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Excerpts of Technical Information from Back Issues of The Salamander News

Everybody's Going for the Gold Elements. June, 1998 issue
What Exactly is Infrared heat? July, 1998 issue
Salamander ESE Heaters for Use with Animals. June, 1999 issue
In Search of the "Best" Heater. September 1999 issue
Will I Need a Flat or Curved Element? September 2000 issue
Ohm's Law - Made Simple. September 2000 issue
The Challenge - Sizing and Layout. December 2000 issue
Technical Issues. March 2003 issue

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June, 1998 issue:

Everybody’s Going For the Gold Since the introduction of our color changing element, the Salamander Gold, last October, requests for them have been growing at a rapid rate. We are a-"maized" at this response and attribute it to the fact that although a more obvious temperature indicator can be a benefit, manufacturers are finding that adding a little color, even to an unobtrusive functioning machine, can add to the final attraction of their product. And why not? Mor Electric Heating Assoc., Inc. has never strongly supported the technical aspect of colored elements as temperature indicators, but realize the growing effect color has had on the economy over the past few years. Pink and purple are now actively worn by both men and women, there are neon cars, brilliant baths and bold appliances. Brilliantly colored products are easy to see, quick to recognize, and creates a good feeling just being around them. It is only natural that the energizing effect of color now enters into the workplace. For a look at the color of the Salamander Gold, visit our web site. Whether a big, bolder color indicator is needed in your application, or you just want to bring some additional attention to your product, the Salamander Gold is an option you may want to consider.

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New Box Insert

Effective immediately, all newly produced individually boxed elements will contain the information as shown on the back of this newsletter. It is important that each customer, whether OEM, distributor, or end user, have access to this information which can be critical to installation and safety. This 3 fold booklet replaces the half sheet of information previously enclosed with each shipment. We feel it is Mor Electric Heating Assoc., Inc.’s responsibility to ensure that this information be accessible with each element.

The term "IR" or infrared heating is used so commonly today that confusion can result over what exactly qualifies as infrared heat and how the different types can be discerned. Infrared heating is the transfer of thermal energy in the form of electromagnetic waves. True infrared heat should have one common characteristic: that the transfer of heat is emitted or radiated from the heated object or substance. The source emits radiation at a peak wavelength towards an object. The object can absorb the radiation at some wavelength, reflect radiation at other wavelengths, and re-radiate wavelengths. It is the absorbed radiation that creates the heat within the object.

Infrared heating varies by efficiency, wavelength and reflectivity. It is these characteristics that set them apart and make some more effective for certain applications than others. Varying levels of efficiency are possible within IR heating and often depend on the material of the heat source. The basic measure of efficiency lays in the ratio between the energy emitted and the energy absorbed, but other considerations may affect this measurement. One is the emissivity value of the heat source as based on the perfect "black body" emissivity level of 1.0. Ceramic heaters are capable of 90% or better emissions as opposed to the lower values of other heater substances.

The useful range of wavelengths for infrared heating applications fall within the range of 0.7 to 10 µm (microns) on the electromagnetic spectrum and are termed short-wave, medium-wave or long-wave. The medium to long-wave wavelengths are most advantageous to industrial applications since almost all materials to be heated or dried provide maximum absorption in the 3 to 10 µm region. Energy from an infrared heat source that also emits light (short-wave) will typically emit 80% of its energy around the 1 µm wavelength, where as the ceramic infrared heater emits 80% of its energy around the 3 µm wavelength.

The emission efficiency of the infrared heating element itself is not enough since they are used within a fixture. The reflectivity of the fixture greatly contributes to the overall efficiency of the heater. Salamander elements are housed within the effective combination of an aluminum clad steel reflector. The steel adds strength and rigidity while the polished aluminum makes for high reflectivity and minimal heat loss.

Add shape of both the element and reflector along with possible configurations and distance from the object to be heated and the opportunities within the realm of infrared heating expand even more.

The use of infrared heat is most commonly associated with the needs of people, but the Edison Screw Base (ESE) heater is especially adaptable for use with animals. It’s delicate nature provides natural sun-like heat to provide animals with the warmth they require, whether it be for comfort, incubating or therapeutic needs. The Edison screw-base design fits in an ordinary light bulb socket with a sufficient wattage rating.

Ceramic heating elements were designed specifically for use with pets such as lizards, iguanas, geckos and other reptiles, birds, domestic pets, exotic and tropical animals, arboreal snakes, and in environments such as zoos, veterinary clinics, and animal boarding or breeding. They are an improvement over ruby red heat lamps or regular light bulbs which emit light, have hot spots because the coil is visible, break or shatter easily, have a short life span, and emit a lower percentage of infrared heat. Infrared heat travels through the air until it contacts a solid object. It heats objects, not the air, which makes it a more efficient heat source than heat rocks, mats or bulbs, or the above mentioned lamps.

Ceramic heaters do not emit light, which can be irritating and disturb the natural light/dark awake/asleep cycle. Using a gentle, evenly heated, ceramic heater instead of heat lamps also eliminates infrared hot spots created by the glowing element inside the bulb. Replacing fan-forced air heating avoids the problems of blowing dust around and creating drafts, and high heat loss where the heated air rises to the ceiling.

Infrared energy also promotes health and healing of animals because it dilates the blood vessels and increases the bloods circulation of oxygen and nutrients. It penetrates deep into skin and muscle tissue, provides comfortable heat, reduces soreness and stiffness of joints and muscles. It also benefits the immune system and reduces stress by creating a more ideal environment, similar to the way an infrared sauna effects humans. Some users of ceramic heaters have reported that their animals are larger, healthier, lay more eggs, eat better and are much more active when using infrared heat.

Because all species of animals have specific temperature requirements, and there are a variety of cages available, the distance from the cage and wattage of the heater you should use, will vary. Research the internet or other herpetology resources for information about the animal being heated and the geographical region it is native to, for temperature ranges that are optimal. By checking temperatures at many different places in the cage you can learn how to best place the ceramic heater and reflector.

An average guideline is as follows:

60 Watt: 10-14 inches
100 Watt: 12-16 inches
150 Watt: 14-24 inches
250 Watt: 22+ inches

The use of infrared heat with animals is a huge market that is relatively untapped in the United States, and easily provides the most suitable alternative for existing heat sources or new applications. Click here for additional information.

The day has still not arrived when we can manufacture a heater that can do all things. That’s why a knowledge of the strengths and weaknesses of all types of heaters is the only way to successfully make choices for specific applications. The four major heat types to be considered are: metal sheath, quartz tube, quartz lamp, and ceramic.

Similarities in the above types of heaters are less important than the differences. They are all good heaters, depending on what application they are being used in. It is also important to realize that some applications may benefit most from using a combination of heat types. By having a good knowledge of the differences of the various heat types, and using a simple process of elimination, it can be easy to match the best heater for an application. Using a combination of heaters can be a little more difficult and in considering it, each phase of the process should be evaluated by the same criteria.

The following are simple explanations of the most appropriate usage for the four heater types:

Metal-sheath elements- are best used for convection heating needs, such as ovens. They are rugged, cost effective for the application, and efficient. For example, metal-sheath elements can be found in every electric household oven.

Quartz tubes- are best used for radiant applications that need instant on, instant off, such as heat sensitive materials that may have to linger in a heat source.

Quartz lamps- are also instant on and off but made in extremely high watt density. These are effective for high speed production processes.

Ceramic elements- are best used for processes requiring an even, gentle heat and where there is a need for zone control.

Wavelength and emissivity value of the material being heated are also essential for heater selection. Though emissivity charts should be used with specific formulas to calculate the wavelength requirements, a simple generality is "the hotter the heating element, the shorter the wavelength." The absorption rate of the material would then need to be considered as to which wavelength would be appropriate. Another generality is "the higher the absorption, the longer the wavelength requirement." A more detailed explanation of wavelength and emissivity will be covered in a future newsletter.

The following chart is designed to help with the process of heater selection when asking these specific questions:

If you are not part of the electrical engineering world, the table to the right may look like a mathematical impossibility. But learning a simple variation of Ohm’s Law can become an easy and useful tool for helping your customers and increasing the value of your stock. In laymen’s terms, it’s sometimes referred to as "The Rule of Fourths", and it is a simple formula that can be used for converting voltages and wattages.

Deciding what elements to stock is always a difficult decision, but it is always based on the desire to meet the customer’s needs. If salespeople are aware of the relationship between wattages and voltages, you will be able to easily substitute one element on your shelf for another if need be. The "Rule of Fourths" is to simply divide the wattage by 4 and the voltage by half, to find an equivalent wattage and voltage.

For example:

A 480 volt, 1000 watt heater is the same as:

a 240 volt, 250 watt heater or (voltage divided by 2 and wattage divided by 4)

Always work from high to low when converting voltage/wattage. Increasing wattage/voltage could cause the emitter to exceed its design criteria and significantly reduced the life of the element or cause immediate failure.

Element conversion can be used in emergency situations or when small quantities are needed. For example, if a customer calls and needs a 120 volt, 250 watt heater, and you don’t have one, a 240 volt 1000 watt heater is basically the same thing. It is important to remember, that when substituting elements, to indicate on the box or somewhere on the element, what they are adapting to, so they will have this information for reordering purposes.

As mentioned above, this is the simplified version of a variation of Ohm’s Law. Substitutions may be made for voltages other than these, but the U.S. sales office should be consulted, where a spreadsheet has been designed to produce conversions quickly and accurately.

December 2000 issue:

Last month you were given the Information and the Example for doing Sizing and Layouts. As promised, this month we give you the Challenge, to try out your skills.

A customer has requested ceramic infrared panels to dry both sides of a glass fiber material being coated with a resin material.

Glass fiber and resin film

His speed is 308 ft. per hour.

The material width is 33.46 inches

The weight per square foot is: glass fiber- .0583 lbs./sq.ft.

resin- .088 lbs./sq.ft.

acid water- .0163 lbs./sq.ft.

Assume the emissivity of resin is .90.

The final temperature is 392°F.

Ambient temperature is 65°F.

The voltage is 380V, 3 phase, 50 Hz

Exterior panel dimensions: 36" x 48"

Using the above information, and the formulas presented in last month’s newsletter, what would you recommend for this customer? We will need type of heater, numbers and design of heaters, wattage and distance from the material.

January 2001 issue

The Answer- in bold type

A customer has requested ceramic infrared panels to dry both sides of a glass fiber material being coated with a resin material.

The facts:

Glass fiber and resin film

His speed is 308 ft. per hour= 5.12ft./min.

The film width is 33.46 inches Area of film per hour= (308ft)(2.8ft) = 862.4ft2

The weight per square foot is: 
glass fiber- .0583 lbs/sq.ft.= .000405 lbs/in2
resin- .088 lbs./sq.ft. = .0006 lbs/in2  
acid water- .0163 lbs./sq.ft= .000114lbs/in2

Assume the emissivity of resin is .90.

 The final temperature is 392°F.

Ambient temperature is 65°F.

The voltage is 380V, 3 phase, 50 Hz

Exterior panel dimensions: 36" x 48"

= 46.9 seconds (use 45 seconds)

Warm up time= .07804 w.hr/in.2/X w/in2 X 60min/1 hr X 60sec/1 hr = 45 sec.

We were disappointed in the lack of response we received for our infrared engineering Challenge in last month’s newsletter. We are wondering what the reasons are for this.

Too busy?

Not in your job description?

My way is easier and faster.

Too difficult?

I would like training made available.

If many of you check the last box, we would like to put together an on site, or at your site depending on the numbers, hands-on, training seminar. Please fax this section to 616-784-7775

Name________________________________ Number of interested people at your location:_____________________________

Company_____________________________ 

Contact phone # _____-______-_______

March 2003 issue:

It has been quite some time since we provided any technical information in The Salamander News. This issue will review highlights of important technical issues. To assist you on technical questions, we offer engineering and design support and we welcome and encourage you to consult with us in helping you to create the perfect solution for your infrared heating needs.

When infrared energy strikes an object it may be absorbed, transmitted, or reflected from the surface. The sum of the amount of energy absorbed, transmitted, and reflected must equal 100% of the total incident energy. A true "blackbody" either absorbs (or emits) 100% of incident infrared radiation. No true "blackbody" source for industrial applications exists. The efficiency of a radiant heater is given by its emissivity value which is the ratio of the radiant energy emitted by an object at a given temperature and the radiant energy emitted by a "blackbody" at the same temperature. Radiant heating elements are available with a wide range of radiant efficiencies. Ceramic elements are rated the highest at 96%.

Electrical connections should be made directly through high temperature ceramic terminal blocks (sold separately,) and not using them can result in injuries and loose connections. Nickel plated copper wire, with insulation suitable for the load amperage and operating temperatures, must be used to make the power connections to the ceramic terminal blocks.

If you are making your own reflectors they should be constructed from 20 to 24 gauge [.036" (.9mm) to .025" .6mm)] aluminized steel or stainless steel. Emitter mounting is done by inserting the ceramic emitter through 15mm x 41mm slots (except the LTE size emitter which mounts in two 15mm x 44mm slots) cut into the reflector and secured in place by a "spring retaining clip".

Panels should be designed to fit your application requirements taking into consideration available space, voltage, working temperature, product specifications, and time requirements. Zoning may be needed to provide different amounts of heat to specific areas of the material to be heated. Each ceramic heater or any combination thereof, can be wired in independent zones. Each zone can be operated at different temperature levels depending on application requirements.

The heater should be as close as practically possible, but far enough away that the infrared radiation pattern from each emitter (in a panel) will overlap each other, creating total coverage. Some materials are very heat sensitive and if the radiant patterns of the heat source do not overlap, "striping" can occur. The distance is dependent on the spacing between emitters. FTE emitters that are spaced 1" apart would require a distance of 8" to achieve even heating.

Salamander ceramic heaters are manufactured with three basic emitter faces: convex as in the ESE, concave as in the FTE, HTE, and LTE, and flat as in the FFE, HFE and HSE. These different shapes create three different emission patterns. The convex shape gives off a "wide area" pattern which is desired in comfort heating or other applications that require dispersed heating. A concave surface will emit a "concentrated" pattern which is highly effective when zone heating is desired as well as radiant heating in general. The flat surface will produce a "uniform" pattern for even heating at a close proximity between the emitter and the material to be heated.

Average Surface Temperature and Associated Peak Wavelengths Emitted

Like all infrared sources the Salamander emitter does not emit one single wavelength but a range of wavelengths. The peak wavelength emitted is dictated by the surface temperature of the emitter which can easily be monitored using closed loop or open loop control. In reference to Planck’s Law, a heater will emit a range of wavelengths which is only dependent on the surface temperature of the emitter.

Controls used to Regulate the Temperature of the Ceramic Heaters (February 2001 Issue)

Since the ceramic emitters are relatively slow responding (8 minute warm-up time required to achieve operating temperature) closed loop control with an inexpensive proportional control and contactor will control the heaters typically between +/- 2°F. Percentage timers and SCR power controls can also be used very effectively. The control of ceramic emitters can be one of two types: open-loop or closed-loop. It is important to be able to differentiate between these two control systems in order to best advise your customers on the products available to them.

Open-loop can control the temperature by two different methods. The first, controls by time, using a percentage-on/percentage-off duty cycle. When the timer is set for the on/off time cycle, the overall temperature of the emitter will stabilize. This can be done with either a mechanical timer or with a computer control. The second method of open-loop is through voltage control. In this method, a manual potentiometer control, or computerized control regulates the voltage potential applied to the elements, thus controlling the temperature.

Closed-loop control, a thermocouple is used to either measure the temperature of the element’s coil or, more accurately, the surface temperature of the element. A feedback signal can also be created with a non contact infrared sensor that can sense the emitters or product temperature. As the temperature of the target changes, the thermocouple creates a millivoltage which is sent back to a temperature controller. The controller then converts the millivoltage into a temperature reading. There are varying ranges of temperature controllers available from a simple on/off, non-indicating controller to a sophisticated digital PID control with ramp soak programming, auto-tuning, etc.

	Our website contains a technical support section at www.InfraredHeaters.com/techsupp.htm and our technical manual is at www.InfraredHeaters.com/page1.htm
	Topics above with issue dates indicated are archived at www.InfraredHeaters.com/acrobat.htm
	Contact us at Mor Electric Heating

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