News

Positive Temperature Coefficient (PTC) Heater Applications

Posted by Sam Pelonis | May 30, 2017 11:10:38 AM | 3 Comments

Offering simple troubleshooting solutions, low maintenance, and highly efficient heat transfer, Positive Temperature Coefficient (PTC) heaters — specialized resistors that vary resistance in accordance with their temperature — offer versatile, easy-to-use solutions for a range of industries.

Thermistor Technology

PTC heating for different industriesA resistor that changes resistance as a function of its temperature is also referred to as a thermistor.

Thermistors increase their resistance when temperature increases, thus resulting in a Positive Temperature Coefficient.

An NTC thermistor, meanwhile, decreases its resistance when temperature increases, resulting in a Negative Temperature Coefficient.

When crafted with very pure semiconducting ceramic, PTC heating discs, fins, and honeycombs make ideal solutions for specialty applications.

PTC heaters can quickly create enormous heat transfers in small spaces; in fact, these heaters can produce an instantaneous flow of heat that is 50% hotter than the flow created by more conventional oil or ceramic chip heaters.

Industries and Applications

With the ability to perform in extremely small spaces with superior heat transfer and safe, powerful, and energy-efficient operation, PTC heaters offer several benefits across a wide range of industries.

Food and Beverage

Versatile and compact, PTC heaters are especially useful in the food and beverage industry. Used for heating and temperature control in various appliances, including coffee hot plates, food warmers, and temperature-controlled containers, PTC heaters allow for consistency and reliability in a range of applications.

Anti-Condensation

With superior dehumidification and anti-condensation properties, PTC heaters are ideal for food safety, food processing, and other high-moisture manufacturing processes. As moisture problems take on increasing importance in plant environments and USDA and federal requirements grow stricter, processors are looking to PTC heating technology to reduce humidity and resulting bacteria growth on food machinery and equipment.

Avoid issues encountered while using coil or conventional heaters including cracking or bursting.

Download the Technical Resource

Automotive

Established automotive heating methods, which utilize the internal combustion engine’s cooling system, can take significant time to heat an automobile’s interior. PTC auxiliary heaters effectively remedy this problem and are frequently used by leading automotive manufacturers worldwide.

PTC Heaters from Pelonis

As a leading manufacturer of specialty heating solutions, axial AC and brushless DC fans and motors, as well as custom blower solutions, the Pelonis team is proud to offer top-of-the-line PTC products. Safe, efficient, and long-lasting, these versatile devices help save our customers time and money.

The Pelonis team is committed to innovation in motion, heating, and cooling technology. To learn more about our unique products, exceptional quality, and competitive pricing, download the Pelonis catalog, or reach out to the team today.

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Custom DC Fans for the Medical Industry

Posted by Sam Pelonis | Jul 20, 2015 4:29:00 PM | 0 Comments

In the medical industry, heart monitors are commonly used in patient care. These precision devices are recognized for the notable benefits they provide.

The use of heart monitors enables healthcare practitioners to recognize heart irregularities a patient may have. With this constant monitoring, practitioners can quickly attend to any potentially life-threatening issues.

dc-fanPreventative medical care has become progressively more demanding, and as such, devices like heart monitors must provide higher levels of performance. Unfortunately, improving the performance of a medical device does not necessarily improve its reliability.

At Pelonis Technologies, we have manufactured heating and cooling custom solutions for many years—and these solutions are frequently used to deliver enhanced reliability to medical applications. The case study below documents our manufacturing of a DC brushless fan for use in the medical industry.

Problem:

A medical company came to Pelonis needing a specialized, high-efficiency DC fan. This fan was to be used to cool the system componentry of a heart monitor machine. In addition to providing adequate cooling, the fan needed a variable air flow speed and custom wire connections and labeling.

Solution:

Our engineering team designed an 80x80x15mm DC fan capable of operating at 48 volts. Along with the client’s distinct specifications, we utilized 2D CAD drawings to conceptualize the product.

The manufactured DC fan was tested meticulously for proper airflow, static pressure, speed, and power. Additionally, the DC fan passed dimensional and functionality inspections.

Result:

With a short turnaround of 12 weeks, Pelonis delivered the new fan directly to the client’s door. Our DC fan offered an exceptional air efficiency of 40.7 cubic feet per minute (CFM) and a water pressure of 0.020 inches. The DC brushless fan was also fitted with Pulse Width Modulation to control the fan’s speed manually.

Heat management is a key concern of medical device users. Pelonis’ extensive industrial experience was instrumental in not only meeting, but exceeding the expectations of this medical company. For more information about the cooling fans available for your industry or application, download our eBook, How to Select a Cooling Fan.

Download How to Select a Cooling Fan

There is no room for error when manufacturing products for medical applications. If your company needs a custom solution, please contact Pelonis Technologies today. 

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High Temperature Ceramic Immersion Heater Performance

Posted by Sam Pelonis | Jul 13, 2015 9:55:00 AM | 2 Comments

Industrial and commercial heating applications are considerably demanding. Though there are many options to choose from, heating solutions often fall short of consumer expectations. Today, it’s not enough to simply meet application requirements—you should strive to exceed them.

Advancements in heat technology have facilitated the creation of highly efficient and versatile products—these products are better suited for modern heating. As a leading manufacturer of specialized heating products, Pelonis Technologies is proud to announce our latest innovation: Ultra-High Temperature Ceramic Immersion Heaters.

immersion-heatersOur immersion heaters are designed to accommodate several applications, which include: central heating systems, steam generation, ignition devices, solar heater support, and much more. These heaters boast higher efficiency and thermal conductivity as compared to other heating elements (either metallic or non-metallic).

Performance of Immersion Heaters

Ultra-High Temperature Ceramic Immersion Heaters are versatile enough for use in both air and underwater. In dry environments, these products are capable of heating up to 1200°C (2192°F); underwater, they can reach up to 98% heating efficiency. These ceramic heating elements are very compact and can be installed into small devices with little effort.

Immersion heaters are completely self-regulating and have desirable insulation properties; this affords the ability to withstand voltages of 2500 volts as well as corrosive, acidic conditions. Additionally, our immersion heaters are safe to use, and do not negatively affect the environment.

Our Solutions:

Regardless of the location, immersion heaters deliver superior performance. Pelonis’ line of immersion heaters features K Series and KC Series products.

k-series-immersion-heaterK Series Ultra-High Temperature Ceramic Immersion Heaters have the following operating specifications:

  • Thicknesses of 4mm
  • Rated voltages ranging from 110Vto 220V
  • Rated power in Water: 210W to 1500W
  • Rated Power in Air: 100W to 600W
  • Temperature range in Air: 400°C (752°F) to > 1200°C

kc-series-immersion-heaterKC Series Ultra-High Temperature Ceramic Immersion Heaters include:

  • Thicknesses of 4mm
  • Rated voltages ranging from 110Vto 220V
  • Rated power in Water: 500W to 3000W
  • Rated Power in Air: 220W to 360W
  • Temperature range in Air: 650°C (1202°F) to 1200°C

Choose an Immersion Heater Today

PTI’s immersion heaters are lightweight, compact, and provide high efficiency and safety to any application. These heaters are resilient enough to ensure long, trouble-free operation.

Download Our Electronics Cooling eBook

Please visit Pelonis Technologies’ Immersion Heater Page for more information, and be sure to peruse our product catalog. If you have any questions pertaining to any of our heating solutions, feel free to contact us.

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Maintenance Tips for Heating & Cooling Systems

Posted by Sam Pelonis | Jun 29, 2015 7:00:00 AM | 0 Comments

When customers choose to undertake custom heating or cooling projects, they may not always make as many considerations as industry professionals.

There are a lot of questions that need to be addressed before any installation can begin, such as those pertaining to the location and characteristics of the desired system, and the cost and energy concerns of the entire project.

There are also many questions to consider when working on the systems once they are set in place; the slightest issue can increase the chances of component degradation or eventual failure. Depending on whether you are working on either a heating or cooling system, there are different questions that are vital to keep in mind.

PTC_heaterHeating Systems

Q:  Is maintenance the same for all kinds of heating systems?

A:  Since heating systems differ slightly, maintenance on those systems will also differ.

For example: household heating applications rely on the thermal conduction of the building, whereas transportation heating applications utilize energy from the vehicle itself. Some applications rely on thermostats to regulate energy, and others are self-limiting.

In any case, you’ll want to consider the specific energy concerns and individual components of the application before making repairs.           

Q:  My heating system is creating unusually high utility costs—how can I resolve the issue?

A:  Higher energy costs can be indicative of poor energy efficiency. The secondary limiting devices that some heating systems depend on can malfunction, leading to an influx of heat energy—which in turn leads to higher energy costs.

To combat this issue, you should regularly check your system for any signs of overheating and replace any defective parts.

Q:  Do PTC heaters need constant maintenance?

A:  A PTC heater has a much longer service life than a traditional resistance heater. PTC heating limits the amount of energy flowing through a system, making them less prone to overheating or shorting out. Like with any machinery, it is possible for PTC heaters to malfunction—if you notice any problems, check the heater for any faulty circuitry.

HVAC_fanCooling Systems

Q:  Is maintenance the same for fans and blowers?

A:  Maintenance will be slightly different for fans and blowers since each has unique airflow and pressure characteristics, but generally you should watch for signs of fatigue on belts, bearings, sheaves, and other components. DC fans, DC blowers, micro fans and cross flow fans will each have some differences when it comes to maintenace.

Q:  Why are there airflow problems in the system?

A:  Your cooling (and heating) system can accumulate debris or other contaminants, which can lead to poor performance and damaged components over time.

Make sure to keep these components clean. Issues like fan degradation (caused corrosive gases or abrasive particles) can be averted with periodic inspection of the system for any flow irregularities.

Q:  What is another component that needs to be checked regularly?

A:  The condition of the fan’s motor is vital to the proper operation of the system. You can use methods such as vibration analysis—of the motor speed and blade pass frequency—to preemptively detect issues within the motor windings. You can also measure insulation resistance at certain voltages to test the motor windings.

More Questions? Contact Us Today

If you have additional questions about diverse, custom heating and cooling systems, Pelonis Technologies has several online resources that can provide you with a better understanding of options available to you.

Access Our  Useful Resources

If you need further assistance pertaining to heating and cooling, don’t hesitate to contact us.

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7 Ways to Lower Costs for Designers of Industrial Heating Applications

Posted by Sam Pelonis | Jan 5, 2015 7:00:00 AM | 0 Comments

Heating applications in industrial settings are not often thought of as prime areas where businesses can save on operating costs. However, designers can engineer efficiencies into heating applications that can deliver significant cost savings over time.

Below, you’ll find seven methods engineers can use to help ensure their heating application designs are both energy and cost efficient.

1. Take the outside environment into account

heatersThe air used to heat the building will come from outside the building, so the climate where the facility is located is a critical element. Heating systems are usually designed to maintain a temperature of 64 to 68°F (18 to 20°C). Transmission losses (which occur through walls, floor, ceilings, doors, and windows) will become lower as the outside ambient temperature gets closer to the desired inside temperature. For that reason, heat generation requirements will usually be less for facilities in warmer areas—designers can keep costs down by defining a smaller heating system that’s appropriate for the geographic region.

2. Don’t overlook boiler efficiency

Not all boilers are created equal. When you’ve determined the application’s heat generation requirements—based on square footage, geographic location, incidental heat gain that is generated by manufacturing processes or sunlight, etc.—research the boiler that is most efficient for that output. Sellers can greatly assist in providing technical information as well as real-world experience.

In addition, a boiler that doesn’t have to constantly operate at maximum output during colder months can help conserve energy and keep costs down; so it may make sense to augment the boiler with extremely efficient modern technologies such as positive temperature coefficient (PTC) heat. PTC uses ceramic stone or chips rather than traditional metal heating elements to provide a heat source that is customizable and scalable. A PTC heating solution can offer a defined maximum temperature at which resistance increases sharply, thus creating a self-regulating element that delivers a specific amount of heat right where it’s needed, rather than taxing the entire system.

3. Distribute heat sources

Since heat rises, engineers typically place the boiler in the lowest part of the building. However, designers of industrial heating applications typically face challenges presented by long, low buildings that make dispersing heat from a central location especially difficult compared to residential or high-rise situations. Often, one or more substations may be needed in addition to the primary system. Once again, the spot application of PTC heating can be a cost-efficient way to deliver targeted heat evenly and safely.

4. Consider the impact of control systems on overall efficiency

Different areas of a building may have different heating requirements, so it’s important to build some adjustability into the system. However, beware of giving individuals too much control over their work area—this can be counterproductive for the application as a whole. It’s a good idea to research the interfaces that will go in each area, how much adjustability they’ll allow, and how they’ll work with the main boiler control system. Computerized control and supervision will go a long way to ensuring that the application realizes all the efficiencies designed into it.

 5. Don’t skimp on pumps, piping, and circulation

As noted earlier, industrial buildings are often long, low structures that make dispersing heat from a central location particularly challenging. For maximum efficiency, consider including a number of evenly distributed sub-stations of fans, heaters or pumps. Several smaller systems operating at peak efficiency will be much less expensive to operate than running a central boiler at a high output for extended periods.

6. Put heat vents where they’ll do the most good

Another characteristic of designing industrial heating applications is that manufacturing processes often generate their own heat. By spacing heating stations evenly throughout the facility, you’ll be able to increase efficiency by allowing users to introduce heat where it’s needed and shut it off where it isn’t needed. And while machines generally don’t need heat, people do; you’ll likely want to concentrate vents in spaces like offices where people will generally spend the most time. PTC heating solutions may be an ideal way to maintain specified heat levels automatically in a variety of different locations.

7. It’s difficult to have too much insulation

Insulation is vital to an efficient heating design application. Insulation on pipes, ducts, and outside walls helps ensure that heated air stays heated longer, and can be delivered over longer distances. That means boilers run less, lowering heating and energy costs and prolonging the boiler’s service life. In addition, insulation works both ways by keeping heat from going where it isn’t wanted; for example, near electronics that are sensitive to higher temperatures. And finally, it’s relatively inexpensive and can serve its purpose for decades.

These are just a few ways that designers of industrial heating applications can deliver significant cost savings for users over time.

You can learn more about PTC heating solutions that we offer with this eBook:

Learn More About PTC Heating Download Our Free eBook

For more information on PTC heating solutions, or other heating and cooling solutions that we provide, please visit Pelonis Technologies’ online resource library or contact us today!

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PTC Heating Technology Benefits

Posted by Sam Pelonis | Aug 18, 2014 11:00:00 AM | 10 Comments

It can be difficult to find the right heating technology for your needs. Most industrial and commercial customers demand an innovative combination of efficiency and safety in their heaters.

At Pelonis, we find that the perfect solution is PTC heating. PTC (Positive Temperature Coefficient) is a unique technology that eschews traditional resistance wire and replaces it with ceramic stones or chips.

This simple switch in materials is what makes PTC electric heaters superior to traditional coil electric heaters. In this blog, we will cover what we believe to be the top three benefits of modern PTC heating technology.

1. Increased Levels of Safety

8689On its own, this is a powerful reason to make the switch to PTC technology. Traditional heaters run at internal temperatures that can exceed 900°F (482°C). Compare this with PTC heaters that usually run at 518°F (270°C). As you might expect, lower running temperatures will always bring an increase in safety. As well, because PTC stones do not generate heat at a constant rate like resistance wires, they will cool down quickly to avoid overheating. PTC heaters are also less susceptible to overheating due to scale buildup or sludge.

Turn up the Heat, Reduce the Cost

2. Longer Lasting

As with any piece of equipment, the longer internal temperatures stay high, the shorter the lifespan. Much like an overheating cellphone or laptop, a heater will not last too long if allowed to operate at extreme temperatures. As mentioned above, PTC heaters only generate the heat necessary to fulfill its preprogramed goal. This limits overheating which means less chance for it to burn out.

3. Lower Operating Costs and Downtime

We have established that PTC heaters are safer and longer lasting. It only makes sense then that these benefits will directly affect your bottom line in a positive way. A self-limiting PTC system means less money spent on special equipment to avoid overheating like trip protectors. As well, the smoother running PTC heater breaks down less and needs less maintenance.

At Pelonis, we are proud to offer our clients the latest in PTC heating technology. Our Honeycomb PTC Heaters offer you proprietary heating discs that are made from a revolutionary ceramic material that has 1,200 round/triangle shaped holes. These unique discs heat 100% of the airflow across their entire surface, which allows them to get 50% hotter than conventional coil heaters. We also carry some innovative Honeycomb PTC holder assemblies and Fin PTC heating elements.

4. Proven Track Record

Back in 2012, PTC changed the industry for the better with our new, revolutionary, Sealed Bearing System (SBS)

As you know, SBS is a cost effective and high performance, environmental DC fan bearing solution.  It increases cooling fan life by actively reducing damaging oil leaks and dust contamination.  In order to understand the real impact of SBS, you first need to take a quick look inside the manufacturing of DC fans.

With thicker, high-additive lubrication, there is less evaporation. This, combined with a lower oil content, means that our lubricant gives the superior ball bearing design the long-lasting edge you’re looking for. 

Pelonis’ customers have found that our SBS is a very practical solution for DC fan application that requires the benefits of both sleeve and ball bearings.

Read more about the benefits of PTC heating in our eBook about heating applications and the uses for positive temperature coefficient systems:

Learn More About PTC Heating Download Our Free eBook

If you are interested in learning more about how Pelonis can help you find the right PTC heating technology for your application, please visit our website or contact us today!

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