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S Ka011 B Eng 2011 06 PDF
S Ka011 B Eng 2011 06 PDF
S Ka011 B Eng 2011 06 PDF
Globar
SD
Silicon carbide heating elements
3
Contents
Introduction 4
Product range
Kanthal
Globar
SD heating elements 5
Kanthal Globar SD elements 5
Kanthal Globar SD multi-leg elements 6
Applications 8
Installation methods 10
Kanthal Globar SD rod element installation 10
Kanthal Globar SD multi-leg element installation 11
Vertical mounting 11
Horizontal mounting 13
Element spacing all element types 14
Electrical characteristics 14
Electrical specications 15
Element performance 16
Element loading 16
Start up procedure 16
Operating temperature 16
Efect of atmosphere 18
Glazes and coatings 19
Continuous or intermittent operation 19
Power supplies 20
Element connections 20
Matching of resistance value 21
Voltage reserve 21
Power supply equipment 21
1 Variable output transformer 22
2 Thyristor (SCR) unit 23
2.1 Phase-angle ring 24
Power monitoring phase-angle 25
2.2 Fast-cycle ring 26
Power monitoring fast-cycle 27
3 Transformer + thyristor (SCR) 27
4 Direct-on-line 27
Ordering 29
Rod type elements 29
Multi-leg elements 29
Accessories 30
4
Introduction
Kanthal is the heating technology brand within
Sandvik; the worlds leading manufacturer of
silicon carbide (SiC) heating elements.
Kanthal
Globar
Globar
SD heating elements
Kanthal Globar SD elements
Kanthal Globar SD heating elements are made from
high purity alpha silicon carbide grains, that are
extruded in the form of rods or tubes, before being
bonded together by a process of re crystallization,
at temperatures of over 2500C (4530F). The
fring process ensures the creation of rods with
strong uniform bonds between adjacent grains, and
the particle size distribution is closely controlled
to ensure optimum density and resistance to the
process atmosphere.
Kanthal Globar SD elements have the conventional
central hot zone and two low resistivity cold ends.
Elements with unequal cold end lengths can also be
supplied if required.
Kanthal Globar SD elements can be supplied in
1-piece or 3-piece construction, according to the
demands of the application. One-piece elements
feature a joint free construction, where the cold
ends are formed by flling the pore structure with a
low resistivity silicon alloy. 3-piece elements feature
special low resistance cold ends that are joined to
the hot zone using a reliable and strong reaction-
bonding technique.
As the resistivity of the hot zone material is consider-
ably higher than that of the cold ends, the majority
of the heat is generated in the hot zone, when pow-
er is applied. The cold ends, which pass through
the furnace lining, remain relatively cool, and are
sprayed over a short length at the end with aluminum,
to form a low resistance contact for the aluminum
terminal braids.
Standard elements are available in a range of diam-
eters between 10 and 55 mm (3/8 and 2 1/8 in) as
detailed in Fig. 1. All of the elements are tubular,
apart from 10 mm (3/8 in) diameter elements,
which are manufactured in the form of solid rods.
Standard dimensions for Kanthal Globar SD elements
Fig. 1 Standard dimensions for Kanthal Globar SD elements.
6
A mm
16
in
5/8
mm
20
in
3/4
mm
20
in
3/4
mm
25
in
1
mm
32
in
1 1/4
mm
38
in
1 1/2
mm
45
in
1 3/4
B max. 500 19.7 800 31.5 800 31.5 850 33.5 1400 55.1 1400 55.1 1400 55.1
C max. 400 15.7 500 19.7 500 19.7 550 21.7 625 24.6 625 24.6 625 24.6
D 35 1.38 38 1.50 52 2.05 52 2.05 64 2.52 89 3.50 108 4.25
E 45 1.77 45 1.77 45 1.77 45 1.77 45 1.77 75 2.95 75 2.95
F 25 0.98 32 1.26 32 1.26 38 1.50 44 1.73 54 2.13 54 2.13
G (U) 60 2.36 65 2.56 79 3.11 87 3.43 102 4.02 145 5.71 165 6.50
G (CU) 35 1.38 38 1.50 52 2.05 52 2.05 64 2.52 89 3.50 108 4.25
G (W) 95 3.74 106 4.17 134 5.28 139 5.47 166 6.54 234 9.21 273 10.7
Kanthal Globar SD multi-leg elements
Kanthal Globar SD multi-leg elements are manu-
factured from 2, 3 or 4 silicon carbide legs of exactly
the same material and manufacture as standard
Kanthal Globar SD elements, each leg being divided
into two clearly defned lengths of hot zone and
cold end. All legs in any one element are matched
in resistance value, to ensure that the load is evenly
distributed, and are joined using silicon carbide
bridges in a special process, which bonds the com-
ponents into a monolithic structure of alpha silicon
carbide. There are no jointing cements or welds
which might limit the temperature capabilities of
the fnished element. The connecting bridges do not
form part of the hot zone and can be used as end
supports if required.
The type U element, manufactured from 2 legs, is a
single-phase unit, although groups of elements may
be connected to form a balanced 3-phase load.
The type CU is similar to the type U, but has a
shortened bridge for applications where only lim-
ited space is available.
The type W element, with 3 legs, forms an effective
star connected 3-phase element.
The type M element, with 4-legs, can replace two
type U elements, reducing the number of terminal
connections, and holes through the furnace lining.
The 4 legs may have identical heated lengths, or
the inner pair may have shorter or longer hot zones
than the outer, to provide non-uniform heat distri-
bution, where required.
Note that the bridge depth F is not included in
the hot zone length. Full details of preferred sizes
and resistance values may be obtained from the
element size list, and non-standard elements will
also be considered on request. Elements having
non-standard leg center distances (D) and support
slot positions (E), to match competitors multi-leg
elements, can be supplied if required.
Standard dimensions for Kanthal Globar SD multi-leg elements
7
M
Special order only
Aluminum sprayed A
B
C
F
U CU W
E
D
G G G
Fig. 2 Standard dimensions for Kanthal Globar SD multi-leg elements.
8
Applications
All Kanthal Globar SD rod and multi-leg elements
may be mounted vertically or horizontally as shown
in Fig. 3. The single ended connection of multi-leg
elements makes them ideally suited to various
applications where standard Kanthal Globar SD
rod elements cannot conveniently be used, such as
where access would be diffcult, where the furnace
span is too wide to allow conventional elements to
be ft, or in any case where single ended connec-
tions are essential.
Kanthal Globar SD elements are used in a wide
variety of furnace applications, from small labora-
tory furnaces to large industrial heating processes,
in different atmospheres and temperature ranges.
The elements allow great freedom in furnace design
which, combined with simple installation and long
operating life, makes them the preferred choice
in many applications including: glass, ceramics,
electronics and metal industries, and also for re-
search and development. Examples of some typical
furnaces where Kanthal Globar SD elements are
the natural choice are illustrated below.
Fig. 3 Typical furnace applications.
Continuous
furnaces
Aluminum melting
and holding furnaces
9
Low pressure die
casting furnaces
Rotary hearth
furnaces
Elevator furnaces
10
Pattern element A L
mm in mm in mm in
SL10 10 3/8 18 0.71 75 2.95
SL14 12 & 14 1/2 & 5/9 26 1.02 75 2.95
SL20 16 & 20 5/8 & 3/4 31 1.22 75 2.95
SL29 25 1 43 1.69 75 2.95
SL32 32 1 1/4 47 1.85 75 2.95
SL38 38 1 1/2 56 2.20 75 2.95
SL45 45 1 3/4 62 2.44 75 2.95
SL55 55 2 1/8 70 2.76 150 5.91
L
A
Ceramic
fber
washer
Note that the hot zone
must not extend into the
element holes
Ceramic fber pad
Kanthal Globar SD rod element installation
Although silicon carbide is rigid and self support-
ing, it has a fairly low impact strength, and care
must be taken when unpacking and handling the
elements so that they are not subjected to mechani-
cal shock. Elements should always be supported in
two hands.
It is important to ensure that the elements are not
restricted in any way and are free to move radially,
as well as axially, in their support holes. Element
holes must be in line, and the whole alignment
should be checked by passing a straight bar, of the
same diameter as the support holes, right through
the furnace, before ftting the elements.
Under no circumstances should the element hot
zones be allowed to enter the element support
holes as this will lead to localized overheating and
premature failure.
Special lead-in sleeves are available for mounting
all diameters of Kanthal Globar SD elements and
these are detailed in Fig. 4 and in the accessories
size list. Sleeves should be ft from the outside of
the furnace, in holes bored to a diameter that will
ensure a loose ft, and the sleeves should never be
cemented into position. In general, the sleeves will
be far shorter than the thickness of the furnace
Installation methods
Fig. 4 Standard sleeve patterns and installation.
Fig. 5 Installation without sleeves.
Pattern standard dimensions
11
Element connections must be kept reasonably cool
and any terminal guards ft should be well venti-
lated. Where sealed terminal boxes are essential,
for example in controlled atmosphere furnaces,
then the following procedures should be followed:
Increase the free length of cold end outside the
furnace to 4 5 times the element diameter
Ensure that the surface area of the terminal
covers is suffcient to ensure adequate cooling.
It may be necessary to provide fnned covers to
increase the surface area
Use type D terminal clamps, and larger section
connecting braids than normal
Introduce a proportion of the process gas via the
terminal boxes, to assist in cooling
In very severe cases, some kind of forced cooling
may be required
Where Kanthal Globar SD elements are to be
mounted vertically, a support of electrically insu-
lating, heat-resistant material should be provided
below the terminal end. Alternatively, elements
of 16 mm (5/8 in) diameter and above may be
supplied to special order with support slots and
washers to allow them to be suspended from the
top of the furnace, in a similar manner to vertically
mounted type U elements (Fig. 6).
Kanthal Globar SD multi-leg element installation
All multi-leg elements must be unpacked and
handled with care, using both hands for support,
and ensuring no stress is placed on the element
legs. Any transit straps ft across the legs should be
removed, just before installation.
Vertical mounting
Multi-leg elements are usually mounted vertically
and suspended through pre-drilled refractory sup-
port blocks shaped to ft corresponding holes in the
furnace roof. Elements and blocks may be pre-
assembled and placed in position as required. The
precise shape and size of the blocks will depend on
the element dimensions and the construction of the
furnace roof.
Elements are usually supported using specially de-
signed support washers as detailed in Fig. 6, but
may be supported on a suitable ceramic ft below
the bridge, if required.
insulation, but the clearance holes should be drilled
right through to the hot face, as shown in Fig. 4, to
prevent any contact between the elements and the
lining, as this can lead to adhesion, and premature
failure.
If sleeves are not to be used, for example in brick-
lined furnaces, then the elements may be ft through
holes about 4 5 mm (1/6 1/5 in) larger than the
element diameter for element sizes up to 20 mm
(3/4 in), and about 8 10 mm (1/3 in) larger for
elements from 25 55 mm (1 2 1/8 in) diameter.
Even larger holes may be required where there is
a possibility of volatiles condensing in the element
holes or on to the cold ends, or where the furnace
lining is exceptionally thick.
Elements should always be centralized by support-
ing each cold end on a small pad of ceramic mate-
rial, to prevent contact between the element cold
ends, and the lead-in holes. Under no circumstances
should the cold ends be wrapped with ceramic fber
or other insulation, as this will lead to restriction
and possible premature failure. To prevent radia-
tion on to the terminal connections and minimize
heat losses, a fexible ceramic fber washer may be
ft over each terminal end and positioned so that
it rests against the outer face of the furnace (Fig. 5).
In all cases, the element ends should extend beyond
the sleeve fange, or the outer face of the fber
washer, by a distance of approximately 2 3 times
the element diameter.
The use of aluminum braid is recommended for
making terminal connections as it does not suffer
from progressive oxidation and is suffciently fat
and soft to allow a good connection to be made.
Braids are normally attached using type H spring
clips, which are easy to install and require no tools.
Where space is restricted, type C clips may be used,
and these require a special tool for installation.
Both H and C clips rely on spring steel to maintain
a good contact, and must be maintained at a tem-
perature below about 250C (480F). For higher
temperatures, types G and D clamps may be used.
These are clamped to the elements using stainless
steel set screws, and high temperature lubricant
should be applied to the threads before installation,
to prevent seizing, and later diffculty in tightening
and removal. Screws should be retightened after 24
hours use.
12
Note that the
hot zone must
not extend into
the element
holes
Support
washer
assembly
Insulating
board
Ceramic fber
location block
Support
washer
Locking
washer
Precautions must be taken to prevent the terminals
from overheating, especially if the elements are
operating at the higher end of their temperature
range or if the roof lining is relatively thin. In most
cases a 25 mm (1 in) thick pad of ceramic fber
ft below the support washers will be suffcient,
providing the terminal boxes are adequately venti-
lated. In more severe cases it may be necessary to
mount the elements through a separate support
plate, ft about 75 100 mm (3 4 in) above the
furnace casing, to allow a free fow of air or process
gas over the exposed cold ends. Alternatively, ele-
ments can be supplied with support slots or holes
in a non-standard position, to allow for a greater
free length of terminal.
Support blocks must be manufactured from a
refractory material capable of withstanding the
maximum element temperature (which may be
considerably higher than the furnace temperature)
and should have a suffciently high electrical resis-
tivity to prevent conduction between adjacent legs
at that temperature. Generally, a high alumina, low
Fig. 6 Typical vertical installation.
iron refractory or vacuum-formed ceramic fber
material will be most suitable.
It is essential to ensure that the element mounting
holes are parallel, and accurately drilled at the
correct center distance. The hole diameter should
generally be about 6 mm (1/4 in) greater than
that of the element legs for elements up to 20 mm
(3/4 in) diameter, and 9 mm (1/3 in) greater for the
larger sizes.
Sandvik supplies special LB ceramic fber location
blocks to ft the most common sizes of U and CU
elements. It should be noted that the fange on the
location blocks is not designed to carry the mass of
the elements, and a separate hard, strong insulating
board, cut with clearance holes for the element legs,
must be ft above the fange, to transfer the load on
to the furnace casing.
The LB location blocks are available in 3 different
temperature ratings of 1250C (2280F), 1400C
(2550F) and 1500C (2730F), which should
13
Ceramic tube to
support legs
Pivot pin
bonded
to bridge
Alumina
tube pivot
correspond to the maximum expected element
temperature.
Under no circumstances should the element hot
zones be allowed to enter the element support
holes as this will lead to localized overheating and
premature failure.
Elements may also be mounted vertically with the
terminals at the base and should be located on an
electrically insulating, heat resistant support ft
below the terminal end. Long elements supported
in this way may need a stabilizing support or hook
ft at the bridge end.
Type M elements have wider cold end spacings than
the 2 and 3-legged elements, and it may be prefer-
able to ft the elements from inside the furnace, us-
ing SL sleeves to isolate the cold ends for the lining
and casing of the furnace.
Horizontal mounting
Special precautions are required where multi-leg
elements are to be installed horizontally, especially
with long elements, and the element cold ends must
be supported on a hard smooth surface in such
a way that they are free to move laterally during
heating and cooling. An alumina tube, installed
with its axis at 90 to the legs axes is a suitable
support. Holes through the furnace insulation
should be in the form of slots, or clearance holes,
so that the legs are supported only by the ceramic
tube, and do not contact the insulation. Elements
should never be cantilevered, and the bridge should
always be supported. It is important to ensure that
the bridge support is level, and co-planar with the
ceramic tube supporting the element legs, other-
wise one of the legs may not be fully supported
and may fail prematurely.
As it is often impossible to ensure that the supports
are exactly in line, self-aligning systems have been
developed by Kanthal, and special elements can be
supplied with a pivot pin attached to the bridge,
to allow it to rotate freely and prevent mechanical
stressing of the legs. Alternatively, standard element
bridges can be supported on a length of alumina
tube, which will allow free rotation of the bridge,
relative to the element legs (Fig. 7).
Fig. 7 Typical horizontal installation methods.
Horizontal elements should generally be installed
with the legs in the same horizontal plane. Installa-
tion with leg centers in the same vertical plane is
possible only with short elements, and is not gen-
erally recommended, due to diffculty in ensuring
that both legs are equally supported.
14
A
D
A
C
A
B A
Element spacing all element types
Elements should be spaced at a minimum of 2
diameters between centers, but 2.5 3 times the di-
ameter is preferred. There should be 1 diameters
between element centers and the refractory lining,
and a distance of at least 2 diameters should be
allowed between the element centers and the prod-
ucts being fred. It may be necessary to increase this
if uniformity of heating is required, especially if the
distance between adjacent elements is large (Fig. 8).
Where multi-leg elements are being used, it is ad-
visable to increase the minimum clearance between
elements slightly, to ensure at least 15 mm (5/8 in)
clearance between adjacent bridges.
Fig. 8 Recommended element spacings.
A = (1.5 D) = Minimum spacing between element center and
any adjacent refractory
B = (2 D) = Minimum spacing between adjacent element
centers
C = (2 D) = Minimum spacing between element centers and
hearth plates or work
D = Element diameter
Note:
If under hearth heating is to be used then the hearth plates
should be as thin as possible and have a thermal conductivity
of at least 14 W/mK.
It may be necessary to limit the power output to prevent
overheating.
Electrical characteristics
Kanthal silicon carbide elements have a much
higher resistivity than metallic elements and can be
operated at higher surface loadings (i.e. W/cm
2
(W/in
2
) of the hot zone surface area).
The resistivity/temperature characteristic is shown
in Fig. 9.
Kanthal Globar SD elements have a high and vari-
able resistivity at room temperature, but this falls
with increasing temperature, reaching a minimum
at about 700C (1290F). At element temperatures
above 700C (1290F), resistivity increases with
rising temperature.
15
300
280
260
240
220
200
180
160
140
120
100
80
0 200 400 600 800 1000 1200 1400 1600C
32 390 750 1110 1470 1830 2190 2550 2910F
Element temperature
% of nominal resistance
Minute variations in the quantities of minor impu-
rities in the material have a disproportionate effect
on the cold resistance value, as indicated by the
dotted curves, and room temperature resistance
measurements give no indication of the resistance
at working temperature.
Resistance measurements should always be carried
out at a constant temperature at or above 1000C
(1830F), and the value determined by dividing the
voltage across each element by the current passing
through it.
Electrical specications
The nominal resistance values detailed in the ele-
ment size lists are based on an element temperature
of 1000C (1830F), as illustrated in Fig. 9. The
resistance values are subject to a tolerance of 15%
and although the nominal value is generally used
when calculating the voltage range of the power
supply, the negative resistance tolerance must be
considered when calculating the maximum current
drawn (see page 22).
Kanthal Globar SD elements are marked with a
standard test voltage, calculated to raise an element
of nominal resistance to a temperature of 1000C
(1830F) in free air. The test current value at this
voltage is also marked on each element, and should
be used when matching element resistances. The
test voltage is for calibration purposes only, and
the maximum recommended voltage with new
elements will not normally exceed 80% of the test
voltage.
The size lists detail the range of preferred element
sizes, but non-standard elements, including Kanthal
Globar SD elements with offset hot zones, can also
be supplied.
Resistivity/temperature characteristic curve
Fig. 9 Typical R/T curve.
16
Element performance
All silicon carbide elements increase in resistance
during their life in operation, and the rate at which
this occurs is affected by the following factors:
Furnace temperature
Diameter, mm ( A)
Nominal resistance,
Ordering
Multi-leg elements
Diameter, mm ( A)
Nominal resistance,
*Note: Standard slot position will be supplied un-
less specifed otherwise (see Fig. 2).
30
Accessories
Accessories available from Sandvik (full size list on request).
LB block
SL sleeve
CT2 (clip-tool, large)
CT1 (clip-tool, small)
HC clip
G clamp
CC clip
D clamp
D1 braid D2 braid
S1 braid S2 braid
Q1 braid Q2 braid
Sandvik Group
The Sandvik Group is a global high technology enterprise with 47,000 employees in 130 countries. Sandviks operations are concentrated
on three core businesses: Sandvik Tooling, Sandvik Mining and Construction and Sandvik Materials Technology areas in which the group
holds leading global positions in selected niches.
Sandvik Materials Technology
Sandvik Materials Technology is a world-leading manufacturer of high value-added products in advanced stainless steels and special alloys,
and of medical implants, steel belt-based systems and industrial heating solutions.
Kanthal is a Sandvik owned brand, under which world class heating technology products and solutions are ofered. Sandvik, Kanthal and
Globar are trademarks owned by Sandvik Intellectual Property AB.
Quality management
Sandvik Materials Technology has quality management systems approved by internationally recognized organizations. We hold, for example,
the ASME Quality Systems Certicate as a materials organization, approval to ISO 9001, ISO/TS 16949, ISO 17025, and PED 97/23/EC, as
well as product approvals from TV, JIS and Lloyds Register.
Environment, health and safety
Environmental awareness, health and safety are integral parts of our business and are at the forefront of all activities within our operation.
We hold ISO 14001 and OHSAS 18001 approvals.
Disclaimer
Recommendations are for guidance only, and the suitability of a material for specic application can be conrmed only when we know the
actual service conditions. Continuous development may necessitate changes in technical data without notice.
This printed matter is only valid for Sandvik material. Other material, covering the same international specications, does not necessarily
comply with the mechanical and corrosion properties presented in this printed matter.
Sandvik Materials Technology
Sandvik Heating Technology AB, Box 502, 734 27 Hallstahammar, Sweden Phone +46 220 21000 Fax +46 220 21166
www.kanthal.com www.smt.sandvik.com S
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