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Product catalog summary

Company Overview
Hillesheim GmbH specializes in flexible electrical heating technology, providing solutions for transporting fluid or gaseous media without temperature loss. With over 35 years of experience, they offer products such as heating hoses, tapes, mats, and plates, capable of handling temperatures up to 1000°C.

Document Structure
The document is organized into sections covering general information, industrial and analytical heating hoses, flexible trace heaters, surface heating elements, heating systems, and control technology.

General Information
Flexible heating hoses are recommended for transporting media without heat loss, maintaining a constant temperature to ensure consistent quality and avoid condensation. Key components include connection fittings, temperature sensors, and thermal insulation.

Application Examples
Hillesheim heating hoses are used in industries such as foam installations, transportation technology, flue gas analysis, plastics processing, food processing, adhesives engineering, medical technology, petrochemicals, and surface technology.

Technical Specifications
The heating hoses are designed for optimal heat distribution and equipped with temperature sensors. They require monitoring with suitable controllers. Specifications include nominal diameter, pressure hoses, connection fittings, and temperature sensors.

Installation Recommendations
Proper installation is crucial to avoid stress and damage. Recommendations include avoiding twisting, ensuring correct bending radii, and providing adequate ventilation to prevent overheating.

Protection Types
The document outlines protection types for electrical equipment according to EN 60529, detailing protection against solid foreign objects and water.

Protection Against Water

Level 5: Protected against water jets from any direction without harmful effects.
Level 6: Protected against powerful water jets from any direction without harmful effects.
Level 7: Protected against temporary immersion in water under standardized conditions without harmful effects.
Level 8: Protected against continuous immersion in water under more severe conditions than Level 7, as agreed between manufacturer and user.

Protection Classes for Electrical Devices

Class I: All exposed metal parts are connected to the mains protective earth conductor.
Class II: Device is isolated with no exposed metal parts that can conduct electric current; no protective earth conductor.
Class III: Operated on low voltage (not exceeding 42 V) from a safety transformer or battery.

Industrial Heating Hoses

Type Codes: Various codes for heating hoses, sensors, outer protection, and fittings.
Nominal Length and Power: Detailed specifications for different types of hoses, including rated power and operating temperatures.
Test Voltage: 2000 Volt high voltage test for heating conductor – PE conductor.

Industrial Pressure Hoses

Types T1 to T46: Different configurations of PTFE hoses with varying pressure ratings, bend radii, and temperature tolerances.
Temperature Correction Factors: Adjustments for pressure capacity based on temperature.
Material Stability: Stainless steel hoses are stable from -190°C to +550°C; PTFE hoses from -70°C to +250°C.

Hose Fittings

Various types of fittings including DKR, RSL/RSS, DKL/DKM/DKS, DKJ, and BDN with specific thread sizes and materials.
Special fittings available in different materials and coatings.

Protective Braiding and Caps

Materials include polyamide, steel, polyurethane, and textile glass with varying temperature stabilities.
Hard and soft caps provide protection against bending and twisting, with integrated connection options.

Applications and Specifications

Heating hoses are used for transporting various substances like oil, grease, adhesives, and more, with specific operating temperatures and pressure loads.
Customizable options available based on customer requirements.

Overview The document provides detailed specifications and applications for various industrial heating hoses used in different industries, including plastics, polyurethane foam processing, and more. These hoses are designed to handle high temperatures and pressures, offering flexibility and ease of maintenance.

Specifications The document outlines the specifications for different series of heating hoses, including operating temperatures, rated voltages, pressure capacities, and production lengths. Key materials used include PTFE, stainless steel, and various insulating materials like silicone foam and textile glass.

Applications The heating hoses are used in applications such as co-extrusion in the plastics industry, polyurethane foam processing, and as frost protection hoses for mobile water supplies. They are also suitable for use in explosion hazard areas and for heating or cooling elements in various industrial processes.

Key Features - Operating temperatures range from -20°C to 600°C depending on the hose type. - Rated voltages typically at 230 V AC/DC, with options up to 500 V. - Pressure hoses are available in various types, including T3 PTFE and stainless steel. - Protection types up to IP54, with some hoses offering IP20 or IP44. - Temperature sensors and control systems are integrated for precise temperature management.

Recommendations The document suggests using specific controllers for temperature regulation and highlights the importance of selecting the right hose type based on the application requirements. It also emphasizes the need for proper installation and maintenance to ensure optimal performance.

Conclusion The industrial heating hoses described in the document are versatile and designed to meet the demands of various industrial applications. They offer high-temperature resistance, flexibility, and ease of integration into existing systems, making them suitable for a wide range of uses.

Overview The document provides detailed specifications and applications for various industrial heating hoses and flexible heating jackets. These products are designed for maintaining and controlling temperatures in industrial settings, suitable for a range of media including chemicals, oils, and foodstuffs.

HFM Series – 600°C Flexible heating jackets constructed from heating tape and insulation, suitable for trace heating of pipes. They offer easy installation and replacement, with operating temperatures from frost protection up to 600°C. Rated voltage is 230 V AC, with options for other voltages. The jackets can be customized in length and are equipped with temperature sensors.

SIM Series – 150°C Clip attachment tracer heaters for thin pipes and hoses, made from silicone profiles with parallel heating elements. They are designed for easy installation without dismantling existing systems, covering pipe diameters from 4-12 mm. Operating temperature ranges from -20 to +150°C, with rated power between 50 - 100 W/m.

HE Heating Hose Developed for maintaining temperatures of various media, suitable for large nominal diameters (DN > 200 mm). Operating temperatures vary with material, with rubber maxing at 90°C and PTFE at 200°C. The hose is available with various outer covers and fittings, and can be customized for specific applications.

HL 40/80 Series Heating hoses with vulcanized heating conductors, approved for foodstuffs. They feature a spiral-wound heating element and integrated temperature sensor, suitable for transporting food and beverages. Operating temperatures are 40°C and 80°C, with a range of connection fittings available.

Analytical Heating Hoses Designed for maintaining temperatures in sample gas lines, preventing condensation and temperature drops. They are available with various inner cores and protective braidings, suitable for temperatures up to 350°C. The hoses can be customized in length and are equipped with temperature sensors and connection fittings.

End Connection Technology Various end cap and connection options are available for the H300 series, allowing for flexible assembly and integration into existing systems. The document also details the specifications for cable screw fittings and strain relief options.

Temperature Control A range of devices is available for temperature control, from mini-controllers to microprocessor-controlled devices, ensuring precise temperature management across different applications.

Overview The document provides detailed specifications and applications for various heating and insulating products, including polymer foam mats, needle-punched fibreglass mats, ceramic fibre mats, glass fabric hoses, quartz fabric hoses, connection wires, porcelain terminals, spring terminals, fuse protection circuit breakers, thermoswitches, thermocouples, PT100 sensors, compensating cables, self-adhesive signs, surface heating elements, heating mats, and heating sleeves.

Specifications

Polymer Foam Mats: Available in various thicknesses and lengths, suitable for temperatures up to 170°C.
Needle-Punched Fibreglass Mats: Insulate pipes and tanks, withstand temperatures up to 450°C.
Ceramic Fibre Mats: High-grade flexible mats for insulation up to 1000°C.
Glass Fabric Hoses: Insulate electrical conductors, with temperature limits of 250°C to 450°C.
Quartz Fabric Hoses: High-grade hoses for temperatures up to 900°C.
Connection Wires: Cu-nickel wires with PTFE insulation, available in various cross-sections.
Porcelain Terminals: For use up to 250°C, available in multiple configurations.
Spring Terminals and Mounting Rails: Various configurations for electrical connections.
Fuse Protection Circuit Breakers: Rated for 30 mA tripping current, with IP54 protection.
Thermoswitches: For temperature control, with various rated switching temperatures.
Thermocouples and PT100 Sensors: Available in different types and configurations for high-temperature applications.
Compensating Cables: For extending thermoelement cables, suitable for up to 200°C.

Surface Heating Elements

Aluminium Heating Plates: Used in various industries, with operating temperatures up to 250°C and customizable designs.
Heating/Cooling Tables: Adjustable temperature up to 100°C, with optional cooling features.

Heating Mats

Robust Heater Tarpaulins: For large surfaces, with operating temperatures up to 80°C.
Flexible Silicone Heating Mats: For complex surfaces, with operating temperatures up to 200°C.
HM Series Heating Mats: Flexible for flat and cylindrical surfaces, with various temperature ratings.

Heating Sleeves

Hinged Heating Sleeves: With metal jackets, designed for specific applications with temperatures up to 250°C.
Glass Silk Fabric Heating Sleeves: For temperatures up to 450°C, adaptable to heated objects.

Applications The products are used across various industries, including automotive, wood and paper, plastics, bookbinding, and catering. They are designed for heating, insulating, and temperature regulation of surfaces, containers, pipes, and electronic components.

Overview The document provides detailed specifications and applications for various heating solutions, including heating sleeves, barrel heating systems, surface heating elements, and explosion-proof electrical heaters. It outlines the technical specifications, materials, and operational parameters for each product type, emphasizing their use in industrial settings.

Heating Solutions

Heating Sleeves: Designed for mobile tanks and pressure sensors, these sleeves offer thermal insulation and temperature control. They are easy to install and remove using Velcro fasteners.
Barrel Heating: Includes flexible heating sleeves and mobile barrel heaters for 200-liter barrels. Specifications such as operating temperature, rated voltage, and material composition are provided.
Surface Heating Elements: These elements are made from safety glass and offer high transparency and uniform heat distribution. They are suitable for various applications, including panel radiators and mist-free windows.

Explosion-Proof Heaters

Classification: The document explains the classification of explosion hazard areas into zones and device categories, detailing the requirements for equipment used in each zone.
HX6 Series: Industrial heating hoses designed for use in explosive environments, certified to ATEX standards. They are suitable for transporting various substances without heat loss.

Technical Specifications

Materials and Construction: Products are made from materials like PU foam, PVC coating, aluminium, and stainless steel, ensuring durability and safety.
Protection and Safety: Products comply with protection types such as IP65 and IP54, ensuring resistance to dust and water ingress.
Temperature Control: Various controllers and sensors, such as PT100, are used to maintain precise temperature settings.

Applications The heating solutions are applicable in industries requiring precise temperature control, such as chemical processing, food and beverage, and manufacturing. They are also used in environments with explosion risks, adhering to strict safety standards.

Overview The document provides detailed specifications and applications for various series of industrial heating hoses and electrical heaters designed for use in explosive (Ex) areas. These products are compliant with ATEX standards and are suitable for different temperature classes and zones.

HX6B Series Industrial Heating Hoses

Designed for heat-loss free transport of substances like oil, grease, resin, and more in Ex areas.
Suitable for temperature classes T6 (85°C), T4 (135°C), and T3 (200°C).
Can be used in zones 1/2 (gas) and 21/22 (dust), but not in zones 0 and 20.
Features self-limiting characteristics, requiring temperature monitoring with controllers.
Complies with Directive 94/9/EC and standards EN 60079-0, EN 60079-7, EN 60079-18.

HX3 Series Analytical Heating Hoses

Designed for maintaining temperature and preventing frost and condensation in Ex areas.
Suitable for temperature classes T1 to T3, with a maximum operating temperature of 200°C.
Equipped with EX-PT100 sensors for temperature monitoring.
Complies with Directive 94/9/EC and standards EN 60079-0, EN 60079-7, EN 60079-18.

HX3B Series Analytical Heating Hoses

Features self-limiting power, suitable for temperature classes T1 to T6.
Used for maintaining temperature and preventing frost and condensation in Ex areas.
Complies with Directive 94/9/EC and standards EN 60079-0, EN 60079-7, EN 60079-18.

Airtherm Air Heater

Designed for heating compressed air, with a temperature range of 20 to 100°C.
Applications include painting technology and breathing air heating.
Complies with PTB 07 ATEX 1051 X, with IP65 protection.

HAPX Series Aluminium Heating Plates

Used for heating parts and moulds in various industries, with a temperature range up to 80°C.
Customizable shapes and designs available.
Complies with Directive 94/9/EC and standards EN 60079-0, EN 60079-7.

HBR-ILL and HBR-ILH Self-Limiting Heating Conductors

Designed for frost protection and maintaining temperature in pipes and containers.
Self-limiting characteristic prevents overheating.
Complies with various international standards, including CENELEC, ATEX, and IEC.

Key Specifications

Operating voltage for most products is 230 V AC.
Temperature monitoring is crucial for safe operation.
Products are designed for use in specific Ex zones and temperature classes.

Overview The document provides detailed technical specifications and guidelines for various types of Ex electrical heaters and associated components, designed for use in explosion hazard areas. It includes information on self-limiting heating conductors, connection and termination sets, thermostats, and controllers.

1. Self-Limiting Heating Conductors

HBR-ILS Type: Designed for industrial use to maintain temperature stability in pipes and conductors. It is self-limiting, preventing overheating even with overlaps. It can be cut to length and installed without special tools. Approved for use in explosive and aggressive environments.
Specifications: Max temperature: 200°C (on), 250°C (off); Voltage: 220-240 V AC; Temperature classification: T3 (200°C); Minimum installation temperature: -40°C.

2. Connection and Termination Sets

HBR-IAL8EX System: For parallel heating systems, easy to fit without special tools, suitable for temperatures up to 180°C, and made of nickel-plated brass.
HBR-IAL4SS: Silicone technology for high-temperature stability up to 200°C, suitable for various heating systems.
HBR-IAL3Ex Series: Shrink technology for flexible and space-saving connections, suitable for high temperatures and various heating tapes.

3. Thermostats

HT-IRM2Ex/AG: Mechanical frost protection thermostat with compact dimensions, suitable for up to two heating circuits, with a switching power of 16A.
HT-IR2M: Mechanical capillary thermostat for explosion hazard areas, with a robust housing and a switching power of 16A.
HT-IRB2M: Dual device with thermostat and limiter, suitable for electrical trace heaters in explosion hazard areas.

4. Temperature Sensors

HBR-IRPT 100Ex: PT100 temperature sensor with a flexible design, suitable for temperatures up to 200°C, and compliant with the latest standards.

5. Control Technology

HT 43 Series: Compact electronic controllers with a switching power of 2300 Watt, suitable for various sensor types and applications.
HT 41/42 Series: Controller/limiter combination with free configurability, suitable for unattended operation with a switching power of 3680 Watt.

Key Approvals and Standards The document lists various international standards and approvals, including ATEX, CENELEC, IEC, CSA, and GOST, ensuring compliance with safety and performance requirements in hazardous environments.

Overview The document provides detailed specifications and features of various temperature controllers and regulators used in industrial applications. These devices are designed for precise temperature control in machinery, systems, and apparatuses, with a focus on ease of use and reliability.

Specifications The controllers support various sensor types such as PT100, Fe-CuNi (J), and NiCr-Ni (K), with features like reference point compensation, sensor breakage protection, and polarity control. They offer a tolerance range of 0.1% to 0.2% of the full range, and the control range varies from -199°C to +999°C depending on the model.

Controller Outputs The devices include electronic switch outputs, triac outputs, and alarm outputs with relays. They are equipped with LED displays for actual and target values, and deviation displays with flashing LEDs for temperature deviations.

Protection and Housing The controllers are housed in materials like Makrolon, ABS, and polycarbonate, with protection types ranging from IP20 to IP65 according to EN 60529 standards. They are designed for easy installation with features like top-hat rail mounting and pluggable connection terminals.

Special Features Some models include self-optimization, dual control channels, and integral controller-monitor combinations. They offer options for external setpoint inputs and are capable of handling high load currents with SSR relays or contactors.

Applications These controllers are suitable for a wide range of applications, including trace heating systems, underfloor heating, antifreeze protection, and general temperature regulation in industrial settings.

Overview This document provides technical specifications and descriptions for various temperature control and heating system components developed by Hillesheim GmbH. It includes details on the HT 54 series SMD miniature controller, SSR relays, and various temperature sensors.

HT 54 Series SMD Miniature Controller

Designed for PT100 sensors, this controller integrates directly into heating systems, saving space in switchgear cabinets.
Features include a voltage supply of 230 V / 50 Hz, switching power of 1000 W / 5 A, and a control range of 0 to 254°C with a +/-5°C accuracy.
Protection type is IP42, with a cast version at IP65, and it uses a two-point controller response.
Housing is made of PA glass-fibre reinforced material with dimensions of 62 x 44 mm.

SSR Relays

The HER series SSR electronic load relay is designed for high switching frequency in electrical heating systems, with no wear on switching contacts.
Load voltage is 230 V AC, with load currents of 0.2 – 30 A AC for HER 30 D and 0.2 – 20 A AC for HER 20 D at temperatures below 40°C.
Protection type is IP20, and it is equipped with a heat sink and over-voltage protection.

Temperature Sensors

Thermocouple flat and rod sensors are available, with maximum temperatures ranging from 450°C to 1000°C, depending on the sensor type and material.
PT100 sleeve sensors are available in various configurations, with maximum temperatures of +200°C, +250°C, and +350°C.
Compensating cables are available for extending sensor connections, with silicone insulation and a diameter of 5 mm.

Contact Information

Hillesheim GmbH is located at Am Haltepunkt 12, D-68753 Waghäusel, Germany.
Contact details include phone: 0049 (0) 7254 / 9256-0 and email: [email protected].

Additional Notes

Technical specifications are subject to change based on development status as of May 2014.

Catalog excerpts

Flexible electrical heating technology Tracer Heater Systems Heating Hose Systems Manufacturing Engineering Hillesheim GmbH · Am Haltepunkt 12 · Industriegebiet 4 · D-68753 Waghäusel Tel.: 07254 / 9256-0 · Fax: 07254 / 9256-20 · e-mail: [email protected] www.hillesheim-gmbh.de · www.heizschlauch.de

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Your contact persons Hillesheim GmbH Am Haltepunkt 12 D-68753 Waghäusel [email protected] www.hillesheim-gmbh.de www.heizschlauch.de Tel.: 0049 (0) 7254 / 9256-0 Fax: 0049 (0) 7254 / 9256-20 Sales department Mr. Baumgart Mr. Trautwein Mr. Wolff Technical specifications in this catalogue may vary according to the state of development. Revision status: May 2014

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Company portrait Providing heat, maintaining heat A warm welcome to Hillesheim GmbH Do you have the problem of transporting fluid or gaseous media without temperature losses from A to B in hoses and pipes? Or should they be heated from temperature "x" to temperature "y"? If you are looking for a technical and economical solution for such tasks, you should consult us. Because we deliver you expertise from over 35 years of practical experience. Thousands of electrical trace heating systems (heating hoses, heating tapes, heating mats, heating plates) are still performing their tasks for our customers...

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1. General information and data . . . . . . 1 -10 2. Industrial heating hoses . . . . . . . . . 11 – 34 3. Analytical heating hoses . . . . . . . . . 35 – 48 4. Flexible trace heaters . . . . . . . . . . . 49 – 68 5. Surface heating elements . . . . . . . . 69 – 82

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General technical data General technical information and data for our heating hose systems

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Description and structure of a Hillesheim heating hose Whenever hot and warm media have to be transported from a device to another part of the device or plant without heat loss and the lines are not intended be rigidly routed, flexible heating hoses are recommended as conveying elements. In most applications, it is necessary to maintain the product temperature at a predefined value. By using Hillesheim heating hoses, a constant temperature of the material conveyed is ensured through to the application site, without the material temperature being influenced by ambient temperatures and heat losses...

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Application examples New: Also for use in explosion hazard areas Foam installations Packaging foam, PUR foam 2-component equipment, 4-component equipment Transportation technology Lorry, ship transfer and delivery hoses silo and levelling hoses Flue gas analysis technology gy Exhaust gas measurement and analysis lines d an Sampling probes Flue gases Emission measurements s Plastics processing Injection moulding Extrusion, co-extruders ers Foams Mould-making Plant and apparatus engineering ratus engineering a s n n er g Filling and sealing equipment ng equipment g q p e t Food processing ng Tool...

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Electrical heating systems info Plug connections: The plug connections on Hillesheim standard heating hoses are equipped with a plug compatible with one of our controllers. The HT43 temperature controller is provided with a round socket as standard. Please note that for unsupervised operation. there must be an additional safety device (limiter, temperature fuse...) fitted in the heating system. We can also supply our hoses without plugs for connecting the cable to terminals or for fitting to customer plugs. We use plug connectors from many well-known manufacturers. We can also fit their plugs...

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Installation recommendations Along the lines of DIN 20066: 2002-10 Wrong Pulling on the ends of rolled hoses causes torsional stress and can subject them to bending radii smaller than is permissible. Hoses are not to be twisted. Remedy: unroll the ring of hose rather than pulling it off. Hose lines should be installed in such a manner that they are free of tensile stress in all operational states; similarly, jamming stress (i.e. axial compression along the length) on short lengths of hose is to be avoided. Axial compression due to incorrect installation or space-reducing motion degrades the hose's...

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Installation recommendations Avoid twisting the hose when connecting it to moving parts, particularly when motion and bending take place in the same plane. This can be achieved through proper installation or design measures (e.g. swivel joint). The danger of kinking is particularly high for handheld devices. Remedy: Depending on the operating position, install a elbow or kink protection (e.g. corrugated hose). For installation in an arc, a hose length should be selected such that the intended bend can be formed beyond a length of ≈ 1.5 d0 ; kink protection may also be necessary (e.g. hard cap)....

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Installation recommendations Heat build-up will occur if heating hoses are routed through a closed channel or shaft. Remedy: hoses may not touch one another. Furthermore, sufficient ventilation is to be provided. If, for example, powder-like substances, adhesives or other thermally insulating materials accumulate on heating hoses, then overheating will occur at such points. Remedy: eliminate the cause with regular cleaning to remove such materials. Heat build-up is caused by incorrect wrapping of the heating hose with other materials. The heating hose will overheat at such points. If the sensor...

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Protection type / protection class Protection types for electrical equipment according to EN 60529 Protection types against solid foreign objects, denoted by the first numeral First Short description Definition numeral Not protected – 0 Protected against solid foreign The object probe, a sphere of 50 mm diameter shall not fully 1 objects penetrate 50 mm diameter and larger Protected against solid foreign The object probe, a sphere of 12.5 mm diameter shall not 2 objects fully penetrate 12.5 mm diameter and greater Protected against solid foreign The object probe, a sphere of 2.5 mm diameter shall...

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Flexible electrical heating
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