clamp Heaters Frequently Asked Questions
A clamp heater is a type of heating element designed to be mounted around a surface in a clamp-like manner. It is primarily used to transfer heat to pipes, pipelines, or similar surfaces. The clamp design allows for easy placement of the heater onto the surface.
Clamp heaters are commonly used in pipeline systems, chemical processing, heating systems, and the machinery industry. They are preferred for applying heat to pipelines or tubes. Additionally, they are widely used in food processing, oil and gas, and liquid heating systems.
Clamp heaters are designed with a resistance wire that conducts electrical current and is wrapped with a heat-resistant material. As electrical current flows through the wire, resistance increases, generating heat. This heat is then transferred to the pipe or surface surrounding the clamp.
Clamp heaters are typically made from materials such as stainless steel, aluminum, ceramic, and tungsten. These materials are highly heat-resistant, ensuring efficient heat transfer and long-lasting performance.
The advantages of clamp heaters include rapid heat transfer, low energy consumption, and easy installation. They efficiently distribute heat directly to the surface and offer high performance in specific areas. Clamp heaters usually operate with minimal heat loss.
The heating capacity of clamp heaters generally ranges between 100W and 50 kW. This capacity may vary depending on the application area and requirements. Factors such as pipe diameter, material, and operating conditions influence the heating capacity.
Clamp heaters typically operate within a temperature range of 50°C to 600°C. However, depending on the type and structure of the materials used, this range can be broader. Some models are capable of withstanding higher temperatures.
A clamp heater is positioned appropriately around the surface to be heated and securely fastened using the clamp mechanism. Electrical connections are then made, and the unit is tested to ensure proper operation. Clamp heaters are generally designed for quick and easy installation.
Clamp heaters require regular cleaning and wear inspections. Electrical connections should also be checked for correctness. In cases of overheating or corrosion, maintenance and repair procedures should be performed to ensure optimal performance.
Clamp heaters are preferred due to their low energy consumption, fast heating, efficient heat transfer, and easy installation. They are particularly used to provide efficient heat transfer in applications such as pipelines and cylindrical surfaces.
