Friday, September 4, 2009

Safety Systems and Fail safe

Understanding the Fail-Safe Concept
Principle of SafetyThe fail-safe concept monitors the sensor status at all times. In the event of a failure, the fail-safe concept will simulate a protected position. The “protected” position is when the sensor is activated (closed) and the “normal” or “run” position is when the sensor is not activated (open).

- Normal Conditions – constant current flow (I) holding relay coil (K1) energized- Loss of Power – no current flow (I) and relay coil (K1) is de-energized- Actuation of Sensor – relay coil (K1) is shorted and de-energized- Failure of Sensor in the closed position – relay coil (K1) is shorted and de-energized- Failure of Sensor in the open position – (broken wire, switch or conductor) interupts current flow (I)and relay coil (K1) is de-energized- Resistor R – limits current flow through the sensor when actuated
Fail-Safe (4 wire system)
Fail-Safe is a shorthand term used to mean Fail to a Safe condition. In machinery with known hazards, the system is fail-safe when any failure leaves the machinery in a safe condition. The 4-wire fail-safe concept is illustrated in the figure above. A small current is constantly flowing through the sensor at all times, holding the relay coil energized at all times. The machine controls, interrupt, or stop circuitry is connected to the contacts of this relay. If the sensor is actuated, the relay coil will be shorted, causing the relay to deenergize. A resistor in series provides current limiting from overdrawing the power supply and limits the current through the sensor in the actuated position. If the sensor fails in the closed position the relay will be shorted and cannot be energized until the failure is corrected. If the sensor fails in the open position, the current path for the relay coil no longer exists and the relay coil cannot be energized until the current path is restored and the failure corrected.
In addition to the safety aspects achieved with Fail-Safe, it also provides:
- Isolation of the machine controls and sensor(s)- Isolation of high amperage and high voltage machine switching from the low voltage sensors- Conversion of a normally-open switch to required normally closed machine controls
Tapeswitch manufacturers safety light curtains, safety mats and safety Tapeswitches.

Thursday, September 3, 2009

UPS - Uninterruptible Power Supply

Green… Green… Green, today that seems to be a constant mantra that we are hearing from various sectors such as Government, Construction, and Consumers. Being Green is not an exotic disease that leaves your complexion looking like a Martian. Rather being Green is about conserving our valuable resources. Our resources are being depleted at a rate that some say will cause us to run out of resources very soon. I don’t know that I would be like Chicken Little running around screaming that the sky is falling, but we do need to take heed to the problems that do exist, and do what we can to conserve the resources we still have.

This brings me to my subject, Efficiency in UPS Systems. As I look through the trade magazines I have noticed that more and more is being talked about having Data Centers and other areas of Critical Power Back Up systems to become more efficient. UPS systems are found in most business’ today whether they be large or small. They are needed to protect the critical power required for Computers, Emergency Lighting Systems, Laboratory Equipment and more. All are using electrical energy to provide an uninterruptible source of power to these critical systems.

In case you haven’t heard, our electrical power generation facilities are being stretched to capacity. Then on top of that we have a Congress that would like to institute a program called Cap and Trade into law. The effect of this will be less energy production and higher prices for what energy we can get. All these possible new regulations and current production capabilities mandates that we need to become more Energy Efficient, this is a must for all of us. Most UPS manufacturers are promoting that their units are energy efficient, but when we begin to compare them side by side you will notice that some do not meet the mark. In the past some have purchased their UPS systems based on Name Brand Recognition alone, this may not be the best approach if you are really interested in getting the best efficiency and performance from a UPS system. Just because a company is large and well known does not mean they have the best equipment. Also saving a buck in the purchase price may end up taking a big bit out of your wallet when paying for wasted electricity for years down the road. Remember the efficiency of the system is what will ultimately save you on your energy bill for back up power, and again in the cost of cooling and cooling capacity, because efficiency means less heat being generated. Also check the output power factor of a UPS unit. This will be the key factor in knowing how much real power (kW) you will have available for your equipment, because you don’t want to be doing this again in a year or so when up grading your servers or add other equipment. The Input Power Factor is extremely important if you are being billed from your utility a power factor penalty charge. Check out the Harmonic feed back level because this can cause problems with other equipment up stream from the UPS. All of these factors will also play a part in Generator selection.

When selecting a UPS you must first know what power requirements you need for today and tomorrow. What amount of floor space will you be willing to allocate for this equipment. How much Back UP Time will be required because this will dictate the battery requirements and additional space for their placement. Think about peripheral equipment such as Maintenance Bypass Switches, Transformers, Surge Suppression Devices, Power Distribution Units, UPS Management Software, Tie-Cabinets (Parallel Systems), and Air Conditioning.

UPS units come in many different sizes and typology. The most popular systems are True On Line Systems or Duel Conversion systems. These will provide you with the best protection and power conditioning for your equipment.

We have many different brands for you to choose from depending on your application requirements. If you want the best system for your application give us a call and we can help you identify your systems requirements and select the best UPS for the job. We deal in UPS systems daily as well as power related problems, and we are familiar with the changes that are occurring in the industry. Call Syd Orr at Anderson Bolds today for more information.


Tuesday, August 4, 2009

Solenoid Valves

Solenoid Valves come in all shapes and sizes and all means of operation. For automation needs, the solenoid valve is the valve of choice.

This will be a brief discussion of the common solenoid valve used in industry today.

A solenoid valve is a combination of a valve body the allows a media to flow through it, water, air, oil and a coil that with a voltage applied energizes a magnetic coil to move a plunger that allows the valve to either open or close. Solenoid valves can be signaled by sensors within a plant via an electrical signal thus an operation can then be achieved.

Solenoid valves come in three basic styles, two way, three way and four way valves. The Two way valves have two ports, an inlet and outlet. The valves can be either normally open or normally closed.
Normally Closed is the more common style as it requires power to open and will close in a power failure.

Three way solenoid valves are designed for operating cylinders, air operated control valves and in some cases diverting flow between two directions. 3-way valves can come in normally open, normally closed and universal operation. Universal operation requires a direct acting valve, normally a small size valve, 1/8, 1/4 or 3/8 ports.

Four way valves are also designed for operating cylinders and valves and can have two solenoids on them, one for each of the two operations.

The valves can come in different body materials, stainless steel, brass, PVC, Teflon or other. The most common is brass and stainless steel. Seals can be Nitrile, viton, neoprene, or Teflon to name the most common. The different seals have different temperature properties and corrosion resistance.

Most solenoid valves come with a NEMA 4X coil, good for washdown and submersion in water. Also available are nema 7/9 or explosion proof and DIN style connections.

Anderson-Bolds stocks valves from Parker and ASCO. We can also provide specialty valves from Valcor.


Saturday, July 18, 2009

Electric Heating Elements

electric tubular elements by Watlow
Electric Heating Elements make the industrial world Hot.

Anderson-Bolds has been selling electric Heating Elements since 1934.
Electric Heating elements are a very simple yet extremely effective way to heat in the industrial work place as well as commercially and in the home.

Electric heating elements can be applied in just about every facet of industrial heating and commercial heating, from surface heating, to tank heating, air heating, drying, heat treating, freeze protection, cooking, air conditioning and frost prevention.

The heating element itself is very simple, made of three main parts, a resistance wire, insulator and metallic sheath. The element then functions under Ohms Law with the relationships of Resistance (ohms), current (amperes), watts and volts. Which one of these can be the constant?
To make an element the three main parts mentioned above are brought together, the sheath material is usually in a tube form (except for plastic cable and strip heaters) and hung in a vertical fashion up to 30 or 40 feet and the resistance wire is then also hung through the center of the tube with spacers at each end (a plug on the bottom end) and stretched taught to keep it centered in the sheath tube. The insulator material is then entered into the tube gently, the material is usually magnesium oxide or MGO. [MGO has the two properties necessary to be very good at its job, to insulate the metal sheath from the electrically charged resistance wire AND be a very good heat transfer medium. MGO does this job very well, unless it gets wet.] The MGO is in a fine sand like consistency when poured and shaken into the tube. [The manufacturing plant has to be fairly tall to make the long elements.] The resistance wire is not straight but in a curl formation running up through the center of the sheath tube. The light shaking of the operation allows the MGO to get in between the curls of the wire to fill all the gaps. No air gaps can be present with the element.

After sufficient time on the vibrators or shakers the filled tubes are capped off and removed and taken to the rollers or presses. The elements are now pressed and squeezed to the desired diameter. There are two other results to this operation, the element is lengthened as it is squeezed and the MGO gets compressed into a solid and fills all remaining spaces within the element and resistance wire spaces.

The Heating element is now ready to be formed into the correct shape, be it straight, hairpin, "M" shaped or any other shape desired for the application. After the element is shaped it is repressed to consolidate any of the MGO that has separated and then terminations are added to the ends of the element.

Heating elements can have sheath materials of Iron, copper, stainless steel, incoloy, inconel, monel or any material needed for temperature ratings or corrosion resistance. The common material are copper for water heating, iron for oil heating, and stainless or incoloy for higher temperatures or corrosion.

Lets return to Ohm's law which is W=I2R or V=IR or I=W/V
are the common formula's used with heating with resistance heating elements. With W = watts, I = amps, v= volts and R=ohms.

When making a heating element, the resistance is the constant in the actual element. The wire diameter and length is chosen to meet the wattage requirement when a specific voltage is present on the element. However different wattages and amperes can be easily achieved with different applied voltages; this can be good and bad. In short, if the voltage is doubled the wattage is quadrupled and conversely if the voltage is halved, the wattage drops to 1/4 of what is was. Example; an element rated at 1000 watts on 240 volts will be 250 watts when 120 volts is applied or will be 4000 watts if 480 volts is applied. The resistance wire is the fixed constant in a heating element and is the key to manufacturing consistent product.

The ease of which electric heating elements can be used to heat product makes them an excellent choice in all manners of heat, from manufacturing, to water heating, floor heating, pipe heating, coffee makers, heat treating and plastic injection molding.

Of course in a heating system, we need to control the temperature, sense the temperature and apply the voltage required, this items make up a heating system. Another blog will describe this system.

Some of our manufactures of heating elements and heaters include, Watlow, Danfoss, Q'Mark, Chromalox, Brisk Heat and Process Heating.

Cleveland, Ohio USA

Friday, July 17, 2009

Photo Electric Switches

How do garage doors know when something is in the way?
How do elevators know where to stop?
How does the store keeper know when someone enters a store?
How does a car wash know where the car is?
How does a manufacture count the cans on an assemble line?


Photoelectric switches use a light source to detect an object. The switch then changes it's logic or switch to make an action, like an alarm or movement of a device.

The photoelectric switch uses either visible light or infrared light as it's source. The object being sensed should be reflective for a diffuse switch or the use of a reflector is required and the object breaks "the beam" as in an elevator or garage door switch.

A thru beam system utilizes a transmitter and receiver. the Transmitter sends out the light beam and is directed at a receiver unit. Both units need to be powered and interconnected together for the system to work. Advantages are the longest field of view is achieved and the most secure sensing is realized via polarization. The main disadvantage is that each unit must be wired and interconnected together. A "thru beam" system can also be utilized using a reflector. this is called retro-reflective. The retro-reflective system has the advantage over a thru beam of all the logic and power supply being located in one box and one area. It is also more secure like the thru beam system by using polarizing filters that turn the light and only allow the correct "polarization" to be sensed by the receiver. The retro-reflective unit as the receiver and transmitter housed in a single unit. Thru Beam and Retro-reflective systems are used for counting, sorting and sensing the presence of an object or person for safety or security reasons.

The Diffuse system relies on the object being reflective, these are usually used in an industrial setting sensing a product or color code or marking on a product or box. Like the retro-reflective unit the transmitter and receiver are in the same unit. The distance is usually quite short so that the reflected light is able to be sensed. The target does not usually have the reflective qualities of a reflector. A diffuse system is used when a thru beam or retro-reflective cannot be used or when sensing color or a bar code.

All Photo Electric systems need an output to communicate with the PLC or system logic. Most use NPN or PNP logic but some have built in relays (1 amp usually) to give the output signal. The signal can go to a computer, PLC or directly to the system like a motor or contactor or alarm.


Friday, June 26, 2009


Going green doesn't have to be expensive.

The Federal Energy Management Program says that the best available exit sign product uses photoluminescent technology. What’s more, the program directs all federal agencies to not purchase incandescent light bulb or tritium exit signs, and requires facility managers to replace them immediately.
There’s no doubt about it. Buildings today are going green, and you need an easy, economical solution to reduce your carbon footprint. Get the green light with the zero energy, zero maintenance solution – the new, photoluminescent Glo Brite® Ecō Exit™ Signs.
By replacing 100 incandescent exit signs in your building with eco-friendly, easy to install Glo Brite® Ecō Exit™ Signs, you will save over $3,500 a year in energy costs - while reducing air pollution by almost a half a million pounds of CO2 over the life of the product.

Going green doesn’t have to be expensive when you start with zero - the new zero energy Glo Brite® Ecō Exit™ Signs
Zero electricity to operate
Zero wiring to run
Zero bulbs or batteries to replace
Zero toxic/radioactive materials
Zero maintenance for 25+ years
Zero problems with safe disposal

GloBrite® Ecō Exit™ PM 100
Non-electric and easy to install, the GloBrite® Ecō Exit™ PM 100 is the only non-radioactive, zero energy and zero maintenance photoluminescent safety sign on the market that is visible at 100 feet.
You save on energy costs because the 100% reliable Ecō Exit™ PM 100 uses the latest photoluminescent technology to absorb and store ambient light. In the event of an emergency blackout or smoky conditions, this stored energy is immediately visible, creating a clearly recognizable, photoluminescent egress indicator.
Product Information:
Sign Options / Colors Mounting Options & Configurations Other Models Available
Conduit Stub

Key Features
Consistent High Visibility Green illumination at 100 feet
100% reliable
Non-electric, no wiring or batteries, zero energy costs
Non-toxic, non-radioactive
Low-cost, easy installation
1-to-1 electrical sign replacement
Maintenance-free for 25+ years
Both high-level and low-level applications
Easy landfill disposal
Designed for either new construction or retrofits in any application
Architects Benefits
LEED points qualified
Reduces cooling and emergency generator loads
Aesthetically-pleasing designs
Multiple product solutions for every application
Contractor Benefits
Lower labor and material cost
No electrical to run or battery backup
Standard bracket options for easy mounting
Building Owner Benefits
Zero energy consumption - zero energy costs
Zero maintenance, zero replacement parts
Non-toxic, non-radioactive
No disposal cost, 100% Recyclable
Movable if egress paths change
Listings & Certifications
Listed to UL 924
Meets current building codes: IBC, NFPA 5000
Meets NFPA Life Safety Code 101 and OSHA requirements
CCMC Evaluation Report CCMC 13211-R (National Research Council of Canada)

ATC Timers and Counters

Anderson-Bolds has been involved with Automatic Timing and Controls and their timers, counters and photoelectric controls for over 40 years and have followed them on their moves from King of Prussia and Lancaster Pennslyvania to Newell West Virginia and their ownership by Marsh Bellofram.

For over 80 years, process engineers and machine designers have turned to Automatic Timing and Controls  (ATC)  first for reliable control products. These high-performance products are engineered to provide accurate and repeatable operation in all types of industrial environments. Our products play an integral part in countless industries; including food processing, plastics, packaging, water treatment and many OEM applications. The ATC product family has expanded to include 1/16 DIN timers, panel-mounted timers, electromechanical timers, counters, solid state cube and plug-in timers, photoelectric laser sensors, and time delay relays (TDR).

ATC manufacturers percentage timers, electromechanical timers, cam timers, repeat cycle timers, 1/16th DIN timers, weekly timers, time delay relays, and panel mount digital timers.
As the industry standard for timers in the USA, ATC will also custom design their timers to fit unique applications. Their timers are UL, CSA and FM approved. The FM approved timers are required in combustion control for purge cycles. (See 339 and 328 timers).

The ATC timers come in all the different modes, on-delay ( delay on make ), off-delay
(delay on break ), interval, repeat cycle, flicker, flasher, percentage, recycle, single shot, and multi-mode.

Below are some defintions of timing modes:

Delay On Make (On Delay)
Has also been referred to as delay-on-operate, delay-on-pickup, and delay-on-energize. This mode of operation indicates that the timing period follows the application of operating voltage, control voltage, or the closure of an separate initiate switch. After the timing period expires, the output is energized. Delay-on-make models are available in both solid state and relay contact output.

ATC On-Dealy Timers include the 305E, 355C365C, 405AR, 407A, 319E, 328D, 339A200Q2X339A359Q2X

Delay On Break (Off Delay)
Delay-On-Break . . . as also been referred to as delay-off, delay-on-release, and delay-on-dropout. This mode of operation indicates that the output energizes first and remains energized until after the timing period which does not begin until operating voltage, control voltage, or the opening of an separate initiate switch. After the timing period expires, the output is de-energized. This mode of operation requires standby voltage during the timing period. Delay-on-Break models are available in both solid state and relay contact output.

An ATC off Delay Timer is the Series 417

TRUE Delay-On-Break . . . Has also been referred to as true delay-off, true delay-on-release, and true delay-on-dropout. This mode of operation is identical to the delay-on-break operation above, but the major difference is that this mode of operation does not require standby voltage during the timing period. True Delay-on-Break models are available only in relay contact output.

Interval  (Like an Oven or fan timer)
This mode of operation indicates that the output is energized when the operating voltage is applied, or an initiate switch is closed. The timing period (interval) also begins when the output is energized. At the end of the timing period (interval) the output de-energizes, even though the operating voltage or the initiate switch is still active.
Characteristic of an interval mode is that the operating voltage must be applied longer than the interval timing period, or the initiate switch, if required by model, must be closed longer than the timing period.

The ATC 409 Series is a Push Button Interval Timer

Single Shot
Single Shot ... Similar to interval, but where the interval had to have the operating voltage, or the initiate switch closed longer than the timing interval, the single-shot requires only a momentary closure of an initiate switch to provide the interval mode of timing.

Repeat Cycle (Flip / Flop )
Repeat Cycle . . . Sometimes referred to as ON / OFF timers, cycling timers, or percentage timers, the repeat cycle mode of operation turns a circuit ON and OFF continuously on a repeating basis for as long as the operating voltage, or an initiate switch is applied. While the repeat cycle timer, and the ON/OFF timer are grouped together here as repeat cycle timers, there is one major difference between the two which may prove critical for your application. With any of Artisan Controls' repeat cycle timers you can vary the ON portion of the repeat cycle and not effect the overall repeat cycle time. With any of Artisan Controls' ON/OFF timers you vary the repeat cycle time when you change either the ON or the OFF timing periods. Available in repeat cycle mode are percentage timers, as well as programmable multiple output repeat cycle timers.

ATC REPEAT CYCLE timers are the 342B200F10PX and the ATC 422AR Series TDR's.
Diversified repeat cycle timers : 

Flashers are a special kind of repeat cycle time. The only difference is the user can control the flash rate (flashes per sec etc.) only. The ON and OFF portion of the cycle are equal (50% duty cycle).

Anderson-Bolds stocks ATC timers and the sockets to go with them. If you are in need of time or in a time of need, please give us a call. 216-360-9800

Anderson-Bolds has an industrial Timer design Form.  Please fill it out and we can help pick out a TIMER for you.

Thursday, June 25, 2009

Fire Shield Cords

Anderson-Bolds Sells Fire Shield Cords and strips.

Fire Shield is the safest cord on the market.

Fire Shield products are ideal for home, office, and campus environments such as residence halls, labs, classrooms, libraries and other facilities. Fire Shield cords, with specially designed shielded conductors, are able to detect series faults and line-to-neutral faults, significantly reducing fire hazards. Available as power strips, surge protectors, appliance cords and extension cords.

Fire Shield is a next generation extension cord with built-in intelligence to sense cord damage and shut off the power before a fire can start. No other extension cord has this capability.

Industry statistics indicate there is a cord fire approximately every 6 minutes. The most frequent causes of such fires are short circuits, overloading, damage, and/or misuse of extension cords.

Cords with grounded conductors only provide a path to ground. GFCI’s detect ground faults. Neither detects the breakdown in the insulation of a standard extension cord, which can lead to an arcing condition that may start a fire. By utilizing a sensing shield around the insulated Fire Shield conductors combined with intelligent electronics in the plug head, Fire Shield can detect damage in the cord such as series faults (broken and frayed conductors) and parallel faults (insulation damage between the live conductors), and shut off the power before a fire can start.

Causes of cord fires are unintentional misuse of extension cords. Cords may be crimped, pinched, frayed, overloaded, overheated, or just worn out. Any of these conditions can lead to an extension cord fire. Fire Shield can detect any leakage currents from these conditions and shut off power before a fire can occur.

Fire Shield should be used anywhere you use standard extension cords or power strips; in children’s rooms, pet areas, with space heaters, electric blankets, waterbeds, etc. Children and pets have been known to bite or chew electrical cords. Fire Shield, with its built-in intelligence may provide protection in these circumstances. Fire Shield Safety Extension Cords should also be used during the holidays with Christmas trees and other holiday decorations because of the tendency to overload extension cords.

Standard surge protectors only provide protection against power surges, which is important. However, standard surge protectors do not provide cord fire prevention. TRC has recently introduced a next generation line of Fire Shield Surge Protectors that not only protects against power surges, but also provides cord fire prevention. Please check our website to find the Fire Shield Surge Protector best suited for your requirements.

Many colleges and Universities, including the University of Richmond in Virginia, now require that only the Fire Shield cord and strips be used in dorm rooms. Cord fires are the leading cause of fire in dorm rooms. Please review the "Can you Prevent University Dorm Room Fires" brochure.

Fire Shield products are UL and CSA approved and can be purchased at Anderson-Bolds .

Wednesday, June 10, 2009

Horner APG ~ HMI/ OCS Systems

All-in-one Controllers for Industrial Applications

By combining a controller, operator interface, I/O, and networking into a single compact unit, OCS (Operator Control Station) provides a better solution for original equipment manufacturers, integrators, and end-users alike. More and more, there is a move to all-in-one controllers because of ease-of-use, cost-savings, and flexibility. Since 1998, OCS has led the way in this emerging market with the largest installed base, and product selection. OCS has been used successfully in a variety of applications, including:
  • Custom OEM products
  • Power Management and Backup Generation
  • Semiconductor Applications
  • Packaging Machinery
  • Water Treatment
  • Compressor Control
  • Pump Control
  • Food Processing
  • Motion Control
  • Distributed Conveyor Control
  • HVAC/Environmental Control
  • Mobile Machinery
  • Automotive Parts Manufacturing

Saturday, June 6, 2009

Watlow Power Controls

Anderson-Bolds sells Watlow Power Controls.

Watlow solid state power controllers complement the rapid switching required by PID temperature controls and help deliver optimum system performance and service life. Available in 1-phase and 3-phase/2-leg and 3-leg configuration, Watlow power controllers meet most industrial heating applications. Random, zero cross or phase angle fire options allow for a variety of applications.

The DIN-A-MITE family is the ideal solid state replacement for mercury displacement relays (MDRs) in an easy-to-install, compact, touch-safe package. The solid state power controllers provides SCR control, heatsink, wiring and touch-safe exterior in one package. By designing the DIN-A-MITE as a total power controller unit, the need to prep wires for terminals, locate the right heatsink and determine adequate terminations is eliminated. It's a complete package you can install easily with CONTROL CONFIDENCE®.

Four DIN-A-MITE styles meet most power controller needs with ratings from 18 to 100 amps with voltages from 24 to 600V~(ac). The four models match load requirements with 1-phase, 3-phase/2-leg and 3-phase/3-leg switching. The controllers also provide a convenient DIN-rail and sub-panel mount package.

ControllersAmpsConfigurationsFiring Options
DIN-A-MITE AUp to 25 ampsSingle-PhaseContactor or Burst Fire
DIN-A-MITE BUp to 40 ampsSingle- & Three-PhaseContactor or Burst Fire
DIN-A-MITE CUp to 80 ampsSingle- & Three-PhaseContactor, Bust, Phase
DIN-A-MITE DUp to 100 ampsSingle-PhaseContactor or Burst Fire


  • Semiconductor processing
  • Plastics processing
  • Heat treating
  • Drying ovens
  • Foodservice equipment
  • Petroleum/chemical
  • Lighting equipment
  • Glass processing
  • Furnace/oven

POWER SERIES Microprocessor-based SCR
  • Ratings from 65 to 250 amperes
  • Offers extensive system and heater diagnostics features and agency approvals

For over thirty years Watlow® has been manufacturing solid state power controllers. Watlow's new POWER SERIES represents the latest in SCR power controller technology. This microprocessor-based product offers features and application flexibility unmatched by any other SCR power controller on the market today.

Capabilities include single-phase and three-phase models from 65 to 250 amps. Field configurable phase angle or zero-cross firing improves application flexibility on site where you need it. 50/60Hz independent operation means you can operate almost everywhere in the world without special calibration considerations. Serial communications utilizing Modbus® protocol allow for remote control setup, and monitoring of load status from a nearby computer station or control room.

On-board semiconductor fusing improves reliability by protecting the SCRs from heater short circuits. Plus, on-board heater bakeout and control diagnostics can help eliminate initial start up problems. All this in a touch-safe package that can be quickly and easily mounted in your control cabinet.

Microprocessor-based technology
  • Extremely versatile, field configurable
Snap-fit on a pre-mounted plate
  • Easy installation
Models 65 through 250 amp ratings
  • Handles a wide range of loads
Adjustable soft start
  • Application flexibility
Heater and control diagnostics capabilities
  • Monitor actual heater and control performance
Electrically touch-safe package
  • Increased safety for installer and users
Serial communications with Modbus® RTU protocol
  • Computer control and/or monitoring
Multi-zone capability
  • Increased application flexibility, reduced panel space


  • Semiconductor processing
  • Plastics processing
  • Heat treating
  • Drying ovens
  • Food processing
  • Petroleum/chemical
  • Lighting equipment
  • Furnace/oven

  • CSA, VDE and UL® recognized contactor
  • Ratings from 18 to 50 amperes single phase
  • Single solid state relays from 10 to 75 amperes

The new SERIES CZR solid state contactor from Watlow®provides a low-cost, highly compact and versatile solid state option for controlling electric heat. With DIN-rail and back panel mounting standard on every controllers, the CZR allows for simple and quick installation.

The extensive capabilities of the SERIES CZR include single-phase, 24 to 50 amp zero-cross and random switching up to 600V~ (see output rating curve). The unique integrated design removes the guesswork associated with selecting a proper heat sink and precise terminations for the application.

This controller holds many agency approvals and is ideal for applications that require UL®, CSA and CE approvals. SERIES CZR contactors are available inVac/dc (ac/dc) input contactor versions. All configurations are model number dependent and factory selectable.

The SERIES CZR is reliably backed by a two-year warranty from Watlow.

DIN-rail or standard panel mount
  • Versatile, quick and low-cost installation
Compact size
  • Reduces panel space; less cost
Touch-safe terminals
  • Increases safety for installer and operator
Mercury free
  • Environmentally safe
Faster switching with solid state
  • Saves energy and extends heater life
UL® 508 recognized, CSA LR700195 certified and CE 60950, VDE 0805 applied for
  • Applications requiring agency approval
Back-to-back SCR design
  • Rugged design


  • Semiconductor processing
  • Plastics processing
  • Heat treating
  • Drying ovens
  • Food processing
  • Petroleum/chemical
  • Lighting equipment
  • Furnace/oven
When it comes to power control, Watlow can provide the right controller built with quality in the USA.

Friday, June 5, 2009

Watlow Electric Heating

Anderson-Bolds is an authorized Watlow Distributor and channel partner.

Watlow is the largest custom designer and manufacturer of industrial electric heaters, sensors, controllers and software; with offices and manufacturing facilities around the world.
Watlow brings its thermal expertise to numerous applications, including semiconductor, analytical instrumentation, medical equipment, plastics processing, foodservice equipment, packaging, aerospace and others.

Watlow manufactures a myriad of types of heaters. Included in the Watlow mix are:

Advanced Ceramic Heaters

When you need a lot of power in a small package, the ULTRAMIC® 600 puts the performance of advanced ceramics to work for you. Constructed of aluminum nitride (AlN), the ULTRAMIC 600 can operate up to 600°C (1112°F) and deliver ultra-fast ramping of up to 150°C (270°F) per second for rapid thermal cycling applications.

Band & Nozzle Heaters

Led by the high performance MI (mineral insulated) Band heater, the patented, flexible THINBAND® heater and the standard mica band heater for specialized constructions, Watlow's band and nozzle heaters are ideal for every type of plastics processing equipment.

Cartridge Heaters

The Watlow FIREROD® heater enters its 50th year of industry leading expertise as the premier choice in swaged cartridge heating. With premium materials and tight manufacturing controls, the FIREROD heater continues to provide superior heat transfer, uniform temperatures and resistance to oxidation and corrosion even at high temperatures.
FIREROD offers many delivery programs to meet your needs: same day shipment, Ship-to-Stock or Just-in-Time. And our experience in customized engineering is reflected in over 250,000 FIREROD cartridge heater designs. Stock or made-to-order, the Watlow FIREROD delivers heat in a hurry.

Cast-in Heaters

When Watlow creates a custom-engineered cast-in product, the result is more than just a heater. It's a "heated part" that becomes a functional component of your equipment, designed in the exact shape and size you need. The IFC heated part consists of a Watlow heater element built into custom metal shapes designed specifically for your application.

Ceramic Fiber Heaters

Ceramic fiber heaters integrate a high temperature iron-chrome-aluminum (ICA) heating element wire with ceramic fiber insulation. Numerous stock, standard and/or custom shapes can be provided, achieving the "heated insulation" concept for your high temperature, non-contact applications. The ceramic fiber insulation isolates the high temperatures inside the heated chamber from the outside. The heaters are low mass, fast heating, with high insulation values and self-supported heating elements that offer some of the highest temperature heating capabilities within the Watlow family of heater designs.

Circulation & Process Heaters

Watlow's circulation heaters are compact heating solutions for fluids such as purified and inert gases, supercritical fluids and liquids like de-ionized water for use in semiconductor and electronics industries as well as for general liquid and gas heating applications.
Watlow's industrial process heater lines of immersion, circulation and duct heaters are used to heat a myriad of high and low viscosity fluids ranging form de-ionized and process water, oils, solvents, rinse agents, caustic solutions, etc. to process gases like air, nitrogen, purified and inert gases as well.

Coil & Cable Heaters

The versatile Watlow cable heater can be formed into a variety of shapes as dictated by its many applications. These small diameter, high performance units are fully annealed and readily bent to your desired configuration.

Flexible Heaters

Flexible heaters from Watlow are just what the name implies: thin, bendable and shaped to fit your equipment. You can use your imagination to apply heat to the most complex shapes geometries conceivable without sacrificing efficiency or dependability.
Click here to find out more about Watlow's syringe heaters. You can also view a short animated presentation demonstrating a syringe heater application.

Multicell Heaters

The multicell heater from Watlow offers independent zone control for precise temperature uniformity, loose fit design for easy insertion in and removal from the equipment and extreme process temperature capability. The heaters are available with up to eight independently controllable zones and one to three internal thermowells for removable sensors. Custom assemblies are available

Nozzle/Slip-on Heaters

Watlow offers a full line of hot runner nozzle heaters for the plastics industry as well as slip-on heaters for the medical and analytical industries. While every heater has a unique set of capabilities, each nozzle heater is designed to meet specific application requirements. Whether you require high performance, high temperature or high watt density Watlow has the heater to best fit your application. Watlow's family of nozzle/slip-on heaters include, THERMASLEEVE™ nozzle, MI nozzle, syringe, thick film cylindrical, mica nozzle, coiled nozzle, mini-coil nozzle and metric mini K-RING® nozzle heaters

The THERMASLEEVE nozzle heater is a low profile, high-performance electric heater with rapid thermal response that allows the heat to be created precisely where it is needed. The patented manufacturing technology features a computer-controlled laser cutting technique that precisely generates the power distribution pattern. The heater is designed to have intimate contact with the surface of the nozzle, which optimizes heat transfer. This intimate contact combined with lower heater mass contributes to rapid thermal response to and from the nozzle tip. This helps reduce cycle times and ensures high quality final parts.

Polymer Heaters

For the latest in heating technology from Watlow, specify a heated plastic part in your next product. Watlow's heated plastic parts combine resistive heating elements with thermoplastic compounds to create a heated assembly. Watlow utilizes standard compression molding techniques to produce heated plastic parts that are durable, safe and cost-effective

Radiant Heaters

With Watlow's diverse RAYMAX® radiant heater line, we have a solution for almost any application requiring radiant heat. Our capabilities cover a wide range of needs, from contamination-resistant panel heaters to fast-responding quartz tubes to rugged tubular elements and high temperature ceramic panels.
Applying radiant heaters can be complicated. Watlow's engineering staff has the level of training required to help you meet your application requirements, providing a high degree of technical support such as conducting testing for your application at our facility, calculating your watt density and temperature requirements, and recommending system components such as sensors and controllers. With our experience in a wide range of industries, chances are Watlow has already helped someone handle a radiant heating application like yours.

Strip Heaters

Watlow's mica and 375 strip heaters are the versatile solution for a number of applications. They can be bolted or clamped to a solid surface for freeze and moisture protection, food warming and other applications. The 375 finned strip heaters are commonly used for air heating, drying ovens and space heaters

Thick Film Heaters

Watlow layers thick film resistor and dielectric materials on quartz and stainless steel to produce high performance industrial heaters. The thick film heaters provide very fast temperature response and uniformity on a low-profile heater. Thick film heaters are ideal for applications where space is limited, where conventional heaters can't be used, when heat output needs vary across the surface, or in ultra-clean or aggressive chemical applications.

Tubular Heaters

Watlow's WATROD tubular heater elements and flat FIREBAR elements are designed primarily for direct immersion in liquids such as water, oils, solvents and process solutions, molten materials as well as air and gases. By generating all the heat within the liquid or process, these heaters are virtually 100 percent energy efficient. These versatile heaters can also be formed and shaped into various geometries for radiant heating and contact surface heating applications. UL® and CSA component recognized elements available.

Watlow also manufactures their own sensors and controls. The new line of EZ-Zone heaters is state of the art. The Watlow sensor plant can deliver custom sensors within a week or less.

Examples of Watlow controllers are :

Integrated Controllers

Watlow has released four revolutionary integrated controller products: the EZ-ZONE® PM panel mount controller, the EZ-ZONE ST integrated control loop, the EZ-ZONE RM multi-loop integrated controller and the EHG SL10 process controller and safety limit. All of these modular products combine multiple functions into one integrated control system leading to:
Fewer components
Fewer aggravations
These products give you the ability to utilize just one component. These products' advanced designs give you the ability to add or subtract modulars as your requirements change.

Single-Loop PID Controllers

All Watlow single-loop auto-tuning temperature and time/temperature profiling controllers are available in 1/32, 1/16, 1/8 and 1/4 DIN sizes. Agency-approved Watlow single-loop, auto-tuning temperature controllers automatically set PID control parameters for optimum system performance. Manual settings also permit on-off, P, PI or PID control modes.
Watlow's time/temperature profiling (ramping) controllers set new standards of performance. All are available with a broad range of industry standard I/O and communication options.
All Watlow single-loop controllers are designed and manufactured to withstand harsh industrial environments and come with a three-year warranty for CONTROL CONFIDENCE®. These single-loop PID controllers are complete with auto-tune for easy setup and both compatible for environmental chamber and semiconductor manufacturing applications.

Multi-Loop PID Controllers

All Watlow® multi-loop time/temperature controllers offer auto-tuning which automatically sets PID control parameter for optimum system performance. Watlow’s multi-loop controllers feature manual settings permitting on-off, P, PI or PID control modes.
With up to 32 control loops, Watlow PID controllers deliver the options and performance demanded by complex process applications. Each time/temperature controller offers a wide range of I/O options with exceptional accuracy. Inputs can be multiple and mixed, including thermocouple, RTD and process. Multiple job/recipe storage makes batch setups fast. Versatile alarms, serial communications and remote operation or data logging round out the features.
These Watlow multi-loop controllers are designed and manufactured to withstand harsh industrial environments, and come with a three-year warranty for CONTROL CONFIDENCE®.


Watlow® single- and multi-loop limits/alarm controllers provide a low-cost solution for single- and multi-channel, redundant temperature monitoring. These limits and alarms can continuously monitor thermocouples, RTDs or thermal switches. Agency approved performance in safety limit applications, including UL®, CSA, A.G.A. and FM (on some models). All are available with industry standard I/O options. All Watlow limit/alarm controllers are designed and manufactured to withstand harsh industrial environments, and come with a three-year warranty for CONTROL CONFIDENCE®.

Power Switching Controllers

Watlow solid state power controllers complement the rapid switching required by PID temperature controls and help deliver optimum system performance and service life. Available in 1-phase and 3-phase/2-leg and 3-leg configuration, Watlow power controllers meet most industrial heating applications. Random, zero cross or phase angle fire options allow for a variety of applications.


Watlow provides more than 80 years of manufacturing, research and quality for your temperature sensing needs. A tremendous stock of general application, mineral insulated, base and noble metal thermocouples are available.
Hundreds of thermocouples are available as part of our Rapid Ship sensor program. These sensors are shipped directly to you in one or two days.
Watlow also has three new surface temperature sensors. The MICROCOIL™, radio frequency thermocouple probe and true surface thermocouples all incorporate isothermal physical principles to achieve superior surface temperature measurement. The isothermal design provides accurate sensing because the areas of the temperature sensor that are exposed to normal process variances are positioned outside the thermal gradient.

RTDs and Thermistors

Watlow's platinum resistance elements are specially designed to ensure precise and repeatable temperature versus resistance measurements. The sensors are made with controlled purity platinum wire and high purity ceramic components. They are constructed in a unique, strain-free manner.
Several RTD styles are available in the recently revamped Rapid Ship sensors program. These sensors are delivered straight to you in one to two days.