Coil heaters HOTSPRING

... Infinite solutions... Coil heaters HOTSPRING MODEL Z.51 - hotspring

... Infinite solution... Index 3 4 5 5 6 7 hotspring coil heaters (WRP) Application examples Possibilities of cooling Exits hotspring /Micro/F/ 1.0 x 1.6 hotspring /Mini Ø 1.8 Variants Maxi 1.8 x 3.2/2.2 x 4.2/3.0 x 3.0/Ø 3.3/Ø 4.0 Micro and Mini 8 10 11 13 14 15 17 19 21 23 24 25 26 28 29 33 34 hotspring /Mini / F 1.3 x 2.3 hotspring /Mini / F 1.3 x 2.3 with clamping band and axial screwing hotspring /Mini / F 1.3 x 2.3 with clamping band tangential screwing hotspring /Mini /M casted in brass Connection options hotspring /Micro and hotspring /Mini hotspring /F/1.8 x 3.2 hotspring /F/2.2 x 4.2 hotspring /Q/3.0 x 3.0 hotspring Ø 3.3 hotspring Ø 4.0 hotspring /M casted in brass Connection options hotspring F/Q/Ø 3.3/Ø 4.0 hotspring /Maxi/ 4.6 x 8.6 Connection options hotspring /Maxi Variants 1 2 2

hotspring coil heaters (type WRP) With this brochure ZRE presents a wide product spectrum of coil heaters: l Starting with hotspring /Micro up to hotspring /Maxi with different lengths and diameters. l E. g. hotspring coil heaters casted in brass or with clamping mechanism and screwing as heating elements for different applications. l Heating systems such as the heated nozzle hotcone (type BMD). l Special product such as hotslot. Already in 1980 hotset had been one idea ahead when they presented the first round hotspring coil heater (type WRP Ø 3.3). Since then further innovations have been made: hotspring /Mini, flat and square coil heater (hotspring /F resp. hotspring /Q), hotspring /Maxi as well as hotspring /Micro. is of high potential for the plastic processing industry. This product is compact, sealed systems based on the heating with a hotspring /Maxi with corresponding power distribution. Hotspring coil heaters inserted in hotslot ensure a precise heating with any power distribution possible. This innovation as well as the humidity resistant coil heaters according to IP 65 (hotspring Ø 3.3, hotspring /F 2.2 x 4.2, hotspring /F 1.8 x 3.2, hotspring /Q 3.0 x 3.0, hotspring Ø 4.0) emphasize the consistant alignment to new challenges. Profit from our long time experience to fit your needs. Special product variants are consequently developed according to the requirements of the user. The heated machine nozzle hotcone (type BMD) 3

Application examples for the use of hotspring Coil Heaters Mass channel Technology Heating of manifolds. Mass channel Technology Heating of mass channel nozzles. Packaging Industry Heating of welding bars Packaging Industry Heating of sealed heads Sheath-surface load hotspring round: hotspring flat: hotspring with 6 W/cm 2 7.5 W/cm 2 Reflectiontube: 10 W/cm 2 hotslot : hotspring brass: 12.5 W/cm 2 15 W/cm 2 nozzle body The above mentioned standard values for maximun sheath-surface load of the different hotspring -variants depends on the operating temperature as well as the heat dissipation. 4

Possibilities of coiling Exits Coiling scheme for coiled heaters Cylindrical standard coiling with following options: l Coiled tight l Coiled with defined pitch (up to max. 50 mm) l Coiled with power distribution Coiling scheme for coiled heaters Tangential exit Alternatively, other geometries can be coiled: Flat coiling Axial exit Meander coiling Radial exit Conical coiling Exit in the mid (for Micro and Mini) 5

Hotspring Coil Heater (type WRP) Micro/F/ 1.0 x 1.6 also as hotspring /Micro Ø 1.3 (upon request) Technical Data l Hotspring coil heater with flat cross-section 1.0 x 1.6 mm (deliverable only in coiled condition) l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): 800 V-AC l Insulation resistance (cold): 5 MΩ bei 500 V-DC l Leakage current (cold): 0.5 ma bei 253 V-AC l Exit axial, radial, tangential or in the middle, see page 5 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz: 25 mm plus connection head l Length tolerance straight: ± 5% l Inner diameter tolerance without reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 with reflection tube: +0.05/+0.15 l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): 3 mm (heated and unheated zone) l Individual connection heads, max. length: 35 mm l Connection version: 1000 mm PTFE insulated Cu-nickel plated leads, multistranded (Standard) l For connection-temperatures max. 260 C l Deliverable with external thermocouple (e. g. coiled) (IEC 60584) l Deliverable with reflection tube L cl ±1.5% (min. ± 1) IØ 1.6 ±0.15 Ø1.3 ±0.15 L uz2 +25 1.0 ±0.15 L uz1 ± 5% (min. ± 15) Ø max. 5.5 ± 5% (min. ± 15) max. 35 Measures [mm] L cl = coiled length L uz1/uz2 = length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] (IØ + 1.3) π number of windings 2 = heated lengthstraight Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33 How to order Hotspring /Mini/F/1.3 x 2.3 Application:... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Quantity:... 6

hotspring Coil Heater (type WRP) Mini Ø 1.8 L cl ±1.5% (min. ±1) IØ L uz1 ±5% (min. ± 15) Ø1.8 ±0.15 Ø1.8 Ø max. 5.5 L uz2 ±5% (min. ± 15) max. 40 Misure [mm] L cl = lcoiled length L uz1/uz2 = llength unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] IØ + 1.8) π number of windings 2 = heated lengthstraight Technical data l Hotspring coil heater with round crosssec tion Ø 1.8 mm l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial, tangential or in the middle, see page 5 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz:25 mm plus connection head l Length tolerance straight: ± 5% l Inner diameter tolerance without reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 with reflection tube: +0.05/+0.15 l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal):3 mm (heated and unheated zone) l Individual connection heads or common connection head l Connection version see page 14, Standard connection length 1000 mm l For connection-temperatures max. 260 C l Deliverable with external thermocouple (e. g. coiled-in) (IEC 60584) l Deliverable with clamping element or collar Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33 How to order hotspring /Mini/F/1.3 x 2.3 Application:... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Collar:... + Quantity:... 7

hotspring Coil Heater (type WRP) Mini/F/ 1.3 x 2.3 Technical data l Hotspring coil heater with flat cross-section 1.3 x 2.3 mm (deliverable only in coiled condition) l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< auf Anfrage) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold):5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial, tangential or in the middle,see page 5 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz:25 mm plus connection head l Length tolerance straight: ± 5% l Inner diameter tolerance without reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 with reflection tube: +0.05/+0.15 l Sheath surface load according to operating temperature and heat dissipation,max. see page 5 l Minimum bending radius (internal):3 mm (heated and unheated zone) l Individual connection heads or common connection head l Connection options see page 14 l For connection-temperatures max. 260 C l Deliverable with external thermocouple (e. g. coiled-in) (IEC 60584) l Deliverable with reflection tube l Deliverable with clamping element or collar L uz1 ± 5% (min. ± 15) Ø1.8 Ø max. 5.5 Other dimensions and product varieties on request. We reserve the right to change technical details. L uz2 ± 5% (min. ± 15) max. 40 Please note the installation and storage instructions at pag 33 8 L cl ±1.5% (min. ±1) IØ 2.3 ±0.15 1.3 ±0.15 Misure [mm] L cl = coiled length L uz =length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] (IØ + 1.8) π number of windings 2 = heated length straight How to order Hotspring /Mini/F/1.3 x 2.3 Application:... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Collar:... + Quantity:...

Standard heaters in stock hotspring Mini/F/1,3 x 2,3 Unheated length Item number Overall length Power Heated length + connection [mm] [W] [mm] [mm] 7580469 426 120 296 65/115+25 7580510 537 160 382 65/115+25 7580671 630 210 475 65/115+25 7580772 730 250 575 65/115+25 7580845 855 300 700 65/115+25 7581057 1005 350 850 65/115+25 7581273 1201 450 1046 65/115+25 9

hotspring Coil Heater (type WRP) Mini/F/1.3 x 2.3 with clamping band and axial screwing Technical data l Hotspring coil heater with flat cross-section 1.3 x 2.3 mm with clamping band and axial screwing l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element:max. 750 C l Voltage: max. 250 V,Standard: 230 resp. 240 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Inner diameter tolerance clampable on indicated nozzle diameter l Minimum bending radius (internal): 3 mm l Separated connection heads l Connection versions see page 14, Standard length 1830 mm l For connection-temperatures max. 260 C l Variant 1: L = 30.5 mm/iø = 19.05 mm length of unheated zone 99/150 mm H max. = 32.3 mm wattage: 149 W or 268 W (Standard) at 240 V l Variant 2: L = 30.5 mm/iø = 22.2 mm length of unheated zone 99/150 mm H max. = 36.4 mm/iø = 22.2 mm wattage: 250 W at 230 V (Standard) Stock dimensions can be found at pag. 12 IØ We reserve the right to change technical details. Please note the installation and storage instructions at pag. 33 ~ 2.1 H max. L ±0.5 max. 15.9 Ø max. 5.5 99 ±25 Ø1.8 ±0.15 150 ±25 max. 40 How to order hotspring /Mini/F/1.3 x 2.3 with axial clamping band Application :... + for nozzle-/clamping band-ø:... _ Variant 1... _ Variant 2... + Wattage:... Measures [mm] + Voltage:... + Length of unheated zone:... + Quantity:... 10 11

hotspring Coil Heater (type WRP) Mini/F/1.3 x 2.3 with clamping band and tangential screwing Technical data l Hotspring coil heater with flat cross-section 1.3 x 2.3 mm with collar and tangential screwing l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Wattage: Variant 1: 125 W Variant 2: 250 W Variant 3: 250 W l Wattage tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Length unheated zones 130/180 mm (Standard) l Inner diameter tolerance clampable on indicated nozzle diameter l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): 3 mm l Individual connection heads l Connection versions see page 14 Standard length 1000 mm l For connection-temperatures max. 260 C l Variant 1: L = 30.5±0.1 mm/iø = 19.05 mm l Variant 2: L = 25.4±0.1 mm/iø = 19.05 mm l Variant 3: L = 30.5±0.1 mm/iø = 22.20 mm Stock dimensions can be found in the stock rang IØ brochure. We reserve the right to change technical details. ~ 2.1 16 8 ±0.1 Please note the installation and storage instructions at pag 33.. L cl ±0.1 ±0.1 Ø max.5.5 Ø1.8 ±0.15 15 130 ±25* 180 ±25* Measures [mm] Lcl = Coiled length max. 40 How to order Hotspring /Mini/F/1.3 x 2.3 with tangential screwing Application :... + For nozzle-/clamping band-ø:... _ Variant 1... _ Variant 2... _ Variant 3... + Wattage:... + Voltage:... + Length of unheated zone:... + Quantity:... * other lengths of unheated zones see Technical Data 11 12

Standard heaters in stock axial screwing: hotspring Mini/F/1,3 x 2,3 Item number Overall length Power ID Max length [mm] [W] [mm] [mm] 7603019 30,5 268 19,05 32,3 7603020 30,5 250 22,20 36,4 12

hotspring Coil Heater (type WRP) Mini/M casted in brass Technical data l Hotspring coil heater casted in brass with outer sheath of stainless steel l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Temperature at brass inner sheath: max. 650 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength: (cold) min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial or radial, see page 5 l Min. length of unheated zone Luz:25 mm l Inner diameter tolerance Standard + 0.05 (H7 on request) l Outer-Ø = Inner-Ø + 5 mm l Minimum outer diameter tolerance: ± 0.25 mm l Coaxiality inner-ø to outer-ø: Ø 0.5 l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): 3 mm (unheated zone) l Connection versions see page 14 l For connection-temperatures max. 260 C l With or without reinforcement tube along the unheated zone against distortion or breakage, for axial exit not possible IØ Ø 0.5 O Other dimensions and product varieties on request. We reserve the right to change technical details. L uz1 ± 5% (min. ± 15) Ø1.8 Ø max. 5.5 Please note the installation and storage instructions at pag 33 O L cl ±0.5 OØ ±0.25 = IØ + 5 mm L uz2 ± 5% (min. ± 15) max. 40 Measures [mm] Lcl = coiled length Luz = length unheated zone How to order Hotspring /Mini/M Application :... + Inner-Ø:... + Tolerance Inner-Ø:... + Length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Length of unheated zone:... + Protection tube:... + Quantity:... 13

Connection options hotspring /Micro and hotspring /Mini Type Micro/Mini individual heads l PTFE 2 insulated Cu-nickel plated leads, multistranded L 1 max. Ø 7.0 mm Type Mini N l Common head l PTFE 2 insulated Cu-nickel plated leads, multistranded (Standard) 3 l With ground wire L 1 max. Ø10 mm max. Ø 7.0 mm Type Mini NG l Common head l PTFE 2 insulated Cu-nickel plated leads, multistranded (Standard) 3 with glass silk insulated protective sleeving l With ground wire L 1 max. Ø 7.0 mm Type Mini ND l Common head l PTFE 2 insulated Cu-nickel plated leads, multistranded (Standard) 3 with braided metal sleeving l With ground wire L 1 max. Ø 7.0 mm Type Mini NT l Common head l PTFE 2 insulated Cu-nickel plated leads, multistranded (Standard) 3 with PTFE-sleeving l With ground wire 1 head length L = 25 mm (Standard) 2 maximum temperature on the connection sector: 260 C 3 other types on request 14

hotspring Coil Heater (type WRP) F/1.8 x 3.2 L cl ±1.5% (min. ±1) IØ L uz ±5% (min. ± 15) 3.2 ±0.15 4.2 ±0.15 1.8 ±0.15 2.2 ±0.15 Ø3.3 ±0.15 25 ±2 Standard: 1000 +5% Ø6.9 ±0.1 max. Ø10 Misure [mm] L cl = coil lenght L uz = untteated zone lenght Approximate formula for calculation the stretched heated length of coiled heaters [mm] (IØ + 1.8) π number of windings = heated length straight Technical data Humidity-resistant hotspring coil heaterwith flat cross-section 1.8 x 3.2 mm l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial or tangential, see page 6 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz: 25 mm plus connection head 25 mm l Length tolerance heated zone: ± 1% unheated zone: ± 5% l Inner diameter tolerancewithout reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 up to IØ 50 mm -0.20/-0.40 > IØ 50 mm on requestwith reflection tube:+0.05/+0.15 l Sheath surface load according tooperating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): heated zone: 4 mm unheated zone: 4 mm l Connection versions see page 25 l For connection-temperatures max. 260 C l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard)or NiCr-Ni (type K) (IEC 60584) (ungrounded) l Deliverable with reflection tube l Can be delivered with clamping band and clamping element l Optional IP 68 water-immersion-protected with water proof connection zone,for connectiontemperatures max. 300 C,connection leads PTFE insulated Ni-leadson request Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions How to order Hotspring /F/1.8 x 3.2 Application :... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Clamping band:... + Clamping element:... + IP:... 15

Standard heaters in stock hotspring F/1,8 x 3,2 Item number Item number with thermocouple Overall Length Power Heated length J Fe-CuNi [mm] [W] [mm] 7540300 7840300 340 130 250 7540301 7840301 390 160 300 7540302 7840302 440 190 350 7540303 7840303 490 220 400 7540304 7840304 540 250 450 7540305 7840305 590 275 500 7540306 7840306 690 330 600 7540307 7840307 840 400 750 16

hotspring Riscaldatore a spirale (tipo WRP) F/2.2 x 4.2 L uz ±5% (min. ± 15) 25 ±2 Standard: 1000 +5% Technical data Humidity-resistant hotspring coil heater with flat cross-section 2.2 x 4.2 mm l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial or tangential, see page 6 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz:25 mm plus connection head 25 mm l Length tolerance heated zone: ± 1% unheated zone: ± 5% l Inner diameter tolerancewithout reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 up to IØ 50 mm -0.20/-0.40 > IØ 50 mm on request with reflection tube: +0.05/+0.15 l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): heated zone: 4 mm unheated zone: 4 mm l Connection versions see page 25 l For connection-temperatures max. 260 C l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard) or NiCr-Ni (type K) (IEC 60584) (ungrounded (standard) or grounded) l Deliverable with reflection tube l Can be delivered with clamping band and clamping element l Optional IP 68 water-immersion-protected with water proof connection zone, for connection-temperatures max. 300 C, connection leads PTFE insulated Ni-leads on request L cl ±1.5% (min. ±1) IØ 3.2 ±0.15 4.2 ±0.15 Ø3.3 ±0.15 Ø6.9 ±0.1 max. Ø10 1.8 ±0.15 2.2 ±0.15 Measures [mm] Lcl = coiled length Luz = length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] (IØ + 2.2) π number of windings = heated length straight Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33. How to order Hotspring /F/2.2 x 4.2 Application :... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Clamping band:... + Clamping element:... + IP:... + Quantity:... 17

Standard heaters in stock hotspring F/2,2 x 4,2 Thermocouple Item number Overall length Power Heated length J (Fe-CuNi) [mm] [W] [mm] 7732519 340 195 250 7832519 340 195 250 x 7732821 370 215 280 7832821 370 215 280 x 7733324 425 240 335 7833524 425 240 335 x 7733829 475 295 385 7833829 475 295 385 x 7734635 550 350 460 7834635 550 350 460 x 7735240 610 400 520 7835240 610 400 520 x 7736046 690 460 600 7836046 690 460 600 x 7737661 850 610 760 7837601 850 610 760 x 7739069 990 690 900 7839069 990 690 900 x 7731185 1200 850 1110 7831185 1200 850 1110 x 7731395 1400 950 1310 7831395 1400 950 1310 x 18

hotspring Coil Heater (type WRP) Q/3.0 x 3.0 L uz ±5% (min. ± 15) 25 ±2 Standard: 1000 +5% Technical data Humidity-resistant hotspring coil heater with square cross-section 3.0 x 3.0 mm l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial or tangential, see page 6 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz:25 mm plus connection head 25 mm l length tolerance: heated zone: ± 1% unheated zone: ± 5% l Inner diameter tolerances without reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 up to IØ 50 mm -0.20/-0.40 > IØ 50 mm on request with reflection tube: +0.05/+0.15 l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): heated zone: 4 mm unheated zone: 4 mm l Connection versions see page 25 l For connection-temperatures max. 260 C l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard) or NiCr-Ni (type K) (IEC 60584) (ungrounded (standard) or grounded) l Deliverable with reflection tube l Deliverable with clamping band or clamping element l Optional IP 68 water-immersion-protected with water proof connection zone, for connection-temperatures max. 300 C, connection leads PTFE insulated Ni-leads on request L cl ±1.5% (min. ±1) IØ 3.0 ±0.15 3.0 ±0.15 Ø3.3 ±0.15 Ø6.9 ±0.1 max. Ø10 Measures [mm] Lcl = coiled length Luz = length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] (IØ + 3.0) π number of windings = heated length straight Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33. How to order Hotspring /Q/3.0 x 3.0 Application :... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Reflection tube:... + Length of unheated zone:... + Clamping band:... + Clamping element:... 19

Standard heaters in stock hotspring Q/3,0 x 3,0 Thermocouple Item number Overall length Power Heated length J (Fe-CuNi) [mm] [W] [mm] 7930316 390 215 300 7940316 390 215 300 x 7930422 540 325 450 7940422 540 325 450 x 7930627 740 470 650 7940627 740 470 650 x 7930835 940 610 850 7940835 940 610 850 x 7931043 1140 630 1050 7941035 1140 630 1050 x 7931395 1400 950 1310 7941395 1400 950 1310 x 20

hotspring Coil Heater (type WRP) Ø 4.0 Technical data Hotspring coil heater with round cross-section Ø 4.0 mm l Sheath material: Stainless Steel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial, radial or tangential, see page 6 l Max. total length straight: 3000 mm l Min. length of unheated zone Luz: 25 mm plus connection head 25 mm l Length tolerance: heated zone: ± 2.5% unheated zone: ± 5% l Inner diameter tolerances without reflection tube: up to IØ 12 mm -0.05/-0.20 up to IØ 30 mm -0.10/-0.30 up to IØ 50 mm -0.20/-0.40 > IØ 50 mm on request l Sheath surface load according to operating temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): 5 mm l Connection versions see page 25 l For connection-temperatures max. 260 C l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard) or NiCr-Ni (type K) (IEC 60584) (ungrounded (standard) or grounded) l Deliverable with clamping band or clamping element l Optional IP 68 water-immersion-protected with water proof connection zone, for connection-temperatures max. 300 C, connection leads PTFE insulated Ni-leads on request L uz ±5% (min. ± 15) 25 ±2 Standard: 1000 +5% L cl ±1.5% (min. ±1) IØ Ø3.8 ±0.15 Ø3.8 ±0.15 Ø6.9 ±0.1 max. Ø10 Measures [mm] Lcl = coiled length Luz = length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] IØ + 4.0) π number of windings = heated length straight Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33. How to order Hotspring Ø 4.0 Application :... + Inner-Ø:... + Coiled length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Length of unheated zone:... + Clamping band:... + Clamping element:... + IP:... + Quantity:... 21

hotspring Coil Heater (type WRP)/M casted in brass Technical data Ootspring coil heater casted in brass with outer sheath of stainless steel l Sheath material: Stainless Steel or Nickel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Temperature at brass inner sheath: max. 650 C l Voltage: max. 250 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): min. 800 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma at 253 V-AC l Exit axial or radial, see page 6 l Min. length of unheated zone Luz: 25 mm plus connection head 25 mm l Inner diameter tolerance: standard + 0.05 mm (H7 on request) l Minimum Outer-Ø = Inner-Ø + 9 up to 11 mm (depending on used coil heater) l Outer diameter tolerance: ± 0.25 mm l Coaxiality Inner-Ø to outer-ø: l Sheath surface load according to operating IØ Ø 0.5 O Ø 0.5 temperature and heat dissipation, max. see page 5 l Minimum bending radius (internal): 4 mm (unheated zone) l Connection versions see page 20 l For connection-temperatures max. 260 C l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard) or NiCr-Ni (type K) (IEC 60584) (ungrounded (standard) or grounded) l Deliverable with reinforcement tube along unheated zone against distortion or breakage (on request) L uz ±5% (min. ± 15) 25 ±2 Standard: 1000 +5% Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33. 22 O L ±0.5 OØ ±0.25 Ø3.3 ±0.15 Ø6.9 ±0.1 max. Ø10 Measures [mm] L = length Luz = length unheated zone How to order Hotspring /M Application :... + Inner-Ø:... + Inner-Ø tolerance:... + Length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Length of unheated zone:... + Reinforcement tube:...

Connection versions hotspring /1.8 x 3.2/2.2 x 4.2/3 x 3/Ø3.3/Ø4.0 L 1 max. Ø 7.0 mm Type N l PTFE insulated Cu-nickel plated leads, multistranded (Standard) 2 l With ground wire L 1 max. Ø10 mm max. Ø 7.0 mm L 1 max. Ø 7.0 mm L 1 max. Ø 7.0 mm L 1 max. Ø 7.0 mm Type NG l PTFE insulated Cu-nickel plated leads, multistranded (Standard) 2 with glass silk insulated protective sleeving l With ground wire Type NM l PTFE insulated Cu-nickel plated leads, multistranded (Standard) 2 with flexible metal sleeving l with ground wire Type ND l PTFE insulated Cu-nickel plated leads, multistranded (Standard) 2 with braided metal sleeving l With ground wire Type NT l PTFE insulated Cu-nickel plated leads, multistranded (Standard) 2 with PTFE-sleeving l With ground wire 1 length of head L = 25 mm (Standard) or 20 mm 2 other types on request Plug connection, with 3 pins l Maximum current at 20 C max. 8,0 A 32 ±1 ca. 37 Plug connection, with 5 pins l Maximum current at 20 C max. 6,5 A Ø10 Ø9.4 Measures [mm] 23

hotspring Coil Heater (type WRP) Maxi/4.6 x 8.6 hotspring /Maxi/4.6 x 8.6 with connection head for connection temperature > 260 C hotspring /Maxi/4,6 x 8,6 without connection head for temperature up to 260 C Technical data Hotspring coil heater with flat cross-section 4.6 x 8.6 mm l Sheath material: Stainless Steel l Insulation sheath: high-compressed MgO l Heating conductor compound: NiCr 8020 l Sheath temperature of heating element: max. 750 C l Voltage: max. 440 V, Standard: 230 V l Power tolerance (cold): ± 10% (< on request) l High voltage strength (cold): 1250 V-AC l Insulation resistance (cold): 5 MΩ at 500 V-DC l Leakage current (cold): 0.5 ma bei 253 V-AC l Exit axial, radial or tangential, see page 5 l Max. total length straight: 3000 mm l with connection-head: min. length of unheated zone Luz: 45 mm without connection-head: min. length of unheated zone: 45 mm, max. length of unheated zone: 65 mm l Length tolerance heated zone: ± 1% unheated zone: ± 5% l Inner diameter tolerances without reflection tube: up to IØ 30 mm -0.10/-0.30 up to IØ 50 mm -0.20/-0.40 > IØ 50 mm on request with reflection tube: +0.05/+0.15 l Minimum bending radius (internal): 10 mm l Connection versions see page 22 l Deliverable with or without integrated thermocouple Fe-CuNi (type J, Standard) or NiCr-Ni (type K) (IEC 60584) (ungrounded, standard) l Deliverable with reflection tube l Deliverable with clamping band L uz ±5% (min. ± 15) 45 Standard: 1000 +5% Other dimensions and product varieties on request. We reserve the right to change technical details. Please note the installation and storage instructions at pag 33. L cl ±1.5% (min. ±1) IØ 8.6 ±0.15 4.6 ±0.15 Ø6.9 ±0.1 Ø12.5 hotspring /Maxi/4.6 x 8.6 with connection head Measures [mm] L = length Luz = length unheated zone Approximate formula for calculation the stretched heated length of coiled heaters [mm] IØ + 4.6) π number of windings = heated length straight How to order Hotspring /Maxi/4.6 x 8.6 Application :... + Inner-Ø:... + Inner-Ø tolerance:... + Length:... + Position of coils:... + Wattage:... + Voltage:... + Exit:... + Connection length:... + Thermocouple:... + Length of unheated zone:... + Clamping band:... + Reflection tube:... + Quantity:... 24 25

Standard heaters in stock Standard heaters in stock Item number Overall Length Heated length Unheated length Power Tension Thermocouple [mm] [mm] [mm] [W] [V] J (Fe-CuNi) 7302521 315 250 65 300 230 7402521 315 250 65 300 230 x 7303527 415 350 65 450 230 7403527 415 350 65 450 230 x 7304531 515 450 65 550 230 7404531 515 450 65 550 230 x 7306543 715 650 65 800 230 7406543 715 650 65 800 230 x 7308550 915 850 65 1000 230 7408550 915 850 65 1000 230 x *Hotspring maxi 4.6x8.6 without connection tube for working Temperature up to 260 C on the leads connection zone 25

Connection options hotspring /Maxi max. Ø10 mm Maxi without head NG, NM, ND l PTFE insulated Cu-nickel-plated leads, multistranded l With glass silk insulated protective sleeving l With braided metal sleeving l With flexible metal sleeving l With ground wire L 1 max. Ø 13 mm Type Maxi N with head l Glass silk insulated nickel-leads, multistranded l With ground wire l High temperature Ni-leads multistranded (with blank groundwire) L 1 max. Ø 13 mm Type Maxi NG with head glass silk insulated nickel-leads, multistranded l with glass silk insulated protective sleeving l with ground wire L 1 max. Ø 13 mm Type Maxi NM with head l Glass silk insulated nickel-leads, multistranded l High temperature Ni-leads multistranded (with blank groundwire) l With flexible metal sleeving l With ground wire L 1 max. Ø 13 mm Type Maxi ND with head Glass silk insulated nickel-leads, multistranded l High temperature Ni-leads multistranded (with blank groundwire) l With braided metal sleeving l With ground wire 1Length of head L = 45 mm (Standard) 26

Variations Reflection tube l Increase of maximum sheath surface load l Protection against mechanical damage l Measures and tolerances according to heater type considering technical data l On option: coiled-in thermocouple Hotspring with reflection tube Reflection tube with pull-off ring l Easy dismantling: removal from front side possible l Increase of maximum sheath surface load l Protection against mechanical damage l Measures and tolerances according to heater type considering technical data l On option: coiled-in thermocouple l Other versions on request Hotspring with reflection tube and pull-off ring Clamping band l High-grade clamping possibility for improving the heat transfer l Increase of maximum sheath surface load l Protection against mechanical damage hotspring with clamping band 27

Variations Multi-part housings Hotspring coil heaters with inner- and outer tube l Even temperature distribution and improvement of heat transfer l Increase of maximum sheath surface load l Protection against mechanical damage l Clampable Hotspring with inner- and outer tube Fixing screw internal (for hotspring /M) l For fixing a hotspring /M on a nozzle l Tension is effected by a slitted knurled screw l Even temperature distribution and improvement of heat transfer lincrease of maximum sheath surface load l Protection against mechanical damage Hotspring with fixing screw (internal) Cap ring (for hotspring /M) For fixing and protection of a sheath thermocouple at a hotspring /M l Sheath thermocouple is exchangeable l Even temperature distribution and improvement of heat transfer l Increase of maximum sheath surface load l Protection against mechanical damage l Easy dismanthing: removal from front side Possible Hotspring with cap ring 28

lock-system (for hotspring /Mini/F 1.3 x 2.3) l Low wall thickness: 2.8 mm l Self clamping mechanism l Front-installation and removal l With anti-twist device Hotspring lock-system spike-system Hotspring spike-system l An optimal heat transition between heating element and tool l Increase of maximum sheath surface load l Adjustable to a wide range of diameters l Strong fit no additional fasteners necessary l Protection against mechanical damage l Measures and tolerances according to heater type considering technical data l On option: Coiled-in thermocouple 29

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Installation and storage instruction Installation l please secure that heating elements will only be connectedfrom instructed operators. l bear in mind the minimum bending radius, formed parts cannot be changed into another shape. l length of the connection head plus 5 mm of the unheated zone are not bendable. l do not hold onto the connection head. l only use non-electrically conductive sprays and pastes for installation (e.g. hotspring /K or hotspring /M) (Our Isolite-Spray is especially designed for these applications). l heating elements and sensors should be installed immovable; Attention: Depending on hotspring -type an uplifting from the tool during heating is possible! Temperature Controllers l temperature controllers have to match the power consumption and the used temperature sensor (suitable temperature controllers are available from hotset) l only install temperature controllers with automatic soft start function so that any moisture which may have entered the heating element will escape slowly Operation l make sure that the heating element is definitely grounded l security procedures for the handling of electrical items and applications must be followed l do not touch heating elements while in use because they can get very hot l please secure that heating elements can not touch flammable material while in use l do not heat hotslot unmounted l hotslot are easily damagable by pressure or other affects Storage l store at room temperature in a dry place Connessione General information l for further security information for special applications please take a look at our order confirmation. l if our heating elements are delivered with connection leads without insulation (naked connection) or with removable insulation (covered with GLS-sleeving), the customer himself has totake care about the protection against electricity. l protect connections against the ingress of liquids (e.g. oil,plastic material) and gases to avoid short circuits l install the connections away from sharp edges or parts as this may also cause short circuits (appropriate accessories to protect connection leads are available from hotset) l protect connection leads against the effects of temperature or lay them accordingly l please take the maximum temperature depending on connection art from the catalogue data l tool temperature must stay below corrosion point for heaters with current return to heater sheath to guarantee smooth current transfer (welded or soldered on connections available for applications with temperatures over corrosion point) l pay attention to the connection voltage l thermocouple leads: pay attention to the correct polarization and complete protection against accidental contact of heating elements with an integrated thermocouple l between power conductors and thermocouple is only a basic insulation l thermo leads and contacts must be shock protected 31

10040 San Gillio - Torino (Italy) - Via Druento, 48/2 Tel. +390119841848 8 linee R.A. - Fax +390119848099 e-mail: info@zre.it www.zre.it Copyright Z.R.E. 2012 - Rev 1.1 - All right reserved Marcatura secondo direttiva 2006/95/CE del 11/12/2006 32