Kanthal Super Electric Heating Elements (Handbook)

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Kanthal Super Electric Heating Elements (Handbook) KSHB foder 99-05-04 11.44 Sidan 1 Copyright by Kanthal AB. May be reproduced only with proper acknowledgement of the source. Catalogue 2–A–1–3 ISBN 91 86720 08 -2 5000 05.99 Edit by Texter med Tryck AB Hallstahammar. Design and set in DTP by Mediaidé, Eskilstuna. (180) Printed in Sweden by PRIMAtryck, Hallstahammar, 1999. This information, which may be subjected to change, is offered solely for your consideration and should not be taken as a warranty or representation for which we assume legal responsibility. It is not to be understood as permission or recommendation to practice a patented invention without a licence and the user should determine wether relevant patents exist. ® KANTHAL is a registered trademark of Kanthal Group companies in Sweden and other countries. TM SUPERTHAL. KSHB Förord s 1-8 99-05-10 08.51 Sidan 3 KANTHAL® SUPER Electric Heating Element Handbook KANTHAL AB P O Box 502 SE 734 27 Hallstahammar, Sweden Telephone: + 46 220 210 00 Fax : +46 220 211 92 www.kanthal.com A Sandvik Company KSHB Förord s 1-8 99-05-10 09.05 Sidan 4 Kanthal AB, Hallstahammar, Sweden. KSHB Förord s 1-8 99-05-10 09.12 Sidan 5 Kanthal Super Handbook Introduction 5 ANTHAL is a world-renowned name within the field of K electric heating and you will find our handbook an indispensable aid when installing and operating our KANTHAL SUPER resistance elements that are designed for all types of electric heated industrial furnaces. When we introduced the now world-famous KANTHAL iron-chromium-aluminium electric resistance alloys in the early thirties this represented a considerable rise in the maximum operating temperature of metallic resistance elements. Again, when KANTHAL SUPER elements were introduced in 1956, this represented a step upwards on the temperature scale for resistance elements. The aim of our R&D department, however, has always been to improve our materials to enable their use at still higher temperatures. Through intense research work, we have been able to raise this temperature from 1650 °C (3000 °F) element temperature in 1956, to 1850 °C (3360 °F) today. New element forms have also been developed and in this handbook you will find information about SUPERTHAL high temperature heating modules. KANTHAL SUPER elements have proved to be very useful not only at high furnace temperatures, but also at lower temperatures, particularly in the field of heat treatment of metallic products in controlled atmospheres and melting of glass. The fields of possible applications are unlimited and have yet to be fully investigated. With the increasing interest in electric heating, we can expect many new designs and applications in the future. In addition to information on the properties of our KANTHAL SUPER material this handbook will also provide data on our standard elements and instructions for element calculation, installation, operation, etc. Further, advice is given on furnace designs, and some examples of actual KANTHAL SUPER element installations are shown in the installation section. We have tried to give you enough information to enable you to calculate and install KANTHAL SUPER elements and how to operate furnaces. If our advice is followed, you will be assured of an efficient and economical installation for your special heat treatment operations. If you need any further advice, specialists at our companies, our agents and the skilled staff at our technical service department in Hallstahammar will be pleased to assist you. Hallstahammar, Sweden 1999 KANTHAL KSHB Förord s 1-8 99-05-10 09.23 Sidan 6 6Contents Kanthal Super Handbook Preface ................................................................................................................. 5 1 Introduction .................................................................................................... 9 This is KANTHAL SUPER ............................................................................................ 9 Quality and product summary ................................................................................... 10 2 Properties ......................................................................................................... 11 Mechanical and physical properties .......................................................................... 11 Chemical resistance ..................................................................................................... 12 3 Elements and tubes ............................................................................. 17 Two-shank elements .................................................................................................... 17 Terminal shapes ........................................................................................................... 18 Two-shank bent elements ........................................................................................... 20 Four-shank 1700 elements for horizontal use ......................................................... 20 Tubes ............................................................................................................................. 22 4 SUPERTHAL heating modules ............................................... 25 Basic data for SUPERTHAL (Table 6) ........................................................................ 27 Temperature-loading diagram .................................................................................... 28 SUPERTHAL terminal design ..................................................................................... 29 5 Electrical data .............................................................................................. 33 6 Performance ................................................................................................. 63 Resistivity ...................................................................................................................... 63 Temperature-loading diagram, KANTHAL SUPER 1700 and 1800 ........................ 64 Temperature-loading diagram, KANTHAL SUPER 1900 ......................................... 65 Wall loading .................................................................................................................. 66 7 Installation ....................................................................................................... 67 Vertically mounted elements ...................................................................................... 67 Horizontally mounted elements .................................................................................. 67 Brick lined furnaces .................................................................................................... 68 Ceramic fibre lined furnaces ....................................................................................... 69 Element holders and anchor systems ....................................................................... 74 Contacts ........................................................................................................................ 78 Assembling of KANTHAL SUPER elements ............................................................... 80 Assembling of SUPERTHAL furnaces ........................................................................ 85 Elements in radiant tubes .......................................................................................... 86 8 Calculations..................................................................................................... 87 Examples of element calculations .............................................................................. 94 Kanthal Super HandbookContents 7 9 Control, power supply and wiring .......................................107 Material characteristics ............................................................................................. 107 Control in general ...................................................................................................... 107 Thyristor control ........................................................................................................ 108 Phase-angle firing ...................................................................................................... 108 Burst firing with phase-angle start .......................................................................... 109 On/off control ............................................................................................................. 110 Tapped transformer ................................................................................................... 110 Contactor switch, changing the element connection ............................................. 111 Scott-connected transformers .................................................................................. 114 Calculation of transformers ...................................................................................... 114 Wiring to counteract electromagnetic forces .......................................................... 115 10 Furnace operation ................................................................................. 121 Initial start-up procedure recommendations .......................................................... 121 Starting up a newly-built furnace ............................................................................ 121 Replacement of elements .......................................................................................... 122 Temperature control .................................................................................................
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