The Flexible Tubular Heaters is kk Solutionlatest innovation for Heating Manifolds in the most efficient manner. Easiest handling, simple assembly, improved thermal performance and the simple storage are some of the crucial advantages of the Flexible Tubular Heaters over the Traditional Manifold Tubular Heating Elements. kk Solution Flexible Tubular Heaters eliminates costly downtime associated with waiting for a custom bent tubular heater. kk Solution Flexible Tubular Heater is your best choice for immediate, durable, high performance replacement heaters.
The Flexible Tubular heaters compress into the groove and provide excellent heat transfer. Straight lengths available Ex-Stock eliminate costly downtime associated with waiting for custom bent tubular heaters. Engineered with a robust design incorporating greater thermal mass, our Flexible Tubular Heater is user-formable with a flexible solid casing that stays in the groove, yet is easy to install.
- Easy installation with a uniform finish
- Can be formed by hand
- Stored in a straight condition to save storage space
- No special installation tools required
- Ground Breaking Technology ensures industry leading heat transfer
- Up to 75% sheath contact with Round and Square section heaters when recommended groove geometry is followed
- Rapid heat-up times
- Minimal temperature difference between heater sheath and heated tool
- 3-dimensional groove geometry possible
- Industry’s smallest bending radius
- kk Solution flexibility enables heat to be located where it is needed; an improvement over rigid cartridge heaters
- Reduced energy costs: tool mass can be reduced
| Dia | Length (mm) | Wattage | Voltage | Bending Radius (mm) |
|---|---|---|---|---|
| Dia 8.0 mm & 8.5 mm | 400 | 800 | 230 | 10 |
| 450 | 900 | 230 | 10 | |
| 500 | 1000 | 230 | 10 | |
| 550 | 1150 | 230 | 10 | |
| 600 | 1250 | 230 | 10 | |
| 650 | 1400 | 230 | 10 | |
| 700 | 1500 | 230 | 10 | |
| 750 | 1600 | 230 | 10 | |
| 800 | 1750 | 230 | 10 | |
| 850 | 1850 | 230 | 10 | |
| 900 | 1950 | 230 | 10 | |
| 950 | 2100 | 230 | 10 | |
| 1000 | 2200 | 230 | 10 | |
| 1050 | 2300 | 230 | 10 | |
| 1100 | 2450 | 230 | 10 | |
| 1150 | 2550 | 230 | 10 | |
| 1200 | 2650 | 230 | 10 | |
| 1250 | 2800 | 230 | 10 | |
| 1300 | 2900 | 230 | 10 | |
| 1350 | 3000 | 230 | 10 | |
| 1400 | 3150 | 230 | 10 | |
| 1450 | 3250 | 230 | 10 | |
| 1500 | 3350 | 230 | 10 |
| Dia | Length | Wattage | Voltage | Bending Radius (mm) |
|---|---|---|---|---|
| Dia 6.5 mm | 300 | 350 | 230 | 10 |
| 350 | 400 | 230 | 10 | |
| 400 | 500 | 230 | 10 | |
| 450 | 600 | 230 | 10 | |
| 500 | 650 | 230 | 10 | |
| 550 | 700 | 230 | 10 | |
| 600 | 800 | 230 | 10 | |
| 650 | 850 | 230 | 10 | |
| 700 | 900 | 230 | 10 | |
| 750 | 1000 | 230 | 10 | |
| 800 | 1100 | 230 | 10 | |
| 850 | 1200 | 230 | 10 | |
| 900 | 1300 | 230 | 10 | |
| 950 | 1350 | 230 | 10 | |
| 1000 | 1400 | 230 | 10 | |
| 1050 | 1450 | 230 | 10 | |
| 1100 | 1500 | 230 | 10 | |
| 1150 | 1550 | 230 | 10 | |
| 1200 | 1600 | 230 | 10 | |
| 1250 | 1650 | 230 | 10 | |
| 1300 | 1700 | 230 | 10 | |
| 1350 | 1800 | 230 | 10 | |
| 1400 | 1900 | 230 | 10 | |
| 1450 | 2000 | 230 | 10 | |
| 1500 | 2100 | 230 | 10 |
| Sheath Material | Stainless Steel |
| Sheath Temperature Of Heating Element | Max. 700°C / 1290°F |
| Standard Connection Voltage | 230 V |
| High Voltage Test* | 1000 V AC |
| Insulation Resistance* | ≥ 5 MΩ at 500 V DC |
| Leakage Current* | < 0.5 mA at 253 V AC |
| Wattage Tolerance | ± 10% |
| Length Tolerance | ± 1.5% |
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Because the heater expands when installed in manifolds with bends, you will need to calculate the correct straight length. Proper length depends on how many bends in the heated path your manifold has and the radius of each bend. Accounting for heater expansion will prevent heated sections from sticking out past the manifold and shortening the heater’s life.
Below, in figure 1, is an example of a manifold with the straight lengths marked in red. The bend groups are marked in green, blue, and orange.
STEP 1: IDENTIFY AND MEASURE THE STRAIGHT LENGTHS.Using the Figure 1, you will see that there are seven straight lengths. Since these do not expand, your equation should look like this:
(60mm x 4) + (25mm x 2) + 20mm = 310mm–the Total Straight Length
STEP 2: IDENTIFY THE BENDS AND MEASURE EACH RADIUS.Group length of the bends with the same radius and add them together. For example in Figure 1, you have 10 radii. Two of these are R10. Using the following formula, Length=2 x π x R x C/360, (where R=bend radius, and C=bend degrees), your equation will look like this:
2 x 3.14 x 10mm (R10 bend radius) x (180/360) = 31.4mm (length of one bend)
31.4mm + 31.4mm = 62.8mm (total length of both R10 bends)
STEP 3: ADJUST BEND SECTION MEASUREMENTS FOR ANTICIPATED HEATER EXPANSION.To adjust for expansion, you will need to identify the diameter of your manifold groove, (See Figure 2).
Diameter R10 R12.5 R15 >R15 ⌀ 6.5 0.83 0.85 0.88 0.92 ⌀ 8.0 0.92 0.93 0.94 0.96 ⌀ 8.2 0.93 0.94 0.95 0.96 ⌀ 8.5 0.94 0.95 0.95 0.96 Find the column for the radius length you measured in Step 2, and then multiply by the corresponding decimal. If we continue with the example from Step 2 using the two R10 bends and assume your groove diameter is 8mm, the Expansion chart shows your expansion factor multiplier is 0.92. Given this information, this is what your equation will look like:
62.8mm (total length of R10 radii) x 0.92 = 57.78mm (adjusted total length of the R10 group of radii)
Repeat this process for each bend group identified in your manifold.
STEP 4: ADD STRAIGHT LENGTHS (FROM STEP 1) WITH ALL ADJUSTED BEND LENGTHS (FROM STEP 3).Once you have the adjusted lengths for all the bends, simply add them together. Using the identified bends in figure 1 as an example, your equation will look like this:
310mm (total straight lengths) + 57.776mm (R10) + 97.39mm (R12.5) + 118.1mm (R15) = 583.266 (adjusted heater length)
STEP 5: IDENTIFY THE CORRECT LENGTH TO ORDER.In the example above, the total heater length is 583.266mm. Rounding up to the next size, the correct length is a 600mm Length heater. Following these instructions, you can be assured you will not have heated sections sticking out of your manifold.
NOTE: IF your total adjusted heater length is less than 10mm from the next size up heater, you will need to move up two sizes in length from your calculated value. For example: your adjusted calculated heater length is 648mm, then you should select the 675mm length heater instead of the 650mm one.