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Coil & Cable Heaters

Cable heaters are highly versatile, high performance mini-tubular heaters that are used in applications where a large amount of heat is required in a confined space. These heaters are fully annealed and can be bent into various shapes and configurations. Their standard cross-section is round but can be formed into a square or a rectangle to improve heat transfer. The sheath material is stainless steel 304, which provides adequate resistance against temperature oxidation and corrosion. The heating core type depends on the electrical and thermal characteristics of the heater. The core is made by embedding either Nickel-Chrome mini-coils or straight, solid resistive wires inside a highly compacted Magnesium Oxide insulating medium. The connection between the main power leads and the internal fine wires is done inside transition adaptors. These adaptors, which remain relatively cold and protect the power leads during operation, have larger diameters than the heater cross-section. Cable heaters can have up to 35w/in2 watt-density and can operate at temperatures as high as 1200°F in a continuous mode (1500°F intermittent).

Coil heaters are special cable heaters that have been shaped into a coil. These heaters are successfully used as powerful heating cells in plastic injection molding hot-runner nozzles. Coil and cable heaters can accommodate "J" or "K" type thermocouple sensors which are positioned internally at the tip or in the middle of the heater. Moreover, coil and cable heaters can have a profiled or a distributed-wattage configuration. It should be noted that although cable heaters are malleable and can acquire any shape, they should be formed into a final shape in a single attempt. Forming and bending operations harden the outside stainless-steel shell, and additional annealing might become necessary if re-changing the form is required

Coil & Cable Heater Cross-sections
Round 0.094"
Round 0.125"
Round 0.150"
Round 0.188"
Round 0.25"
Square 0.13"x0.13"
Rectangular 0.09"x0.145"
Rectangular 0.10"x0.175"
 Coil Heater - Bucan

Typical Heating Applications:

  • Hot Runner Nozzles
  • Cutting & Sealing Bars
  • Medical Equipment
  • Rod, Pipe & Tube Heating
  • Heat Tracing
  • Semiconductor Manufacturing
  • Forming Dies
  • Printing & Laminating Presses

Plain leads with high-temperature sleeving

High temperature Teflon leads (480° F) with a fiberglass jacket exiting from a transition bracket. This bracket is sealed with high temperature cement.

Stainless steel braid

The stainless steel braid, which is crimped to the transition bracket, provides abrasion resistance and maintains high flexibility.

Stainless steel armor

Stainless steel armor is less flexible than stainless steel braid. It provides protection from contamination and abrasion. This style is standard on heaters.

Termination Orientation

Installation Tips For Coil Heaters

  • The inside diameter of a coil heater is 0.020” smaller than the nominal diameter of a nozzle. This is done intentionally to secure a positive grip at all times. During installation, a coil heater should be screwed to its proper position. Pushing forcefully, or slightly opening the coil to facilitate installation could permanently damage the heater.
  • During installation, only the straight cold section could be slightly bent. This should be done in a single attempt. The bending radius shouldn’t be less than 0.5”. It is always recommended to contact our factory when modifications of form are required.
  • The straight cold section can withstand temperatures of up to 1500° F. However, to protect the lead wires, the temperature of the section beyond the transition adapter should be maintained below 480° F.
  • Usually the sensing tip of a thermocouple is located at the end of the last loop of a coil heater. Care should be taken to insure that the last loop is properly gripping the nozzle.

Coil Heaters Available from Stock

Part # OEM EQ # I.D. Length Watts Volts Lead Length Type Ground Yes/No Cold Lead Type J T/C Profiled Heat
BK51492 SSTC-62-90 0.5 1.45 250 240 36" FLX HOSE Yes 2 Yes Yes
BK51992 SSTC-72-90 0.5 1.95 250 240 36" FLX HOSE Yes 2 Yes Yes
BK52502 SSTC-42 0.5 2.5 450 240 48" FLX HOSE Yes 1/1 No No
BK52592 SSTC-42-90 0.5 2.5 450 240 48" FLX HOSE Yes 2 No No
BK54601 SSTC-31 0.5 4.62 300 120 48" FLX HOSE Yes 1/1 Yes Yes
BK54691 SSTC-31-90 0.5 4.62 300 120 48" FLX HOSE Yes 2 Yes Yes
BK54602 SSTC-32 0.5 4.62 300 240 48" FLX HOSE Yes 1/1 Yes Yes
BK54692 SSTC-32-90 0.5 4.62 300 240 48" FLX HOSE Yes 2 Yes Yes
BK60902 SCH0003 0.625 0.975 225 240 42" SS BRAID Yes 2 Yes Yes
BK62002 SCH0081 0.625 2 300 240 36" SS BRAID Yes 2 Yes Yes
BK62502 SCH0082 0.625 2.5 350 240 36" SS BRAID Yes 2 Yes Yes
BK63002 SCH0083 0.625 3 400 240 36" SS BRAID Yes 2 Yes Yes
BK63502 SCH0084 0.625 3.5 425 240 36" SS BRAID Yes 2 Yes Yes
BK64002 SCH0085 0.625 4 500 240 36" SS BRAID Yes 2 Yes Yes
BK65002 SCH0086 0.625 5 500 240 36" SS BRAID Yes 2 Yes Yes
BK66002 SCH0087 0.625 6 500 240 36" SS BRAID Yes 2 Yes Yes
BK71402 SCH0060 0.75 1.44 250 240 36" SS BRAID Yes 2 Yes Yes
BK71702 SCH3142 0.75 1.75 315 240 42" SS BRAID Yes 2 Yes Yes
BK71902 SCH0061 0.75 1.94 300 240 36" SS BRAID Yes 2 Yes Yes
BK72402 SCH3242 0.75 2.44 315 240 42" SS BRAID Yes 2 Yes Yes
BK72432 SCH0062 0.75 2.44 350 240 36" SS BRAID Yes 2 Yes Yes
BK72902 SCH0063 0.75 2.94 400 240 36" SS BRAID Yes 2 Yes Yes
BK73402 SCH0064 0.75 3.44 425 240 36" SS BRAID Yes 2 Yes Yes
BK74402 SCH0065 0.75 4.44 500 240 36" SS BRAID Yes 2 Yes Yes
BK75402 SCH0066 0.75 5.44 500 240 36" SS BRAID Yes 2 Yes Yes
BK82102 SCH0088 0.875 2.13 400 240 36" SS BRAID Yes 2 Yes Yes
BK82602 SCH0089 0.875 2.63 450 240 36" SS BRAID Yes 2 Yes Yes
BK83102 SCH0090 0.875 3.13 550 240 36" SS BRAID Yes 2 Yes Yes
BK83602 SCH0091 0.75 3.63 700 240 36" SS BRAID Yes 2 Yes Yes
BK86102 SCH0094 0.875 6.13 1000 240 36" SS BRAID Yes 2 Yes Yes
BK84102 SCH0092 0.875 4.13 800 240 36" SS BRAID Yes 2 Yes Yes
BK85102 SCH0093 0.875 5.13 900 240 36" SS BRAID Yes 2 Yes Yes