Flexible Tubular Heaters

The Flexible Tubular Heaters is Anupam’s latest 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. Anupam’s Flexible Tubular Heaters eliminates costly downtime associated with waiting for a custom bent tubular heater. Anupam’s 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.

Features

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
Anupam’s 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%

^*Tested at environmental temperature

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.

Flexible Tubular Heaters

Features

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