Compact-Catalog

2
 Product-
Range
Coil Heater
hotspring
Product Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

hotspring Coil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

hotslot
hotslot Nozzle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

hotflex
hotflex Flexible Tubular Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

hottube
hottube Tubular Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

hotrod
hotrod Cartridge Heaters (HHP, LHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

hotform
hotform Silicon Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

hotcast
ZD
hotcast Sprue Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

hotcast
MH
hotcast Die-Casting Nozzle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

hotcontrol
Controller
hotcontrol Temperature Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

hotcontrol
TC/RTD
hotcontrol Thermocouples – RTDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Automotive
hotcontrol

hotcontrol Automotive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Isolite Keramikschmiermittel (Spray, Suspension). . . . . . . . . . . . . . . . . . . . . 81

Isolite
Z-System

Z-System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Projects
 Product Range
hotspring® for heating applications: Application field
Coil Heaters L Hot runner nozzles
with power distribution
L Small hot runner
distribution plates
L Sealing bars and jaws

hotslot® L Hot runner nozzles

Nozzle Heaters with high precision
power distribution,
very low wall thickness,
high surface loads

hotflex® for heating applications:

Flexible Tubular Heaters L Hot runner manifold plates.
hotflex‘ flexibility enables
heat to be located directly
to the resin flow path with
three dimensional heat
distribution. Can be formed
by hand, stored in a straight
condition to save storage
space. No pre-bent
design details required.

hotrod® for heating applications: Application field

Cartridge Heaters L Extruders
(LHT and HHP) L Sealing bars and jaws
L Hot-melt machines
L Die-casting goose necks
L Special applications

hotform® for heating applications:

Silicon Heating Elements L Longevity and weather-
proof plate heating
L Freeze protection
L Heating of surfaces,
cylindrical surfaces or
parabolic reflector

4
Please observe operating instructions and safety 04/2016+
information!
SM · Errors
Pleaseand
observe operating
technical changes instructions and safety information!
reserved · www.hotset.com · Errors and technical changes reserved · www.hotset.com
· 12/2017 SM
2
 Product-
Range
Product Range Product Range

Coil Heater
hotspring
hotcast® for heating applications: Application field
Sprue Nozzle L Improves cycle time
and part quality

hotslot
L Reduces porosity
and eliminates costly
sprue cone
L Traditional cold plug
designs can be replaced

hotflex
by the hotcast sprue nozzle

hottube
hotcast® L Heated machine nozzles
Die-Casting Nozzle Heate
Heater for melt transportation from
(GMH and OMH) goose neck to sprue nozzle
within zinc die-casting
process

hotrod
hotform
hotcontrol Application field hotcontrol Application field
Thermocouples and RTDs L Temperature measurement Control Units L Heat control to meet required

hotcast
of heating elements, tools tool and mold temperatures

ZD
and molds
L Temperature measurement
to conrol heat

hotcast
MH
hotcontrol
Controller
Isolite Application field
Ceramic Lubricant
icant L Improves installation and
(Spray or Composite)
mposite) removal, heat conductive,
electric insulator
hotcontrol
TC/RTD
Automotive
hotcontrol

Projects Application field L Design of heated machine components

L Optimizing and design of heating systems for industrial applications
Isolite

L Engineering and development service

Analysis Conception Prototype Testing Solution

Z-System

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com 12/2017 SM
Hotset America Corp. · 713 Kite Road · Swainsboro, GA 30401 · USA · Office +1 912 289 1844 · Fax +1 866 496 4123 · usa@hotset.com
Projects

Hotset Singapore Pte Ltd · 362 Upper Paya Lebar Road · Unit 07-02 · Da Jin Factory Building · Singapore · Office +65 6777 7993 · Fax +65 6777 7656 · hspl@hotset.com
Hotset Heating Elements (Suzhou) Co. Ltd · Luzhi Innovation Park · Suzhou · China · Office +86 512 6502 6218 · Fax +86 512 6502 6238 · szsales@hotset.com
HIPL India Pvt Ltd · Toyota Kirloskar Motor Company Road · Bidadi · Karnataka · India · Office +91 99 00 266 271 · rraghavendra@hotset.com 5
Hotset GmbH (HQ) · Hueckstraße 16 · 58511 Lüdenscheid · Germany · Office +49 2351 4302-0 · Fax +49 2351 4302-25 · DEsales@hotset.com
6
 Product-
Range
hotspring®

Coil Heater
hotspring
Coil Heater

L For heating applications:

- Hot runner nozzles with and without wattage distribution
- Small hot runner distribution plates

hotslot
- Sealing bars and jaws for packaging machines
- Machine nozzles for plastics and die-casting industries
L Multi-purpose and economical with a variety of
- wattages, surface loads and customized heat distribution
- wall thicknesses and mounting options

hotflex
L Range of clamping options:
- Undersized inner diameter for open coiled heater fitting
- Lower thermal expansion with reflection tube
- Tight fitting with axial screw clamping band
- Tangential screw clamping band

hottube
- hotspring Lock-System
Technical key features
Insulation material compressed MgO
Maximum sheath temperature

hotrod
of heating element max. 750 °C / 1380 °F
with reflection tube or clamping band
max. 650 °C / 1200 °F
Maximum connection
head temperature max. 260 °C / 500 °F
Connection voltage 230 V standard, 250 V max.

hotform
hotspring Maxi 440 V max.
Wattage tolerance* ± 10%
High voltage test* min. 800 V AC,
hotspring Maxi 1250 V
Insulation resistance* ≥ 5 MΩ at 500 V DC

hotcast
Leakage current* ≤ 0.5 mA at 253 V AC

ZD
Max. total length straight max. 3000 mm / 118 inch
Coiled inner Ø tolerance up to Ø 12 mm: -0.05 / -0.20 mm up to 0.47 inch: -0.2 / -7.9 mils
up to Ø 30 mm: -0.10 / -0.30 mm up to 1.18 inch: -3.9 / -11.8 mils
up to Ø 40 mm: -0.20 / -0.40 mm up to 1.57 inch: -7.9 / -15.7 mils

hotcast
with reflection tube: +0.05 / +0.15 mm with reflection tube: +2.0 / +5.9 mils

MH
Coiled length tolerance ± 1.5% least ± 1 mm / 0.039 inch
* tested at environmental temperature

Application Fields

hotcontrol
Controller
hotcontrol
TC/RTD
Automotive
hotcontrol
Isolite
Z-System

Hot runner industry Hot runner industry Packaging Industry Packaging Industry
Heating of small distribution plates Heating of various nozzles Heating of sealing bars Heating of sealing jaws
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 04/2016+ SM 7
1
 hotspring®
Coil Heater

Sheath surface load

Nozzle

® ® ®
hotspring round hotspring flat hotspring with reflection tube hotslot® hotspring® brass
6 W/cm2 7.5 W/cm2 10 W/cm2 12,5 W/cm2 15 W/cm2
3.9 W/inch2 48 W/inch2 65 W/inch2 81 W/inch2 97 W/inch2

Coiling options
bottom top
middle

Cylindrical Flat coiling Serpentine coiling Conical coiling

Options: - coiled tight
- coiled with defined pitch
(up to 50 mm per coil)
- coiled with wattage distribution

Exit options

Tangential Axial Radial In the mid

(hotspring Micro and hotspring Mini only)

Approximate calculation of the stretched heated length

heated length straight = (I Ø coiled + heater height) x p x number of windings (x 2)*

(* "x 2" applicable for hotspring Micro and hotspring Mini with two heads only)

8 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
2
 Product-
Range
hotspring®

Coil Heater
hotspring
Coil Heater

Performance Range

hotslot
Specifications l = Options L = Special Editions

be
tu
ion
ct n
fle d
tio ds

hotflex
le
re up di ea d nd
ert in co
e
c on h
n hea ba
a d ld i o
he oile ht ng nd
a t n
ec tio
m
m
]
[ W
]
in c e
er
th ring aig s n c pi ba
le le h
b wi ur st ras co r n m g
ns [m ne
t e
e la in
tio ns t ag o up oup n tu tubemeas in b of on ial c mp ste
m
c a io a t c c i o n l e i n r r c t a y
s o o t e l

hottube
o r
ifi en .w m m c ect ratu lab ed be lle
i
en l c -S
hotspring® pec im ax h er her efle Reflmpe vai ast um ma ang xia ock
S D M T T R t e A C N S T A L
Micro /F flat 1.0 x 1.6 300 l l l 2 L
Mini /R round 1.8 550 l l l l 2
Mini /F flat 1.3 x 2.3 550 l l l l 1*/2 L L L

hotrod
Midi /F flat 1.8 x 3.2 650 l l l 1 L* L
Classic /F flat 2.2 x 4.2 1000 l l l l 1 L
Classic /Q square 3.0 x 3.0 1000 l l l 1 L
Classic /R round 3.0 740 l l 1

hotform
Medium /R round 4.0 740 l l l 1
Maxi flat 4.6 x 8.6 2100 l l l 0/1 L
* Ø max. 4.9 mm / 0.193 inch, max 2.3 A, lead protection sleeve option, without thermocouple
General Options

hotcast
ZD
IØ
Ø 0.5 A

hotcast
MH
L ±0.5

hotcontrol
Controller
A

AØ ±0.25
Straight Reflection tube Casted in brass
With coiling electrical specifications will be - Increased max. sheath surface load - With or without protection tube along unheated zones
changed. Isolation resistance and high - Optimized heat transfer to the nozzle - Exit: axial or radial
voltage must be checked before operation. - Protection against mechanical damage - Wall thickness Mini = 2.5 mm / 0.984 inch Midi, Classic = 4.5 to 5.5 mm / 0.18 to 0.22 inch
- Thermal decoupled temperature measure - Inner Ø-tolerance: +0.05 mm / +2.0 mils or H7
hotcontrol
TC/RTD
ring option - Outer Ø-tolerance: min ±0.25 mm / ±9.8 mils
- Temperature at brass sheath: max 650 °C / 1200 °F
- Inner Ø: 7 to 28 mm / 0.27 to 1.10 inch (more on request)
- Max. length: 200 mm / 7.9 inch (if Inner Ø > 28 mm / 1.10 inch max. length : 3x Inner Ø)

General Options
Automotive
hotcontrol

Clamping options for optimized heat transfer from heating element to the heated tool
Increases max. allowed sheath surface load and protects against mechanical damage
Isolite
Z-System

Tangential screw clamping band Axial screw clamping band hotspring Lock-System
Ø I = min. 30 mm / 1.18 inch as special edition for hotspring Mini Front installation and removal
Ø I = 15 … 25 mm / 0.59 … 0.98 inch
Projects

Length = 25 … 60 mm / 0.98 … 2.36 inch

Wall thickness 2.8 mm / 0.11 inch

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 04/2016+ SM 9
3
 hotspring®
Coil Heater

hotspring® Micro /F 1.0 x 1.6 L uz1

Coil heater with flat cross section Ø1.8 ± 0.15

L uz2

L cl
Specifications
Sheath material Stainless steel or nickel
Connection head dimensions Ø 5.5 x 40 mm / 0.22 x 1.57 inch IØ
L heated
Minimum Length unheated zone 25 mm / 0.98 inch L2unheated
L1unheated

Length tolerance unheated zone ± 5%, least ± 15 mm / 0.59 inch

Length tolerance heated zone ± 5% Ø
L total
Minimum inner bending radius 3 mm / 0.12 inch
Lcl = coiled length
Luz = length unheated zone
Items to be configured

hotspring® Mini /F 1.3 x 2.3 L uz1

hotspring® Mini /R 1.8 Ø1.8 ± 0.15

L uz2
Coil heater with flat or round cross section
L cl
Specifications
Sheath material Stainless steel or nickel IØ
L heated
Connection head dimensions Ø 5.5 x 40 mm / 0.22 x 1.57 inch L2unheated
L1unheated

Minimum Length unheated zone 25 mm / 0.98 inch

Ø
Length tolerance unheated zone ± 5%, least ± 15 mm / 0.59 inch L total
Length tolerance heated zone ± 5% Lcl = coiled length
Minimum inner bending radius 3 mm / 0.12 inch Luz = length unheated zone

Stock range
Flat cross section coiled, 230 V
Total length Wattage [W] Length [mm] Length [mm]
Stock ID incl. heads [mm] coiled, flat heated unheated
7580469 556 120 296 65 / 115
7580510 642 160 382 65 / 115
7580671 735 210 475 65 / 115
7580772 835 250 575 65 / 115
7580845 960 300 700 65 / 115
7581057 1110 350 850 65 / 115
7581273 1306 450 1046 65 / 115
Part no. changes after adding options or coiling.

Stock range
Round cross section straight, U-shaped bent, 230 V,
connection 2,000 mm / 78.4 inch, PTFE isolated, Cu-nickel plated, multi stranded
Total length Wattage [W] Length [mm] Length [mm]
Stock ID incl. heads [mm] straight, round heated unheated
7580480 556 120 296 65 / 115
7580521 642 160 382 65 / 115
7580682 735 210 475 65 / 115
7580783 835 250 575 65 / 115
7580856 960 300 700 65 / 115
7581068 1110 350 850 65 / 115
7581284 1306 450 1046 65 / 115

10 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
4
 Product-
Range
hotspring®

Coil Heater
hotspring
Coil Heater

hotspring® Mini /F 1.3 x 2.3 IØ

with axial screwed clamping band

hotslot
Coil heater with flat cross section
~ 2.1
H max.

max. 15.9
Specifications
Sheath material Stainless steel or nickel

hotflex
Connection head dimensions Ø 5.5 x 40 mm / 0.22 x 1.57 inch

L ± 0.5
Minimum Length unheated zone 25 mm / 0.98 inch
Length tolerance unheated zone ± 5%, least ± 15 mm
Length tolerance heated zone ± 5%
Minimum inner bending radius 3 mm / 0.12 inch

hottube
Wall thickness 2.1 mm / 0.083 inch
Stock range
Sheath material nickel, connection voltage 240 V, connection 1,800 mm / 70.9 inch, PTFE isolated,
Cu-nickel plated, multi stranded
Total length Wattage Length unheated Inner Ø Max. height

hotrod
Stock ID [mm] [W] [mm] [mm] [mm]
7603019 30.5 268 100 / 150 19.05 32.3
7603020 30.5 250 100 / 150 22.20 36.4

hotform
hotspring® Midi /F 1.8 x 3.2

hotcast
ZD
Coil heater with flat cross section

Specifications
Sheath material Stainless steel
Connection head dimensions Ø 6.9 x 25 / 0.27 x 0.98 inch

hotcast
MH
Minimum Length unheated zone 25 mm / 0.98 inch L unheated
L heated
Length tolerance unheated zone ± 5%, least ± 2 mm / 0.08 inch
Length tolerance heated zone ± 3%
L total
Minimum inner bending radius 4 mm / 0.16 inch

hotcontrol
Controller
Lcl = coiled length
Luz = length unheated zone
Stock range
Straight or coiled, connection 1,000 mm / 39.4 inch, type N (see connection options),
brown/blue, Thermocouple ungrounded
hotcontrol
TC/RTD
Total length Wattage Length heated Length thermocouple type J
Stock ID incl. head [mm] [W] [mm] unheated [mm] (Fe-CuNi)
7540300 340 130 250 65
7840300 340 130 250 65 l
7540301 390 160 300 65
Automotive
hotcontrol

7840301 390 160 300 65 l

7540302 440 190 350 65
7840302 440 190 350 65 l
7540303 490 220 400 65
7840303 490 220 400 65 l
Isolite

7540304 540 250 450 65

7840304 540 250 450 65 l
7540305 590 275 500 65
7840305 590 275 500 65 l
Z-System

7540306 690 330 600 65

7840306 690 330 600 65 l
7540307 840 400 750 65
7840307 840 400 750 65 l
Part no. changes after adding options or coiling.
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 04/2016+ SM 11
5
 hotspring®
Coil Heater

hotspring® Classic/F 2.2 x 4.2

hotspring® Classic/Q 3.0 x 3.0
hotspring® Classic/R 3.0

3.3
Coil heater with flat, square or round cross section

Specifications
L unheated
Sheath material Stainless steel
L heated
Connection head dimensions Ø 6.9 x 25 mm / 0.27 x 0.98 inch
Minimum Length unheated zone 25 mm / 0.98 inch L total
Length tolerance unheated zone ± 5%, least ± 15 mm / 0.59 inch Lcl = coiled length
Length tolerance heated zone ± 1% Luz = length unheated zone
Minimum inner bending radius 4 mm / 0.16 inch

Stock range
2.2 x 4.2, Straight or coiled, connection 1,000 mm / 39.4 inch type NG (see connection options),
brown / blue, Thermocouple ungrounded
Total length Wattage Length heated Length thermocouple type J
Stock ID incl. head [mm] [W] [mm] unheated [mm] (Fe-CuNi)
7732519 340 195 250 65
7832519 340 195 250 65 l
7732821 370 215 280 65
7832821 370 215 280 65 l
7733324 425 240 335 65
7833524 425 240 335 65 l
7733829 475 295 385 65
7833829 475 295 385 65 l
7734635 550 350 460 65
7834635 550 350 460 65 l
7735240 610 400 520 65
7835240 610 400 520 65 l
7736046 690 460 600 65
7836046 690 460 600 65 l
7737661 850 610 760 65
7837601 850 610 760 65 l
7739069 990 690 900 65
7839069 990 690 900 65 l
7731185 1200 850 1110 65
7831185 1200 850 1110 65 l
7731395 1400 950 1310 65
7831395 1400 950 1310 65 l

3.0 x 3.0, straight or coiled, connection 1,000 mm / 39.4 inch, Type NG (see connection options),
brown / blue, Thermocouple ungrounded
7930316 390 215 300 65
7940316 390 215 300 65 l
7930422 540 325 450 65
7940422 540 325 450 65 l
7930627 740 470 650 65
7940627 740 470 650 65 l
7930835 940 610 850 65
7940835 940 610 850 65 l
7931043 1140 630 1050 65
7941035 1140 630 1050 65 l
7931395 1400 950 1310 65
7941395 1400 950 1310 65 l

Part no. changes after adding options or coiling.

12 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 Product-
Range
hotspring®

Coil Heater
hotspring
Coil Heater

hotspring® Medium /R 4.0

Coil heater with round cross section

hotslot
4.0
Specifications
Sheath material Stainless steel
Connection head dimensions Ø 6.9 x 25 mm / 0.27 x 0.98 inch
Minimum Length unheated zone 25 mm / 0.98 inch L unheated

hotflex
L heated
Length tolerance unheated zone ± 5%, least ± 2 mm / 0.08 inch
Length tolerance heated zone ± 2.5%
L total
Minimum inner bending radius 5 mm / 0.20 inch
Lcl = coiled length
Items to be configured Luz = length unheated zone

hottube
hotspring® Maxi /F 4.6 x 8.6
Coil heater with flat cross section with or

Ø 12.5
Ø 6.5 ± 0.15
without connection head

hotrod
Specifications
IØ
Sheath material Stainless steel
Connection head dimensions Ø 12.5 x 45 mm / 0.49 x 1.77 inch L unheated
L heated
Minimum Length unheated zone 45 mm / 1.77 inch

hotform
Length tolerance unheated zone ± 5%, least ± 2 mm / 0.08 inch
L total
Length tolerance heated zone ± 1% L = coiled length cl
Minimum inner bending radius 10 mm / 0.40 inch L = length unheated zone uz

Connection voltage max. 440 V

Stock range

hotcast
ZD
Straight or coiled, connection type N (see connection options), Thermocouple ungrounded
Total length [mm] Wattage Voltage L heated L unheated with connection- Thermo-
Stock ID incl. head [W] [V] [mm] [mm] connection-head length [mm] couple
7508551 605 550 230 505 55 l 1.500 Type K, NiCr-Ni

hotcast
7508564 700 700 230 600 55 l 1.500 Type K, NiCr-Ni

MH
7508557 770 750 230 670 55 l 1.500 Type K, NiCr-Ni
7508552 800 700 230 700 55 l 1.500 Type K, NiCr-Ni
7508558 900 900 230 800 55 l 1.500 Type K, NiCr-Ni
7508565 980 1500 230 880 55 l 1.500 Type K, NiCr-Ni

hotcontrol
Controller
7508566 1000 1000 230 900 55 l 1.500 Type K, NiCr-Ni
7508567 1100 1100 230 1000 55 l 1.500 Type K, NiCr-Ni
7508553 1215 1300 230 1115 55 l 1500 Type K, NiCr-Ni
7508554 1300 1500 230 1200 55 l 1.500 Type K, NiCr-Ni
7508568 1347 1700 230 1247 55 l 1.500 Type K, NiCr-Ni
hotcontrol
TC/RTD
7508559 1370 1600 230 1270 55 l 1.500 Type K, NiCr-Ni
7508569 1500 1700 230 1400 55 l 1.500 Type K, NiCr-Ni
7508555 1625 1800 230 1525 55 l 1.500 Type K, NiCr-Ni
7508560 1700 1900 230 1600 55 l 1.500 Type K, NiCr-Ni
7508570 1737 1700 230 1637 55 l 1.500 Type K, NiCr-Ni
Automotive
hotcontrol

7508571 1800 2000 400 1700 55 l 1.500 Type K, NiCr-Ni

7508572 1874 1700 230 1774 55 l 1.500 Type K, NiCr-Ni
7508556 2310 2600 400 2210 55 l 1.500 Type K, NiCr-Ni
7302521 315 300 230 250 65 1.000
7402521 315 300 230 250 65 1.000 Type J, Fe-CuNi
7303527 415 450 230 350 65 1.000
Isolite

7403527 415 450 230 350 65 1.000 Type J, Fe-CuNi

7304531 515 550 230 450 65 1.000
7404531 515 550 230 450 65 1.000 Type J, Fe-CuNi
7306543 715 800 230 650 65 1.000
7406543 715 800 230 650 65 1.000 Type J, Fe-CuNi
Z-System

7308550 915 1000 230 850 65 1.000

7408550 915 1000 230 850 65 1.000 Type J, Fe-CuNi
7508561 2460 2800 400 2360 65 1.000 Type K, NiCr-Ni
7508573 2960 2800 400 2860 65 1.000 Type K, NiCr-Ni
Projects

Part no. changes after adding options or coiling.

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 04/2016+ SM 13
7
 hotspring®
Coil Heater

Connection options
Micro Mini Midi Classic Medium Maxi Maxi
Connection types with head no head
Micro / Mini 2 heads
PTFE insulated Cu-nickel plated
L
leads, with 2 connection heads
Ø max. 5.5 mm / 0.22 inch
max. Ø L max 40 mm / 158 inch

Mini single headed /

PTFE insulated Cu-nickel plated
Midi small head
L
leads, with 1 connection head
Ø max. 4.9 mm / 0.193 inch,
max. Ø
L max 25 mm / 0.98 inch, max. 2.3 A

Type N PTFE-
PTFE insulated Cu-nickel plated glass silk
L Cu-nickel-plated,
Ni-leads
leads, multistranded, multistranded,
multistranded,
max. Ø10 mm / 0.4 inch Ø max. 7,0 mm / 0.28 inch Ø max. 10 mm /
max. Ø Ø max. 13 mm/0.51 inch,
0.4 inch,
L = 25 mm / 0.98 inch L = 45 mm / 1.77 inch,
option: ground wire max. 7 A

Type NG glass-silk Ni-leads PTFE- Cu-nickel-pla-

PTFE insulated Cu-nickel plated
L multistranded, ted, multistranded,
leads, multistranded, Ø max. 13 mm/0.51 inch, Ø max. 10 mm /
max. Ø10 mm / 0.4 inch Ø max. 7,0 mm / 0.28 inch, L = 25 mm / 0.98 inch L = 45 mm / 1.77 inch, 0.4 inch,
max. Ø
glass silk protective max.7 A, glass silk
glass silk protective sleeving
option: ground wire sleeving protective sleeving

Type NM PTFE,
glass-silk
L PTFE insulated Cu-nickel plated Cu-nickel-plated,
Ni-leads
multistranded,
leads, multistranded, multistranded,
Ø max. 10 mm /
max. Ø
max. Ø10 mm / 0.4 inch Ø max. 7,0 mm / 0.28 inch, L = 25 mm / 0.98 inch Ø max. 13 mm/0.51 inch, 0.4 inch,
L = 45 mm / 1.77 inch,
flexible metal sleeving max. 7 A, flexible
option: ground wire flexible metal sleeving
metal sleeving
Type ND PTFE,
PTFE insulated Cu-nickel plated glass-silk Ni-leads Cu-nickel-plated,
L
multistranded, multistranded,
leads, multistranded,
Ø max. 13 mm/0.51 inch, Ø max. 10 mm /
max. Ø
max. Ø10 mm / 0.4 inch Ø max. 7,0 mm / 0.28 inch, L = 25 mm / 0.98 inch L = 45 mm / 1.77 inch, 0.4 inch,
braided metal sleeving braided metal sleeving max. 7 A, braided
option: ground wire metal sleeving
Type NT
L
PTFE insulated Cu-nickel plated
leads, multistranded,

max. Ø
max. Ø10 mm / 0.4 inch Ø max. 7,0 mm / 0.28 inch, L = 25 mm / 0.98 inch
PTFE sleeving
option: ground wire

Plug connection LEMO 3 pins

max. 8,0 A at 20 °C / 68°F

Plug connection LEMO 5 pins

32 ±1 ca. 37

max. 6,5 A at 20 °C / 68°F

Ø10 Ø9.4

14 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 hotslot®

15
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
16
 Product-
Range
hotslot®

Coil Heater
Nozzle heater with power distribution

hotspring
L Pressed-in coil heater with user-defined groove profile
L Reproducible power distribution
L Minimal wall thickness for reduced clearances

hotslot
L Lowest power available in the middle of a nozzle
L Brass as cylinder raw material
L Same connection options as hotspring coil heaters

hotflex
hottube
Technical key features
hotslot cylinder material brass
Heater sheath material stainless steel
Lowest wall thickness 1.5 mm
Sheath temperature of heater max. 450 °C / 840 °F

hotrod
Standard connection voltage 230 V
High voltage test* 800 V AC
Insulation resistance* ≥ 5 MOhm at 500 V DC
Leakage current* < 0.5 mA at 253 V AC

hotform
Wattage tolerance ± 10 %
Length tolerance ± 0.5 mm flat heating element with power flat heating element
distribution with seperate coil
Inner diameter tolerance + 0.05 mm
Length unheated zone
of coiled heater min. 25 mm

hotcast
Length tolerance of

ZD
unheated zone ± 5 %, min. ± 15 mm

* tested at environmental temperature

hotcast
MH
cylinder tube to insert lowest wall thickness
a changeable thermocouple

hotcontrol
Controller
Options
L H7 inner diameter tolerance available
L Surface thermocouple
L hotslot-cylinder with slot to insert a
hotcontrol
TC/RTD
changeable thermocouple
L Variouse plate configurations with cut-outs
or bores available
L Connection voltage from 12 V to 250 V
L Serpentine coil
Automotive
hotcontrol

L individual length and wattage reproducible and uniform power distribution

Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2016+ SM 17
 hotslot®
Nozzle heater with power distribution

L
b AØ
removal bore
A IØ
A-A

L uz head 1
A Ø coiled-in heater

L uz head 2
rem
d oval
head max bo
L TC

L head max re

Thermocouple
xxx

Ø inner Wall thick- Length Wattage*

Type di ness min. min./max. Pmax
hotslot Micro 5 to 25 mm 1.5 mm 25 to 250 mm 400 W
hotslot Mini 7 to 75 mm 2.0 mm 25 to 250 mm 700 W
*Wattage depends on length, diameter and power distribution

Stock range hotslot® Mini

Power distribution
Item Length Ø inner Ø outer Wattage Bottom Head b
L-0.4 [mm] [mm] (H7) [mm] P [W] [mm] | % [mm] | % [mm]

7803100 35.0 10.0+0.015 13.5+0.2/-0.1 200 13.0 | 45 13.5 | 45 16.0±0,5

7803101 55.0 10.0+0.015 13.5+0.2/-0.1 250 16.0 | 40 16.5 | 40 19.0±0,5
7803102 75.0 10.0+0.015 13.5+0.2/-0.1 300 16.0 | 37 16.5 | 37 20.0±0,5
7803103 95.0 10.0+0.015 13.5+0.2/-0.1 400 19.5 | 37 20.0 | 37 25.0±0,5
7803104 115.0 10.0+0.015 13.5+0.2/-0.1 450 23.0 | 36 24.0 | 36 28.0±0,5
7803105 135.0 10.0+0.015 13.5+0.2/-0.1 500 23.0 | 34 24.0 | 34 30.0±0,5
7803106 155.0 10.0+0.015 13.5+0.2/-0.1 550 23.0 | 33 24.0 | 32 30.0±0,5
7803107 35.0 12.0+0.018 15.5+0.2/-0.1 225 13.0 | 46 13.5 | 45 16.0±0,5
7803108 55.0 12.0+0.018 15.5+0.2/-0.1 250 15.5 | 41 16.5 | 41 19.0±0,5
7803109 75.0 12.0+0.018 15.5+0.2/-0.1 300 15.5 | 38 16.5 | 38 20.0±0,5
7803110 95.0 12.0+0.018 15.5+0.2/-0.1 400 19.5 | 38 20.0 | 38 25.0±0,5
7803111 115.0 12.0+0.018 15.5+0.2/-0.1 450 23.0 | 39 24.0 | 38 28.0±0,5
7803112 135.0 12.0+0.018 15.5+0.2/-0.1 500 23.0 | 37 24.0 | 36 30.0±0,5
7803113 155.0 12.0+0.018 15.5+0.2/-0.1 550 23.0 | 34 24.0 | 34 30.0±0,5

Dimensions products stock range hotslot® Mini

Luz head1 65±15 mm LTC 115±35 mm Thermocouple Type L (Fe-CuNi), Ø 1.0 mm (RD/BL), ungrounded
Luz head2 115±15 mm dhead max 5.5 mm
Lhead max 40 mm dremoval bore 3.2 ±0.1 mm Connection CU-Ni-lead (BK/WH),
PTFE-isolated, 2000 mm,
max 260°C / 500°F, braided metal sleeving

18 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 hotslot®

19
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
20
 Product-
Range
hotflex®

Coil Heater
hotspring
Flexible tubular heater

L Easy installation with a uniform finish

L Can be formed by hand
L Stored in a straight condition to save storage space

hotslot
L No special installation tools required
L Patented technology ensures industry leading heat transfer
L Up to 75% sheath contact with round and square hotflex
heaters when recommended groove geometry is followed
L Rapid heat-up times

hotflex
L Minimal temperature difference between heater sheath
and heated tool
L 3-dimensional groove geometry possible
L Industry’s smallest bending radius

hottube
L Hotflex’s flexibility enables heat to be located where it is
needed; an improvement over rigid cartridge heaters
L Reduced energy costs: tool mass can be reduced

Technical key features

hotrod
Sheath material stainless steel
Sheath temperature
of heating element max. 700 °C / 1290 °F
Standard connection voltage 230 V
High voltage test* 1000 V AC

hotform
Insulation resistance* ≥ 5 MΩ at 500 V DC
Installation without special tools Ideal heat transfer
Leakage current* < 0.5 mA at 253 V AC
Wattage tolerance ± 10%
Length tolerance ± 1.5%
* tested at environmental temperature

hotcast
ZD
Options
L Bendable unheated zones
L Connection voltage from 12 V to 250 V
L Individual length

hotcast
MH
L Individual wattage
L Individual connection options
Installed, round groove geometry Installation example
Recommended groove geometry

hotcontrol
Controller
Type hotflex Groove dimensions [mm] w x h
W
6.0±0.1 6.1+0.1 x 6.1+0.1 hotflex Ø
30°
Ø 6.5±0.1 6.0+0.1
x 6.5+0.1 30° W

Ø 8.0±0.1 7.7±0.05
x 8.0±0.1
1

8.0±0.1 8.1+0.1
x 8.1+0.1 hotcontrol
TC/RTD
1,2

h
h

Ø 8.2±0.1 7.9±0.05 x 8.2±0.1

Ø 8.5±0.1 8.2±0.05 x 8.5±0.1
Ø 10.0±0.1 9.7±0.05 x 10.0±0.1
Automotive
hotcontrol

Round groove geometry Square groove geometry

Isolite
Z-System

Ceramic terminal connector Standard: threaded pins M2.5 Plain Ni-leads Insulated Ni-leads High temperature mineral fibre Flat plug
“plug ’n’ heat” Option: M4 from Ø 8.0 mm with ceramic beads insulation, Glass silk: up to 230 °C / 445 °F insulated Ni-leads,with W = 6.3 mm / 0.248 inch,
Temp. resist. 230 °C / 445 °F with set of nuts and washers, up to 600 °C / 1110 °F PTFE: up to 230 °C / 445 °F ceramic sealed tube section Temp. resist.
Short term max. 280 °C / 535 °F Temp. resist. 350 °C / 660 °F Silicon: up to 180 °C / 350 °F 350 °C / 660 °F
14 x 21 x 25 mm / 5.51 x 8.27 x 9.84“ Option: eyelet connector M4 available with stock items
Projects

available with stock items available with stock items

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 01/2018 SM 21
 hotflex®
Flexible tubular heater

Ceramic insulator Tube Section Midpoint mark Cross section round or square

6
20 ±3 Luz 30 ±5 Lheated Luz 30 ±5 20 ± 3

35 35
Not bendable Not bendable
L

Dimensions
Depending on the number of bends the hotflex length can increase. For a more precise calculation of the extension you might use
our template for assistance: www.hotset.com/hotflex_extensionfactors

Tube section Min. Bending Max. Sheath surface

Type hotflex L min [mm] L max [mm] max [mm] radius internal load [W/cm2]
6.0 300 1,800 24 6.5 10
Ø 6.5 300 1,800 24 6.5 10
Ø 8.0 300 3,000 10 10 15
8.0 300 3,000 10 10 15
Ø 8.2 300 3,000 10 10 15
Ø 8.5 300 3,000 10 10 15
Ø 10.0 300 3,000 10 10 12.5

Stock range
Ø 6.5 mm (230 V) Ø 8.0 mm (240 V*) Ø 8.5 mm (230 V) Ø 8.5 mm (230 V)
with threaded pins M2.5 with threaded pins M4 with threaded pins M2.5 with threaded pins M2.5
Stock ID L P Stock ID L P Stock ID L P Stock ID L P Stock ID L P Stock ID L P
[mm] [W] [mm] [W] [mm] [W] [mm] [W] [mm] [W] [mm] [W]
6500300 300 350 6301025 1025 2260 6100300 300 650 6101025 1025 2725
6500350 350 400 6301050 1050 2316 6100350 350 750 6101050 1050 2800
6500400 400 500 6300400 400 795 6301075 1075 2370 6100375 375 825 6101075 1075 2865
6500450 450 600 6300425 425 850 6301100 1100 2430 6100400 400 900 6101100 1100 2930
6500500 500 650 6300450 450 910 6301125 1125 2480 6100425 425 975 6101125 1125 2995
6500550 550 700 6300475 475 970 6301150 1150 2545 6100450 450 1050 6101150 1150 3060
6500600 600 800 6300500 500 1025 6301175 1175 2600 6100475 475 1100 6101175 1175 3095
6500650 650 850 6300525 525 1090 6301200 1200 2665 6100500 500 1150 6101200 1200 3190 6110500 500 700
6500700 700 900 6300550 550 1145 6301225 1225 2730 6100525 525 1225 6101250 1250 3320 6110550 550 780
6500750 750 1000 6300575 575 1200 6301250 1250 2780 6100550 550 1300 6101300 1300 3450 6110600 600 860
6500800 800 1100 6300600 600 1260 6301275 1275 2840 6100575 575 1375 6101350 1350 3580 6110650 650 950
6500850 850 1200 6300625 625 1320 6301300 1300 2895 6100600 600 1450 6101400 1400 3710 6110700 700 1000
6500900 900 1300 6300650 650 1380 6301325 1325 2960 6100625 625 1525 6101450 1450 3840 6110750 750 1100
6500950 950 1350 6300675 675 1440 6301350 1350 3015 6100650 650 1600 6101500 1500 3970 6110800 800 1190
6501000 1000 1400 6300700 700 1495 6301375 1375 3070 6100675 675 1675 6110850 850 1250
6501050 1050 1450 6300725 725 1550 6301400 1400 3130 6100700 700 1750 6110900 900 1350
6501100 1100 1500 6300750 750 1615 6301425 1425 3180 6100725 725 1825 6110950 950 1430
6501150 1150 1550 6300775 775 1670 6301450 1450 3245 6100750 750 1900 6111000 1000 1500
6501200 1200 1600 6300800 800 1730 6301475 1475 3300 6100775 775 1975 6111050 1050 1590
6501250 1250 1650 6300825 825 1790 6301500 1500 3365 6100800 800 2050 6111100 1100 1650
6501300 1300 1700 6300850 850 1845 6301525 1525 3420 6100825 825 2125 6111150 1150 1750
6501350 1350 1800 6300875 875 1900 6301550 1550 3480 6100850 850 2200 6111200 1200 1830
6501400 1400 1900 6300900 900 1960 6301575 1575 3530 6100875 875 2275 6111250 1250 1900
6501450 1450 2000 6300925 925 2020 6301600 1600 3600 6100900 900 2350 6111300 1300 1990
6501500 1500 2100 6300950 950 2080 6100925 925 2425 6111350 1350 2070
6300975 975 2140 6100950 950 2500 6111400 1400 2150
6301000 1000 2195 6100975 975 2575 6111450 1450 2230
6101000 1000 2650 6111500 1500 2300

Ceramic terminal connector „plug ’n’ heat“ Stock ID 229005 * with connection voltage 230 V wattage will decrease by 8%.

22 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
23
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
24
 Product-
Range
hottube

Coil Heater
hotspring
Tubular heater Ø 5.0 mm

Technical key features

Diameter 5.0 mm / 0.197 inch

hotslot
Diameter tolerance ± 0.1 mm / ± 3.94 mils
Sheath material Stainless Steel, Incoloy or Nickel
Max. Sheath temperature 700 °C / 1292 °F
Wattage tolerance* ± 10 %
High voltage resistance* 1.000 V AC

hotflex
in straight condition
Insulation resistance* ≥ 5 MΩ at 500 V DC
Leakage current* ≤ 0.5 mA at 253 V AC
Max. Sheath surface load 10 W/cm2 / 64.5 W/inch2, according to

hottube
application (depending on heated length)
* tested at environmental temperature

Length min. 300 mm / 11.8 inch, straight

Length max. 3.000 mm / 118.1 inch, straight

hotrod
Length tolerance ± 1.5 %
Length UBa 25 mm / 0.98 inch
Length UBb 25 mm / 0.98 inch
Length tolerance UB ± 5 mm / ± 0.197 inch
Minimum bending radius

hotform
- Stainless Steel Rmin = 6.0 mm / 0.24 inch (internal)
- Incoloy Rmin = 10.0 mm / 0.39 inch (internal)
- Nickel Rmin = 8.0 mm / 0.31 inch (internal)
Not bendable area 30 mm / 1.18 inch, on both ends

hotcast
Max. voltage 250 V, standard 230 V

ZD
Connection options** M 2.5 with set of nuts
Rmin
and washers made of
stainless steel, ceramic insulator

hotcast
** additional connection options available upon request

MH
Minimum bending radius

Available Versions
L straight

hotcontrol
Controller
L bent according to benchmark 1:1 drawing
Options
L Custom length
L Custom connection options
L Custom wattage hotcontrol
TC/RTD
Application fields
L Plastics industry
L Apparatus construction
Threaded pins M2.5 Insulated Ni-leads Flat plug
L Casting industry
Automotive

with set of nuts and washers, Glass silk: up to 230 °C / 445 °F W = 6.3 mm / 0.248 inch,
hotcontrol

L Packaging industry Temp. resist. 350 °C / 660 °F PTFE: up to 230 °C / 445 °F Temp. resist.
Silicon: up to 180 °C / 350 °F 350 °C / 660 °F
L Laboratory industry
Custom connection options

Sheath Ø 5,0 ±0,1 Ceramic insulator

Isolite

4 4
25 ±3 LUB 25 ±5 Lheated LUB 25 ±5 25 ±3
Z-System

30 30
not bendable not bendable
L

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com 04/2016+ SM
Hotset America Corp. · 713 Kite Road · Swainsboro, GA 30401 · USA · Office +1 912 289 1844 · Fax +1 866 496 4123 · usa@hotset.com
Projects

Hotset Singapore Pte Ltd · 362 Upper Paya Lebar Road · Unit 07-02 · Da Jin Factory Building · Singapore · Office +65 6777 7993 · Fax +65 6777 7656 · hspl@hotset.com
Hotset Heating Elements (Suzhou) Co. Ltd · Luzhi Innovation Park · Suzhou · China · Office +86 512 6502 6218 · Fax +86 512 6502 6238 · szsales@hotset.com
HIPL India Pvt Ltd · Toyota Kirloskar Motor Company Road · Bidadi · Karnataka · India · Office +91 99 00 266 271 · rraghavendra@hotset.com 25
Hotset GmbH (HQ) · Hueckstraße 16 · 58511 Lüdenscheid · Germany · Office +49 2351 4302-0 · Fax +49 2351 4302-25 · DEsales@hotset.com
26
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

L For heating applications:

- Packaging machines
- Extruders

hotslot
- Casting machines
- Hot melt
- Cutting knives
- Analytical equipment in laboratories
L Custom options:

hotflex
- Power distribution
- Numerous attachments and protection sleeves
- Various moisture protection options
L Special Features:
- High quality stainless steel with special alloy properties for improved

hottube
heat conductivity, thermal expansion and corrosion resistance
- Standard diameter tolerances to fit H7 bore tolerances
- The most precise diameter tolerances in the industry: up to -0.02 -0.04 mm available
- Various VDE certified versions
- Certified according to UL and CSA standards on request

hotrod
- Protection class IP67 available on request
General Technical Key Features
Sheath material Stainless steel 1.4541
Heating conductor material NiCr 8020

hotform
Max. sheath temperature 750 °C / 1380 °F
Max. voltage 480 V, UL rated: 250 V
Wattage tolerance* ± 10%
Dielectric strength* 1500 V AC for > 24 V operation voltage
500 V for ≤ 24 V operation voltage

hotcast
Insulation resistance* ≥ 5 MΩ at 500 V DC

ZD
Leakage current* ≤ 0.5 mA at 253 V AC
Length tolerance ± 1.5%, min ± 1 mm
Standard diameter tolerance for metric sizes: -0.02 -0.06 mm
Standard diameter tolerance for imperial sizes: ± 0.79 mil [± 0.02 mm]

hotcast
MH
*tested at environmental temperature

Application Fields

hotcontrol
Controller
hotcontrol
TC/RTD

Plastic injection molding Hot runner systems Packaging industry Packaging industry
Automotive
hotcontrol

Internal heating of nozzles Heating of manifolds Heating of sealing bars Heating of hot stamps
Isolite
Z-System

Textile industry Paper industry Laboratories

Heating of cutting knives Heating of embossing rollers Heating of analytical equipment,
for example, mass spectrometer
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 27
1
 hotrod®
Cartridge Heaters

Performance Range Options

n
io
h] 2 2 °F
]
le ut
nc 2
ch C/ up ts ri b
ce /i m /c
m [° ] en st n
an m /c /in W ted p [V co Di re tio
pe le
r [m . W W . e m U o h m r tu tec es
s
Ty o . L
a x
ax
. x
a L r a
x.
T
ax
.
er m
ta
c
w
e i s
o ro pr
Ø -T ax m m m U a m h At o M P x
Ø m m T P E
-0.02 mm
4 -0.06 mm 350 / 13.8 20 129 n/a 275/527 250 no limited no
-0.02 mm
-0.06 mm 1500 / 59 65* 419* 57*
6.0 limited
± 0.1 mm 3000 / 118 10 65 10
-0.02 mm
-0.06 mm 1500 / 59 65* 419* 57*
6.5 limited
± 0.1 mm 3000 / 118 10 65 10
-0.02 mm
24 h
-0.06 mm 1500 / 59 65* 419* 57*
8
± 0.1 mm 3000 /118 10 65 10
-0.02 mm
IP67
-0.06 mm 1500 / 59 65* 419* 57* 750/ yes
10 480
± 0.1 mm 3000 / 118 10 65 10 1380
-0.02 mm
-0.06 mm 1500 / 59 65* 419* 57*
12.5 yes
± 0.1 mm 3000 / 118 10 65 10
-0.02 mm
-0.06 mm 1500 / 59 65* 419* 57*
16 48 h
± 0.1 mm 3000 / 118 10 65 10
-0.02 mm
HHP -0.06 mm 1500 / 59 65* 419* 57* yes
20
± 0.1 mm 3000 / 118 10 65 10
limited
1/8“ ± 1.97 mil 150 20 700 250 no no no

± 0.79 mil 1500 / 59 65* 419* 57*

1/4“ limited
± 3.94 mil 3000 / 118 10 65 10
24 h
± 0.79 mil 1500 / 59 65* 419* 57*
3/8“ yes
± 3.94 mil 3000 / 118 10 65 10
IP67
± 0.79 mil 1500 / 59 65* 419* 57*
1/2“ yes
± 3.94 mil 3000 / 118 10 65 10
± 0.79 mil 1500 / 59 65* 419* 57*
5/8“ no 48 h
± 3.94 mil 3000 / 118 10 65 10 750/
± 0.79 mil 1500 65* 419* 57* 1380
3/4“ yes limited limited
± 0.394 mil 3000 10 65 10 480
6.5 ± 0.1 mm 3000 / 118
8 ± 0.1 mm 3000 / 118
10 ± 0.1 mm 3000 / 118
LHT
12.5 ± 0.1 mm 3000 / 118
16 ± 0.1 mm 3000 / 118 10 65 10 no limited no limited no
20 ± 0.1 mm 3000 / 118
LHT
6.5 ± 0.2 mm 3000 / 118
bendable 700/
LHT 1292
8 ± 0.2 mm 3000 / 118
bendable

*Surface load > 10 W/cm2฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀฀ ฀ ฀ 2

฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀

Formula for calculating the surface load Wattage [ W ]

W/cm2 =
Circumference [cm] x heated length [cm]

28 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
2
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

hotrod® HHP/G
Casting Cartridge Heater

hotslot
L Optimal temperature of the material in the goose neck
L Removal stud
L With angle block, tube section and metal sleeving

hotflex
Specifications
Sheath material Stainless steel 1.4541
Heating conductor material NiCr 8020
Diameter mm 6.5 / 8.0 / 10.0 / 12.5 / 16.0 / 20.0

hottube
Max. length 1500 mm / 59 inch
Max. sheath temperature 750 °C / 1380 °F
Max. voltage 480 V, UL rated: 250 V
Wattage tolerance* ± 10%
High voltage test* 1500 V AC for > 24 V operation voltage

hotrod
500 V for ≤ 24 V operation voltage
Insulation resistance* ≥ 5 MΩ at 500 V DC
Leakage current* ≤ 0.5 mA at 253 V AC
Length tolerance ± 1.5%, min ± 1 mm
Standard diameter tolerance for metric sizes: -0.02 -0.06 mm

hotform
NØ
Standard diameter tolerance for imperial sizes: ± 0.79 mil [± 0.02 mm] stud
*tested at environmental temperature

L
Options

hotcast
L Wattage distribution

ZD
Heating of the goose neck NØ = Nominal diameter
L Thermocouple type K L = Length

L Various connection options

L Certified according to UL and CSA standards

hotcast
MH
hotcontrol
Controller
Stock Range HHP/G
Connection Voltage: 230V, GLS Lead, 1500 mm
Diameter Length Connection Wattage Voltage Goose neck /
Stock ID [mm] [mm] Length [mm] [W] [V] Nozzle type
hotcontrol
TC/RTD
9906100 10.0 80 1500 250 230 Nozzle DAW 5
9906101 12.5 60 1500 200 230 DAW 5
9906104 12.5 90 1500 350 230 Nozzle DAW 20
9906103 16.0 80 1500 315 230 DAW 10/20
9906106 16.0 100 1500 500 230 DAW 40-125
Automotive
hotcontrol

9906113 16.0 100 1500 600 230 DAW 40-125

9906105 16.0 160 1500 630 230 Nozzle DAW 40-50
9906110 20.0 100 1500 630 230 DAW 160-200
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 29
3
 hotrod®
Cartridge Heaters

hotrod® HHP Ø 4 mm
High Power Cartridge Heater

Specific key features

UBb UBa
Max. sheath temperature 275 °C / 527 °F
Max. voltage 250 V
Max. sheath surface load 20 W/cm2 / 129 W/inch2 Ø
Max. Length 350 mm / 13.8 inch
UBa Length 13 mm / 0.512 inch
UBb Length 6 mm / 0.236 inch
Dialectric strength
UB = Length of the unheated zone
For supply voltage ≥ 24V: 800 V AC
< 24V: 500 V AC
Max. current 1.6 A
Length tolerance ± 2.5%, min. ± 1.5 mm / 0.059 inch
Connection type Type 5a

Options
L Power distribution
L Thermocouple, ungrounded
type J or K (IEC / ANSI color codes),
measuring point at bottom, up to 80 mm heater length
L Diameter tolerances up to -0.02 -0.04 mm

hotrod® HHP Ø 6.0 – 20 mm

High Power Cartridge Heater

Specific key features

For metric sizes: UBb UBa
Max. length / Ø-tolerance 1500 mm
Ø-tolerance -0.02 mm -0.06 mm
Ø
3000 mm
Ø-tolerance ± 0.1 mm
For imperial sizes:
Max. length / Ø-tolerance 59 inch UB = Length of unheated Zone
Ø-tolerance ± 0.79 mil
118 inch Express Service
Ø-tolerance ± 3.94 mil
Order by 10:00 a.m CET / CEST, following hotrod are ready
Length tolerance ± 1.5%, min. ± 1.0 mm / 0.039 inch for shipping from HQ Germany within:
UBa Length 4 to 20 mm / 0.157 to 0.787 inch L 24 hours: Ø 6.5 mm to 10.0 mm Ø 1/4 inch to 3/8 inch
UBb Length 4 to 9 mm / 0.157 to 0.354 inch L 48 hours: Ø 12.5 mm to 20.0 mm Ø 1/2 inch to 5/8 inch
L Max. order quantity: 20 pcs.
L Max. length: 1,000 mm / 39 inch

Options Available Connection types

L Certified according to UL and CSA standards L Max. lead length mounted externally: 2.000 mm
L Wattage distribution L Max. lead length mounted internally: 1.500 mm
L Thermocouple, grounded or ungrounded L With PTFE-disc: requires 48 hours
type J or K (IEC / ANSI color codes) L With ceramic sealing: requires 48 hours
measuring point at the bottom or in the middle
L Ground lead Options not available
L Moisture protection up to IP67 L Epoxy or silicone sealing
L Various connection options L Multicore silicone cables
L Various attachments L Thermocouples grounded
L Diameter tolerances up to -0.02 -0.04 mm

30 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
4
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

hotrod® LHT

hotslot
Low Power Cartridge Heater

L For lower surface loads with max. 10 W/cm2

L Cost effective heating with a long lifespan

hotflex
Specific key features
Diameter 6.5 / 8.0 / 10.0 /
12.5 / 16.0 / 20.0
Max. sheath temperature 750 °C / 1380 °F

hottube
Max. sheath surface load 10 W/cm2 / 64 W/inch2
Max. length 3000 mm / 118 inch
Length tolerance ± 1.5%, min. ± 1.5 mm / 0.059 inch

Options

hotrod
L Moisture protection UBb UBa
L Various connection options
L In case of extra low voltage, current return Ø
via the cartridge sheath is possible
L No high voltage test and no insulation resistance in case of

hotform
current return via the cartridge sheath (only extra low voltage)
L Connection leads attached to each end
of the cartridge possible UB = Length of unheated Zone
L Certified according to UL and CSA standards

hotcast
ZD
hotrod® LHT bendable
Low Power Cartridge Heater

hotcast
MH
Specific key features
Diameter 6.5 or 8.0
Sheath material nickel or stainless steel
Max. sheath temperature 700 °C / 1292 °F

hotcontrol
Controller
Max. sheath surface load 10 W/cm2 / 64 W/inch2
Max. length 3000 mm / 118 inch
Length tolerance ± 1.5%, min. ± 1.5 mm / 0.059 inch
Diameter tolerance ± 0.2 mm / 0.008 inch
Connection glass silk insulated Ni-leads
hotcontrol
TC/RTD
mounted externally
Min. bending radius 15 mm / 0.59 inch (internal)
No high voltage test and no insulation resistance in case
of current return via the cartridge sheath (only extra low voltage).
Automotive
hotcontrol

Options
L Moisture protection
L Various connection options
L Certified according to UL and CSA standards
Ø

Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 31
5
 hotrod®
Cartridge Heaters

hotrod® LHT Knife Cartridge

Low Power Cartridge Heater

L Cutting knife for textiles and foils

Specific key features

Diameter 4.9 mm / 0.193 inch
5.0 mm / 0.197 inch
5.3 mm / 0.209 inch
6.5 mm / 0.256 inch
Sheath material Incoloy
Max. sheath temperature 950 °C / 1742 °F
Max. sheath surface load 15 W/cm2 / 96 W/inch2
Diameter tolerance ± 0.1 mm / 0.059 inch
Max. connection voltage 24 V, with current return via sheath
Connection options connection pin
Cutting knife wear-resistant hard metal alloy,
pre-formed, ungrinded

L2
Min. bending radius 12.5 mm / 0.049 inch (internal)

Options
L Manufactured straight or bent

b
R min. 12,5
Ø

L1 32,5 min. 15
a

M = Cutting knife
a, b, L1, L2 = Variable length
R = Inner bending radius
All dimensions in mm

32 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

Connection with leads mounted externally

hotslot
hotflex
Type 1 Type 2 Option Type 3 (for all) Type 3a
Leads mounted externally, Ceramic head, Tube section 40 mm instead Ring sleeve, silicone leads,
max. 230 °C / 446 °F any leads, of ring sleeve, e.g. with large sealed with silicone, moisture
siliconized lead, 180 °C / 356 °F see ”Connection leads“ lead cross sections (25 mm protected, max. 180 °C / 356 °F,

hottube
tube section on request) UL rated: max. 150 °C / 302 °F

hotrod
Type 3b Type 3c Type 6
Ring sleeve, PTFE leads, sealed Ring sleeve, GLS leads, cera- Multi core silicone cable with tube section 40 mm,

hotform
with epoxy resin, moisture pro- mic sealing, sealed with silicone, moisture protected
tected, max. 250 °C / 482 °F max. 320 °C / 608 °F Max. 180 °C / 356 °F, UL rated max. 150 °C / 302 °F
UL rated: max. 130° C / 266 °F

Connection with leads mounted internally

hotcast
ZD
hotcast
MH
Type 4 Type 5a Type 5b Type 5c
Any Leads, PTFE disc*, PTFE leads, PTFE disc*, siliconized internal Silicone disc, silicone leads,
with ceramic closure, moisture protected, structure, IP67 up to max. 180 °C / 356 °F

hotcontrol
Controller
max. 320 °C / 608 °F max. 260 °C / 500 °F 40 W/cm2 / 258 W/inch2, UL rated: max. 150 °C / 355 °F
UL rated: max 150 °C / 302 °F max. 350 °C / 662 °F at sheath,
260 °C / 500 °F at leads,
UL rated: max 180 °C / 355 °F
hotcontrol
TC/RTD
* PTFE disc can extend length by 1.5 mm.

Connection Leads
Glass silk insulated Ni-leads max. Temp: 320 °C / 608 °F
Automotive
hotcontrol

Silicone Ni-leads max. Temp: 180 °C / 356 °F UL rated: max. 150 °C / 302 °F
PTFE insulated Ni-leads (multi-stranded) max. Temp: 260 °C / 500 °F UL rated: max. 180 °C / 356 °F
High temperature resistant glass silk insulated Ni-leads max. Temp: 600 °C / 1112 °F
Bare, beaded leads (breakage risk) max. Temp: 600 °C / 1112 °F
Sleeves
Isolite

(Examples) (Examples)
Standard ≥ Ø 8 mm
Flexible metal: Standard ≥ Ø 6.5 mm
Option: ≥ Ø 10 mm Stainless steel: Standard ≥ Ø 10 mm, 3/8 inch
Z-System

≥ 3/8 inch

Special: Ø 6.5 mm Flexible metal: Option ≥ Ø 10 mm, 3/8 inch

Stainless steel: Option ≥ Ø 12.5 mm

GLS sleeving Flexible metal sleeving

Braided metal sleeving Stainless steel sleeving, moisture proof
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 33
7
 hotrod®
Cartridge Heaters

Right Angle Attachments*

C ØB
B

A
A

ØC
ØB

Angular block Bent pipe Right angle exit

Ø hotrod ØB A/C Ø hotrod A B Ø hotrod A B C
6.5 7.5 10.0 6.5 15.15 15.15 8.0 10.0 7.5 7.5
8.0 9.0 10.0 8.0 19.1 15.0 10.0 11.0 9.0 9.0
10.0 11.0 14.0 10.0 22.6 19.0 12.5 13.0 12.0 11.0
12.5 11.0 14.0 12.5 26.1 22.0 16.0 16.0 15.0 14.0
16.0 14.0 18.0 16.0 34.1 29.0 20.0 18.0 19.5 18.0
20.0 18.0 25.0 20.0 39.6 35.0 3/8“ 11.0 9.0 9.0
1/4“ 7.5 10.0 1/4“ 15.15 15.15 1/2“ 13.0 12.0 11.0
3/8“ 11.0 14.0 3/8“ 22.6 19.0 5/8“ 16.0 15.0 14.0
1/2“ 11.0 14.0 1/2“ 26.1 22.0 3/4“ 18.0 18.5 18.0
5/8“ 14.0 18.0 5/8“ 34.1 29.0
3/4“ 18.0 25.0 3/4“ 39.0 35.0

Flange and Threaded Nipple Attachments*

A
C D D B
C
C

B B
A A

Threaded nipple Threaded nipple with removal aid Flange

Ø hotrod A B C Thread Ø hotrod A B C D Thread Ø hotrod A B C D
6.5 10.0 4.0 12 M10 x 1.0 6.5 10.0 4.0 2.5 12 M10 x 1.0 6.5 18.0 13.0 2.2 1.0
8.0 10.0 4.0 14 M12 x 1.0 8.0 10.0 4.0 2.5 14 M12 x 1.0 8.0 18.0 13.0 2.2 1.2
10.0 12.0 4.0 17 M14 x 1.5 10.0 12.0 4.0 2.5 17 M14 x 1.5 10.0 27.0 20.0 3.2 1.2
12.5 12.0 4.0 19 M16 x 1.5 12.5 12.0 4.0 2.5 19 M16 x 1.5 12.5 27.0 20.0 3.2 1.5
16.0 12.0 4.0 24 M20 x 1.5 16.0 12.0 4.0 2.5 24 M20 x 1.5 16.0 33.0 25.6 3.2 1.5
20.0 14.0 4.0 27 M26 x 1.5 20.0 14.0 4.0 2.5 27 M26 x 1.5 20.0 33.0 25.6 3.2 1.5
1/4“ 10.0 4.0 12 G 1/8“ 1/4“ 10.0 4.0 2.5 12 G 1/8“ 1/4“ 18.0 13.0 2.2 1.0
3/8“ 12.0 4.0 17 G 1/4“ 3/8“ 12.0 4.0 2.5 17 G 1/4“ 3/8“ 27.0 20.0 3.2 1.2
1/2“ 12.0 4.0 19 G 3/8“ 1/2“ 12.0 4.0 2.5 19 G 3/8“ 1/2“ 27.0 20.0 3.2 1.2
5/8“ 12.0 4.0 24 G 1/2“ 5/8“ 12.0 4.0 2.5 24 G 1/2“ 5/8“ 33.0 25.6 3.2 1.5

Mounting clamp Thickness: 1.5 mm

Ø hotrod A B C D
10.0 10.0 5.0 10.0 14.0 Ø A
B
12.5 12.2 5.5 7.95 14.7
16.0 12.2 6.9 10.9 17.7
20.0 12.2 5.5 12.5 20.0 C
D

* Remarks
L All attachements are mounted at the unheated zone of the heater
L Please state immersion depth with order

34 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
8
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

Stock Range

hotslot
Stock Range HHP Ø 6.5 mm, 230 V
Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple
HT5210404 40 100 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4010404 40 100 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotflex
HT4010405 40 125 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4010410 40 160 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4010411 40 175 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hottube
HT4010415 40 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4010504 50 100 H7-tolerance bore 4, GLS 1 m
HT4010510 50 160 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5210515 50 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J

hotrod
HT4010515 50 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4010517 50 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4010605 60 125 H7-tolerance bore 4, GLS 1 m

hotform
HT5210615 60 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4010615 60 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5210617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4010617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotcast
ZD
HT4010805 80 125 H7-tolerance bore 4, GLS 1 m
HT4010815 80 200 H7-tolerance bore 4, GLS 1 m
HT4010817 80 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotcast
HT4010822 80 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

MH
HT4011010 100 160 H7-tolerance bore 4, GLS 1 m
HT4011017 100 250 H7-tolerance bore 4, GLS 1 m
HT5211023 100 350 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J

hotcontrol
Controller
HT4011023 100 350 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4011316 130 220 H7-tolerance bore 4, GLS 1 m
HT4011323 130 350 H7-tolerance bore 4, GLS 1 m
hotcontrol
TC/RTD
2
For components subjected to a surface load of more than 20W / inch , it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.
Automotive
hotcontrol
Isolite
Z-System

Final part ID may be different to stock ID

Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 35
9
 hotrod®
Cartridge Heaters

Stock Range HHP Ø 8.0 mm, 230 V

Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple
HT5220404 40 100 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4020404 40 100 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020410 40 160 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020415 40 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5020415 40 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020417 40 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020505 50 125 H7-tolerance bore 4, GLS 1 m
HT4020515 50 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5220517 50 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4020517 50 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020522 50 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020605 60 125 H7-tolerance bore 4, GLS 1 m
HT4020615 60 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5220617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4020618 60 280 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020815 80 200 H7-tolerance bore 4, GLS 1 m
HT5220822 80 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4020822 80 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4020826 80 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4021015 100 200 H7-tolerance bore 4, GLS 1 m
HT4021017 100 250 H7-tolerance bore 4, GLS 1 m
HT5221022 100 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4021022 100 315 H7-tolerance bore 4, GLS 1 m
HT4021026 100 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4021317 130 250 H7-tolerance bore 4, GLS 1 m
HT4021322 130 315 H7-tolerance bore 4, GLS 1 m
HT5221326 130 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4021326 130 400 H7-tolerance bore 4, GLS 1 m
HT4021615 160 200 H7-tolerance bore 4, GLS 1 m
For components subjected to a surface load of more than 20W / inch2, it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.

Final part ID may be different to stock ID

36 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
10
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

Stock Range HHP Ø 10.0 mm, 230 V

Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple

hotslot
HT4030404 40 100 H7-tolerance bore 4, GLS 1 m
HT4030405 40 125 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5230415 40 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4030415 40 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotflex
HT4030422 40 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030504 50 100 H7-tolerance bore 4, GLS 1 m
HT4030510 50 160 H7-tolerance bore 4, GLS 1 m

hottube
HT4030515 50 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5230517 50 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4030517 50 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030526 50 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotrod
HT4030612 60 180 H7-tolerance bore 4, GLS 1 m
HT5230617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4030617 60 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030622 60 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotform
HT4030626 60 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030630 60 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030810 80 160 H7-tolerance bore 4, GLS 1 m
HT5230817 80 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J

hotcast
HT4030817 80 250 H7-tolerance bore 4, GLS 1 m

ZD
HT4030822 80 315 H7-tolerance bore 4, GLS 1 m
HT4030826 80 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4030830 80 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotcast
MH
HT4030835 80 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4031016 100 220 H7-tolerance bore 4, GLS 1 m
HT4031017 100 250 H7-tolerance bore 4, GLS 1 m
HT4031022 100 315 H7-tolerance bore 4, GLS 1 m

hotcontrol
Controller
HT5231023 100 350 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4031023 100 350 H7-tolerance bore 4, GLS 1 m
HT4031026 100 400 H7-tolerance bore 4, GLS 1 m
HT4031030 100 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m hotcontrol
HT4031035 100 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m TC/RTD

HT4031044 100 850 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

HT4031322 130 315 H7-tolerance bore 4, GLS 1 m
Automotive
hotcontrol

HT4031326 130 400 H7-tolerance bore 4, GLS 1 m

HT4031330 130 500 H7-tolerance bore 4, GLS 1 m
HT4031335 130 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4031343 130 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5231626 160 400 H7-tolerance bore 4, GLS 1 m Fe-CuNi Typ J
Isolite

HT4031626 160 400 H7-tolerance bore 4, GLS 1 m

HT5231635 160 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4031635 160 630 H7-tolerance bore 4, GLS 1 m
Z-System

HT4032026 200 400 H7-tolerance bore 4, GLS 1 m

HT4032035 200 630 H7-tolerance bore 4, GLS 1 m
2
For components subjected to a surface load of more than 20W / inch , it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.

Final part ID may be different to stock ID

Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 37
11
 hotrod®
Cartridge Heaters

Stock Range HHP Ø 12.5 mm, 230 V

Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple
HT4050417 40 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4050426 40 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4050615 60 200 H7-tolerance bore 4, GLS 1 m
HT4050622 60 315 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4050817 80 250 H7-tolerance bore 4, GLS 1 m
HT4050822 80 315 H7-tolerance bore 4, GLS 1 m
HT4050830 80 500 H7-tolerance bore 4, GLS 1 m
HT4050835 80 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4050843 80 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4051026 100 400 H7-tolerance bore 4, GLS 1 m
HT5251030 100 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4051030 100 500 H7-tolerance bore 4, GLS 1 m
HT4051035 100 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4051043 100 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4051326 130 400 H7-tolerance bore 4, GLS 1 m
HT4051330 130 500 H7-tolerance bore 4, GLS 1 m
HT4051335 130 630 H7-tolerance bore 4, GLS 1 m
HT4051343 130 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4051352 130 1250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4051630 160 500 H7-tolerance bore 4, GLS 1 m
HT4051635 160 630 H7-tolerance bore 4, GLS 1 m
HT4051643 160 800 H7-tolerance bore 4, GLS 1 m
HT4051836 180 670 H7-tolerance bore 4, GLS 1 m
HT4051850 180 1000 H7-tolerance bore 4, GLS 1 m
HT4052035 200 630 H7-tolerance bore 4, GLS 1 m
HT4052043 200 800 H7-tolerance bore 4, GLS 1 m
HT4052047 200 900 H7-tolerance bore 4, GLS 1 m
HT4052543 250 800 H7-tolerance bore 4, GLS 1 m
HT4052547 250 900 H7-tolerance bore 4, GLS 1 m
For components subjected to a surface load of more than 20W / inch2, it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.

Final part ID may be different to stock ID

38 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
12
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

Stock Range HHP Ø 16.0 mm, 230 V

Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple

hotslot
HT4060417 40 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4060615 60 200 H7-tolerance bore 4, GLS 1 m
HT4060622 60 315 H7-tolerance bore 4, GLS 1 m

hotflex
HT4060626 60 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4060826 80 400 H7-tolerance bore 4, GLS 1 m
HT4060830 80 500 H7-tolerance bore 4, GLS 1 m
HT4060835 80 630 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hottube
HT4060843 80 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4061026 100 400 H7-tolerance bore 4, GLS 1 m
HT4061030 100 500 H7-tolerance bore 4, GLS 1 m

hotrod
HT4061035 100 630 H7-tolerance bore 4, GLS 1 m
HT4061043 100 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4061050 100 1000 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4061330 130 500 H7-tolerance bore 4, GLS 1 m

hotform
HT4061335 130 630 H7-tolerance bore 4, GLS 1 m
HT4061343 130 800 H7-tolerance bore 4, GLS 1 m
HT4061347 130 1000 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotcast
HT4061635 160 630 H7-tolerance bore 4, GLS 1 m

ZD
HT4061643 160 800 H7-tolerance bore 4, GLS 1 m
HT4061650 160 1000 H7-tolerance bore 4, GLS 1 m
HT4061652 160 1250 H7-tolerance bore 4, GLS 1 m

hotcast
MH
HT4061852 180 1250 H7-tolerance bore 4, GLS 1 m
HT4062030 200 500 H7-tolerance bore 4, GLS 1 m
HT4062043 200 800 H7-tolerance bore 4, GLS 1 m

hotcontrol
Controller
HT4062050 200 1000 H7-tolerance bore 4, GLS 1 m
HT4062052 200 1250 H7-tolerance bore 4, GLS 1 m
HT4062061 200 2000 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4062550 250 1000 H7-tolerance bore 4, GLS 1 m hotcontrol
HT4062552 250 1250 H7-tolerance bore 4, GLS 1 m TC/RTD

HT4062555 250 1600 H7-tolerance bore 4, GLS 1 m

HT4063050 300 1000 H7-tolerance bore 4, GLS 1 m
Automotive
hotcontrol

HT4063052 300 1250 H7-tolerance bore 4, GLS 1 m

HT4063054 300 1500 H7-tolerance bore 4, GLS 1 m
HT4063056 300 1800 H7-tolerance bore 4, GLS 1 m
For components subjected to a surface load of more than 20W / inch2, it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.
Isolite
Z-System

Final part ID may be different to stock ID

Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 39
13
 hotrod®
Cartridge Heaters

Stock Range HHP Ø 20.0 mm, 230 V

Stock ID Length [mm] Wattage [W] Tool Preparation Connection Type Thermocouple
HT4070622 60 315 H7-tolerance bore 4, GLS 1 m
HT4070843 80 800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4071050 100 1000 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4071643 160 800 H7-tolerance bore 4, GLS 1 m
HT4071650 160 1000 H7-tolerance bore 4, GLS 1 m
HT4071656 160 1800 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Measuring point
HT4072050 200 1000 H7-tolerance bore 4, GLS 1 m on the ground
HT4072055 200 1600 H7-tolerance bore 4, GLS 1 m
HT4072552 250 1250 H7-tolerance bore 4, GLS 1 m
HT4072561 250 2000 H7-tolerance bore 4, GLS 1 m
HT4073055 300 1600 H7-tolerance bore 4, GLS 1 m
HT4073062 300 2200 H7-tolerance bore 4, GLS 1 m
For components subjected to a surface load of more than 20W / inch2, it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.

Final part ID may be different to stock ID

40 09/2017 SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
14
 Product-
Range
hotrod®

Coil Heater
hotspring
Cartridge Heaters

Stock Range HHP Ø 1/4“ (Ø 6.3 mm), 230 V

Stock ID Length [inch] Wattage [W] Tool Preparation Connection Type Thermocouple

hotslot
HT4110305 1 1/2 125 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5310311 1 1/2 175 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4110311 1 1/2 175 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4110315 1 1/2 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotflex
HT4110505 2 125 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5310515 2 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4110515 2 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hottube
HT5310617 2 1/2 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4110617 2 1/2 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT5310721 3 300 Press fit (DIN EN ISO 286-1) 4, GLS 1 m Fe-CuNi Typ J
HT4111023 4 350 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotrod
Stock Range HHP Ø 3/8“ (Ø 9.46 mm), 230 V

Stock ID Length [inch] Wattage [W] Tool Preparation Connection Type Thermocouple
HT4130315 1 1/2 200 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotform
HT4130317 1 1/2 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4130517 2 250 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4130726 3 400 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4131030 4 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m

hotcast
ZD
HT4131230 5 500 H7-tolerance bore 4, GLS 1 m
HT4131530 6 500 H7-tolerance bore 4, GLS 1 m

Stock Range HHP Ø 1/2“ (Ø 12.61 mm), 230 V

hotcast
MH
Stock ID Length [inch] Wattage [W] Tool Preparation Connection Type Thermocouple
HT4150630 2 1/2 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4150726 3 400 H7-tolerance bore 4, GLS 1 m

hotcontrol
Controller
HT4150730 3 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4151030 4 500 H7-tolerance bore 4, GLS 1 m
HT4151040 4 750 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
HT4151230 5 500 H7-tolerance bore 4, GLS 1 m
hotcontrol
HT4151240 5 750 H7-tolerance bore 4, GLS 1 m TC/RTD
HT4151530 6 500 H7-tolerance bore 4, GLS 1 m
HT4151540 6 750 H7-tolerance bore 4, GLS 1 m
HT4151550 6 1000 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
Automotive
hotcontrol

HT4152050 8 1000 H7-tolerance bore 4, GLS 1 m

HT4152554 10 1500 H7-tolerance bore 4, GLS 1 m
HT4153054 12 1500 H7-tolerance bore 4, GLS 1 m
Isolite

Stock Range HHP Ø 5/8“ (Ø 15.81 mm), 230 V

Stock ID Length [inch] Wattage [W] Tool Preparation Connection Type Thermocouple
HT4160730 3 500 Press fit (DIN EN ISO 286-1) 4, GLS 1 m
Z-System

HT4161550 6 1000 H7-tolerance bore 4, GLS 1 m

For components subjected to a surface load of more than 20W / inch2, it is necessary to use a press fit, which can be achieved by individual adjustment of the cartridge.

Final part ID may be different to stock ID

Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 09/2017 SM 41
15
42
 Product-
Range
hotform®

Coil Heater
hotspring
Silicon Heating Elements

L Used to heat hydraulic cylinders in machinery for the packaging and textile industry
L Can be used for cabinet heating
L Flat or cylindrical shapes possible

hotslot
L Can be built into small spaces
L Can be cut to individual requirements for asymmetric surfaces
L Resistant against chemicals
L Age proof and resistant against atmospheric corrosion
Safe in a food environment

hotflex
L
Technical Features
Power Density see table
Thickness of Material 1.5… 5 mm
Max. Heated Area 2.5 m2

hottube
Bending Radius 50 mm
Wattage Tolerance ± 10%
Connection Silicon, flat vulcanized Connection Options
Temperature Resistance -60 … +200 °C / -76 … +392 °F L Single insulated connection wires
max. 300 °C / 572 °F short-term L Double insulated connection wires

hotrod
Heat Conductivity at + 100°C ca. 15 x 10-4 W L Single insulated double leads
Dielectric Strength 12 KV/mm cm x K L Connection leads with/without
Standards VDE 0700 Part 1, DIN EN 60335 mechanical protection
Options L Connection leads with a looped protective
L Operating Voltage up to 750 V conductor for metalwork

hotform
L Smaller Bending Radius L Flat plugs
L UL Approval L With strain relief and bend protection
Types of Fastening Connecting Parts Mounting Surface Temp. Range Installation Notes
Vulcanite Aluminium, stainless Any -60 … +200 °C Factory connection

hotcast
steel, steel, metal -76 … +392 °F

ZD
Equipped with Metal, composite Flat, cylindrical 0 … +150 °C Clean and degrease adhesive surface. Stick
Self-Adhesive ceramic, glass, 32 … +302 °F on with light pressure and ensure there are
wood no air bubbles. Ready for immediate use.
Silicon Cold-Vulcanite Metal, composite Any -60 … +180 °C Clean and degrease adhesive surface. Prime

hotcast
MH
ceramic -76 … +356 °F if applicable. Coat both sides with adhesive.
Apply ensuring there are no air bubbles. Cure
for 24 hrs with pressure at room temperature.
Press using Any Flat -60 … +200 °C Place hotform between the functional part

hotcontrol
Controller
pressure plates -76 … +392 °F and pressure plates. Alternatively, vulcanize.
Stretch using tension Any Cylindrical -60 … +200 °C Easy installation and quick to change.
springs or laces -76 … +392 °F

Power Density and Surface Temperature

hotcontrol
Power Density Surface Power Density Surface TC/RTD
Power Density [°C ]
260
Surface Temperature [W/cm2] [W/cm2] temp [°C/°F] [W/cm2] temp [°C/°F]
240 0,90 0.050 40 / 104 0.750 238 / 460
0,80 0.075 60 / 140
220 0.800 247 / 477
0,70 Temperature limit
0.100 70 / 158 0.850 253 / 487
Automotive

200
hotcontrol

0,60 for Silicon Heating

180 0,50 Elements 0.125 80 / 176 0.900 259 / 498
160 0,40 0.150 90 / 194 0.950 265 / 509
140 0,30
120 0,25
0.200 105 / 221 1.000 270 / 518
100 0,20 0.250 121 / 250 1.100 280 / 536
0,15
80 0.300 135 / 275 1.200 290 / 554
0,10
0.350 150 / 302 1.300 300 / 572
Isolite

60
0,05
40 Radiation 0.400 164 / 327 1.400 310 / 590
at the flexible
20
heating element 0.450 176 / 349 1.500 320 / 608
1 2 3 4 5 6 7 Minutes 0.500 188 / 370 1.600 330 / 626
0.550 200 / 392 1.700 340 / 644
Z-System

Flat hotform element, 0.600 210 / 410 1.800 350 / 662

horizontal test position, environmental temperature 20 °C / 68 °F
0.650 220 / 428 1.900 360 / 680
0.700 230 / 446 2.000 370 / 698

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com 02/2012+ DV
Hotset America Corp. · 713 Kite Road · Swainsboro, GA 30401 · USA · Office +1 912 289 1844 · Fax +1 866 496 4123 · usa@hotset.com
Projects

Hotset Singapore Pte Ltd · 362 Upper Paya Lebar Road · Unit 07-02 · Da Jin Factory Building · Singapore · Office +65 6777 7993 · Fax +65 6777 7656 · hspl@hotset.com
Hotset Heating Elements (Suzhou) Co. Ltd · Luzhi Innovation Park · Suzhou · China · Office +86 512 6502 6218 · Fax +86 512 6502 6238 · szsales@hotset.com
HIPL India Pvt Ltd · Toyota Kirloskar Motor Company Road · Bidadi · Karnataka · India · Office +91 99 00 266 271 · rraghavendra@hotset.com 43
Hotset GmbH (HQ) · Hueckstraße 16 · 58511 Lüdenscheid · Germany · Office +49 2351 4302-0 · Fax +49 2351 4302-25 · DEsales@hotset.com
44
 Product-
Range
hotcast Sprue Nozzle

Coil Heater
hotspring
ZD 50/80 and ZD 125 for zinc die-casting application

L Improves cycle time and part quality

L Reduces porosity and eliminates costly sprue cone
L Decreases tool costs

hotslot
L Traditional cold plug designs can be replaced
by the hotcast sprue nozzle
L Improved mold design options
L Reduced scrap after electro-plating process
L Continous heating from goose neck to the mold

hotflex
L Integrates into 50 t, 80 t and 125 t die-casting machines

hottube
hotrod
Advantages
L Up to 40% reduced cycle time
L Up to 30% less shot weight
L Up to 7% more part weight due to

hotform
higher microstructure density

hotcast
Technical key features

ZD
Standard connection voltage 230 V Nozzle with insulation ring Classic and optimized sprue
Temperature sensor type K (NiCr-Ni), internal
Max temp. insulation ring 800 °C / 1470 °F (short term)
500 °C / 930 °F (long term)

hotcast
MH
Pressure resistance
insulation ring 330 N/mm2
Heater hotspring classic, brass
Insulation resistance* ≥ 5 MOhm at 500 V DC

hotcontrol
Controller
High voltage test* min. 800 V AC
Leakage current* ≤ 0.5 mA at 253 V AC
Connection lead PTFE insulated, CU nickel
with stainless steel sleeving
Max. lead temperature 260 °C / 500 °F
hotcontrol
TC/RTD
* tested at environmental temperature Mounted nozzle Pin configuration
1: Sensor - 2: Sensor +
3: Heater L 4: Heater N

Performance Range Stock Range

Automotive
hotcontrol

ZD 50/80 ZD 125 Stock-ID Description

Machine pressure 50 / 80 t 125 t 5660000 ZD 50/80 with insulation ring
Power 1000 W ±10% 1250 W ± 10% 5660000R ZD 50/80 with insulation ring
Connection lead length 1500 mm 3000 mm and hotcontrol c448*
5660001 ZD 125 with insulation ring
Isolite

Options 5660001R ZD 125 with insulation ring

L Compatible hotcast Sealed Heater (GMH) and hotcontrol c448*
L hotrod die-casting cartridge heaters (HHP/G) * Thermocouple input suitable for type K
L Temperature control unit hotcontrol C448
Z-System

L hotcast Set sprue nozzle + control unit

L hotcast Set sprue nozzle, GMH, HHP/G, control unit
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 04/2016+ SM 45
 hotcast Sprue Nozzle
ZD 50/80 and ZD 125 for zinc die-casting application

Section A-A
L
1 x 45° chamber-bevel if required

Centering ring and other

A
fixing parts touching this
surface shall not generate
any thermal bridge.
d3 H7
d2

d4

d1

Thermal strain of sprue nozzle A

dL = approx. 0.46 mm at 500 °C / 930 °F

Mold-parting
surface
ZD 50/80 ZD 125
F Length L 73.5 95.0
Gap G
d1 [mm] 70.0 96.0
min. Insulation
Gap d2 [mm] 43.2 54.0
d3 [mm] 30.0 42.0
Remarks
L Observe minimum inner bending radius: 4 mm / 0.16 inch. d4 [mm] 39.2 52.0
L Do not bend the unheated areas back and forth. F 0.7 to 1.5 1.5 to 2.0
L Do not bend the heater within 5 mm from the connection head. G 0.7 to 1.5 1.5 to 2.0
L The connection head of the hotspring must not be used
as a handle / lever
Installation instruction

ZD 50/80 ZD 125
L1 62.0 78.5
X
d8 L2 73.5 95.0
L3 8.0 12.5
L3
L4 16.0 18.0
d4

d1 70.0 96.0
d3 30.0 42.0
90°

m6

d4 39.2 52.0
90°
Ø d6

d5
d7

d3

d5 22.0 34.4
d6 16.3 24.4
d7 10.3 15.4
X L4
d1 L1 d8 3.3 3.3
L2

General tolerance due to ISO 2768-m

46 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
47
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
48
 Product-
Range
hotcast®Die-Casting Nozzle Heater

Coil Heater
hotspring
GMH - Sealed Nozzle Heater

L Heated machine nozzle with integrated hotspring maxi coiled heater

L Completely sealed system
L Power distribution for equal heat distribution

hotslot
L Deep immersion into the cavity, extra long
L Small outer diameter
L Long lifespan
L High energy savings in comparison to gas heating

hotflex
Technical Key Features
Heating element hotspring Maxi
Max. heating element temperature 750 °C / 1380 °F
Max. connection area temperature 260 °C / 500 °F

hottube
Voltage 230 V standard
Wattage tolerance* ± 10 % glass silk insulated
High voltage test* 1250 V AC nickel lead

Insulation resistance* ≥ 5 M at 500 V DC

stainless steel sleeving
Leakage current* ≤ 0.5 mA at 253 V AC

hotrod
Standard connection lead glass silk insulated, nickel,

max. 140
approx. Ø 15
multistranded, with ground wire

AØ
and stainless steel sleeving,

KØ
L = 1500 mm / 59 inch

hotform
Thermocouple integrated, Type K (NiCr-Ni)
*tested at environmental temperature heated length
L
K Ø = inner diameter L = length
A Ø = outer diameter all measurements in mm

hotcast
Options

ZD
L Insulation tube for energy saving
L Surface treatment of the flow path for GMH Sealed
Nozzle Heater
flow velocity > 50 m/s / 164 ft/s
L Various connection types available

hotcast
(moisture protection required)

MH
L Nozzle tip heated/unheated
L Easy removal nut

hotcontrol
Controller
Nozzle tip

heating system of a hotcast GMH sealed heater

hotcontrol
TC/RTD
Automotive
hotcontrol
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 10/2012+ DV 49
1
 hotcast®Die-Casting Nozzle Heater
GMH - Sealed Nozzle Heater

Stock Range
Inner Ø Outer Ø Length Heated Length Wattage Voltage
Stock ID Type [mm] [mm] [mm] [mm] [W] [V]
5630133 GMH 5 7.0 42.0 149 81 550 230
5630139 GMH 20 9.5 42.0 178 110 700 230
5640165 GMH 50 11.0 55.2 257 167 1300 230
5640154 GMH 80 11.0 55.2 286 196 1500 230
5650258 GMH 125 18.0 62.2 330 240 1800 230
5650365 GMH 200 18.0 77.2 422 302 2600 400
5630135 GMH 5-T 7.0 42.0 169 101 750 230
5630144 GMH 20-T 9.5 42.0 208 140 900 230
5630254 GMH 80-T 11.0 55.2 316 226 1600 230
5630256 GMH 125-T 18.0 62.2 370 281 1900 230
5630257 GMH 200-T 18.0 77.2 462 342 2800 400
5630258 GMH 20-TT 9.5 42.0 228 160 900 230
5630260 GMH 50-TT 11.0 55.2 310 220 1600 230
5630259 GMH 80-TT 11.0 55.2 336 246 1600 230
5630261 GMH 125-TT 18.0 62.2 380 290 1900 230

50 10/2012+ DV · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
2
 Product-
Range
hotcast®Die-Casting Nozzle Heater

Coil Heater
hotspring
OMH – Open Ended Nozzle Heater

L Sheathed, flat hotspring maxi coiled heater for nozzles

L Replaces traditional block or propane heat

hotslot
L Power distribution for even temperature control
L Tight fit clamping band with end rings prevents
penetration of material from overmoulding
L Long lifespan

hotflex
Technical Key Features
Heating element hotspring Maxi
Max. heating element temperature 750 °C / 1380 °F
Max. connection area temperature 260 °C / 500 °F

hottube
Voltage 230 V standard
Wattage Tolerance* ± 10 %
High voltage test* 1250 V AC
Insulation Resistance* ≥ 5 M at 500 V DC
Leakage Current* ≤ 0. 5 mA at 253 V AC

hotrod
Standard connection leads PTFE insulated, CU nickel,
multistranded, with ground wire
and stainless steel sleeving
L = 1500 mm / 59 inch
Thermocouple integrated, Type J (Fe-CuNi)

hotform
*tested at environmental temperature

hotcast
Options

ZD
L Various connection types available
(moisture protection required)

Nozzle tip

hotcast
MH
hotcontrol
Controller
Open Ended Heaters
(type OMH)
with power distribution

hotcontrol
TC/RTD
Automotive
hotcontrol
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 10/2012+ DV 51
3
 hotcast®Die-Casting Nozzle Heater
Accessory

Heated Nozzle Tip (BMV)

L Balances the temperature drop from the

heater body to the nozzle tip
L Higher temperature in the flow path

standard nozzle tip heated nozzle tip

Heated
Nozzle Tip

GMH Sealed
Nozzle Heater

Easy Removal Nuts

hexagon nut for disassembly of the nozzle tip draw off nut for nozzle body

Easy Removal Nut Stock Range

for GMH-
Stock ID Type wrench size
252000 GMH 5/20 55
252001 GMH 50/80/120 65
252002 GMH 200 100

Insulation Tube
L Reduces heat radiation of GMH Sealed Nozzle Heater
by almost 60%
L Shorter heat up time
L Optimized flow and temperature distribution
L Outer diameter of the heater increases by
about 11 mm / 0.43 inch

Application Notes:
Insulation of the nozzle body covers the entire heated length
of the GMH, not in sections.

52 04/2016+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
53
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
54
 Product-
Range
hotcontrol

Coil Heater
hotspring
Built-In Temperature Controllers

L Single channel temperature controllers for use in:

- Hot runner applications - Ovens
- Machines for plastics processing - Food processing

hotslot
- Packaging machines - Dryers, etc.

hotcontrol c148

hotflex
Features and Functions
L PID- and two-level controller
L Manual mode
L Auto tuning
L Digital filter

hottube
L Automatic sensor break detection
L Ramp function (e. g. for start-up mode)
L Fuzzy logic

hotrod
Stock Range
Dimensions Voltage
Stock ID Type [mm] [V AC] Comment Delivery
8814800 C 148 48 x 48 x 116 90… 250 V AC

hotform
8814800H C 148 48 x 48 x 116 90… 250 V AC SSR D 2425
264004 D 2425 240 V, 16 A SSR
264012 cover plate

hotcontrol c248 / c296

hotcast
ZD
Features and Functions
L PID-, two-level and three-level controller
L Manual mode
L Auto tuning

hotcast
MH
L Automatic sensor break detection
L Ramp function and automatic ramp function
L Second set point can be combined (absolute/relative)
L Four timers (e. g. for start-up mode)

hotcontrol
Controller
L Digital outputs for control heating/cooling or alarm to be configured
L Monitoring of actual value, sensor, heat current and the actuator in the heat circuit c248
L Remote operation – handle several controllers concurrently
L Overall functions of controller such as automatic ramp through networking by CAN-bus
L Digital data interfaces RS485 and CAN-bus
hotcontrol
TC/RTD
L Engineering tool WinKonVis: configuration and parameter settings through
RS485 and/or CAN-bus
L Operating hour counter
L Update of firmware by RS485 possible
Automotive
hotcontrol

Stock Range c296

Dimensions Voltage
Stock ID Type [mm] [V AC] Comment Delivery
Isolite

8804800 C 248 48 x 48 x 120 85 … 264 V AC incl. RS 485, MODBUS

8804801 C 248 48 x 48 x 120 24 V AC DC incl. RS 485, MODBUS
8804800H C 248 48 x 48 x 120 85 … 264 V AC incl. RS 485, MODBUS incl. SSR D 2425
8804801H C 248 48 x 48 x 120 24 V AC DC incl. RS 485, MODBUS incl. SSR D 2425
Z-System

8809600H C 296 48 x 96 x 120 85 … 264 V AC incl. RS 485, MODBUS incl. SSR D 2425
8809600 C 296 48 x 96 x 120 85 … 264 V AC incl. RS 485, MODBUS
264004 D 2425 240 V, 16 A SSR
264012 cover plate
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 07/2014+ SM 55
1
 hotcontrol
Built-In Temperature Controllers

Technical Data hotcontrol c148 hotcontrol c248 hotcontrol c296

Number of regions 1 1 1
Nominal voltage 90 … 250 V AC, 47 … 63 Hz 85 … 240 V AC
Input 12 VA, 5 W max. 150 mA
Display 2 x four digit 7-Segment-LED
Control membrane keypad
Status Display 3 x LED 5 x LED 8 x LED
Dimension (H x W x D) [mm] 48 x 48 x 116 48 x 48 x 94 96 x 48 x 94
Mounting front mounting
Casing plastic
Weight [kg] 0.15 0.2 0.25
Operating temperature -10 … 50 °C 0 … 55 °C
Connections integrated clamps
Protection mode Front: IP65, Front: IP54
indoor use only Casing, Connectors: IP20
Addressing - via configuration parameters
Data Back up - EEPROM
Data interfaces hotcontrol c148 hotcontrol c248 hotcontrol c296
RS 485 – Modbus, 1200 … 19200 Baud
CAN – Canopen (CiA 401 V 2.01) up to 1 Mbps
Measuring input temp. hotcontrol c148 hotcontrol c248 hotcontrol c296
Number 1 1 3
Resolution 18 bit 14 bit
Sample rate 5 Hz
Type Thermocouple type J, K, L or Pt100 in 2- oder 3-conduction connection
Range Typ J/L: -120 … 1000 °C Typ J/L: 0 … 850 °C
Typ K: -200 … 1370 °C Typ K: -50 … 1200 °C
Pt 100: -210 … 700 °C Pt 100: -50 … 700 °C
Reference junction internal
Input resistance 2.2 MΩ (Pt 100: 1.3 KΩ) > 47 kΩ
Measuring accuracy ± 2K (Pt 100: ± 0.4 K) <1K
Monitoring sensor break, sensor break, reversed polarity
sensor short circuit (Pt100 only) sensor short circuit (Pt100 only)
Heat current meas. inputs hotcontrol c148 hotcontrol c248 hotcontrol c296
Number – 1, single phase, via converter
Signal – 42 mV/A
Resolution 14 bit
Digital input hotcontrol c148 hotcontrol c248 hotcontrol c296
Number – 1 2
Specification – externall potential-free contact 0 … 30 V DC, < 10 mA at 24 V DC
Function configurable
Digital output hotcontrol c148 hotcontrol c248 hotcontrol c296
Number 1 2 4
Type pulsed voltage to drive SSR 1 electr. switch contact, 1 relay output
Specification 14 V DC, max. 40 mA 12 V, 100 mA; 250 V, 2 A
Function relay output relay output, alarm output

56 07/2014+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
2
 Product-
Range
hotcontrol

Coil Heater
hotspring
Desktop Temperature Controller

hotcontrol c448
Features and Functions

hotslot
L Desktop control device for 1 or 2 control areas
L Micro processor operating controller c248 inside
L Start-up and boost mode
L Alarm output or machine release by potential free contact

hotflex
Options
L Stand-by mode
L Heat current monitoring

hottube
L Measuring point 0 to 60 A
L Resolution 1/10 A, tolerance 1% of full scale value
L Interfaces CANbus and RS485

hotrod
hotform
hotcast
ZD
Stock range
Dimensions Voltage
Stock ID Type [mm] [V AC] Comment Delivery

hotcast
8844810 C 448/1 FeCuNi 1 1 x 16 A 90 … 264 V AC, 50-60 Hz

MH
8844810G C 448/1 FeCuNi 1 1 x 16 A 90 … 264 V AC, 50-60 Hz incl. connector kit
8844820 C 448/2 FeCuNi 2 2 x 16 A 90 … 264 V AC, 50-60 Hz
8844820G C 448/2 FeCuNi 2 2 x 16 A 90 … 264 V AC, 50-60 Hz incl. connector kit
9600000 connector kit

hotcontrol
Controller
hotcontrol
TC/RTD
Automotive
hotcontrol
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 07/2014+ SM 57
3
 hotcontrol
Desktop Temperature Controller

Technical Data hotcontrol c448/1 hotcontrol c448/2

Number of control units inside 1 2
Nominal voltage 90 … 264 V AC ± 10%, 50 ... 60 Hz, 1P / N / PE
Standard power connection 3 m power connection cable
Display 2 x four digits 7-Segment LED 4 x four digits 7-Segment LED
Control membrane
Status Display 5 x LED 2 Displays, each 5 x LED
Dimension (H x W x D) [mm] 105 x 110 x 230
Casing aluminium, silver anodized
Weight [kg] app. 2 kg
Operating temperature 0 … 55 °C
Addressing via configuration parameters
Data Back up EEPROM
Optional Data interfaces hotcontrol c448/1 hotcontrol c448/2
RS 485 Modbus, 1200 … 19200 Baud
CAN Canopen (CiA 401 V 2.01) bis 1 Mbps
Measuring input temperature hotcontrol c448/1 hotcontrol c448/2
Number 1 2
Resultion 14 bit
Sample rate 5 Hz
Type Thermocouple type J
Range 0 … 500 °C, switchable to °F
Reference junction internal
Input resistance > 47 kΩ
Measuring accuracy <1K
Monitoring sensor break, reversed polarity sensor short circuit (Pt100 only)
Heat current measuring inputs hotcontrol c448/1 hotcontrol c448/2
Number 1, single phase via converter 2, single phase via converter
Signal 42 mV/A
Resolution 14 bit
Digital input hotcontrol c448/1 hotcontrol c448/2
Number 1 2
Specification external potential-free contact, 0 … 30 V DC, < 10 mA at 24 V DC
Function configurable
Digital output hotcontrol c448/1 hotcontrol c448/2
Number 2 4
Type 1 x relay 2 x relay
Specification 250 V AC, 2 A, resistive load
Function Collective alarm message for: temp. threshold, sensor failure, reversed polarity, heat
current tolerance alarm, short circuit of power output
Power Outputs hotcontrol c448/1 hotcontrol c448/2
Output power 90 … 264 V AC / max. 3.6 kW, switch with SSR 25 A
Protection ultra rapid fuse FF 16 A, 6.3 x 32 mm
Tool connection 10-pole Wieland conncetor 2 x 10-pole Wieland conncetor

58 07/2014+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
4
 Product-
Range
hotcontrol

Coil Heater
hotspring
Multi Channel Temperature Controllers

hotcontrol cDT-Range
L Up to 30 control areas in the „desktop“ edition

hotslot
L Multilingual
L Reports from monitoring functions
and suggested troubleshooting measures
L Statistic analysis

hotflex
L Data input/output over USB

Features and Functions

L Clear text information in LCD display
L Per control area: 2 LED displays, 4 status/alarm LEDs, area selection key

hottube
L Display fade efect for unselected area (shaded LED displays)
L Storage option for 10 set point value settings
L Grouping of areas and storage
L User administration with password protection
L Online help

hotrod
L Mold check
L Mold stat (QA)
L Heat’n’Dry
L Leakage Detection

hotform
L Data storage on USB stick
L Area on/off, control mode/manual mode, standby/boost/time controlled boost,
start up mode, leading area mode and more
L PID control algorithm DynControl
L Auto tuning

hotcast
L Heating output with impulse group mode/phase angle

ZD
L Safety shutdown of heating output

hotcast
Options

MH
L Temperature measuring input for PT100
L Country specific plug
L Smaller CEE plugs depending on model and available power supply connection

hotcontrol
Controller
hotcontrol
TC/RTD
Automotive
hotcontrol
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 07/2014+ SM 59
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 hotcontrol
Multi Channel Temperature Controllers

Technical Data hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Number of Regions 6 12 18 24
Nominal Voltage 400 V AC, ± 10%, 3P/N/PE, 50… 60 Hz
Power Supply CEE 16 A CEE 32 A CEE 63 A CEE 63 A
Max. Power Output 11 kW 22 kW 43 kW 43 kW
Status Display 2 x 3-point 7 segment LED
Control membrane keypad with 6 soft keys
Status Display of each Zone 4 Alarm LEDs
Dimensions (H x W x D) 190 x 400 x 500 230 x 400 x 500 370 x 400 x 500 500 x 400 x 500
Weight 15 20 25 30
Operating temperature 0 … 55°C
Casing Steel ST37, 1.5 mm
Protection IP41
Sensor Input hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Number 6 12 18 24
Resolution 0.1°C / 0.1 °F
Type Thermocouple type J, L, K (Pt100 optional)
Range 0 … 500 °C (type J and L), 0 … 900 °C (type K)
Monitoring temperature, heat current, fuse failure, sensor brake, reversed polarity, sensor short circuit
Power Outputs hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Number 6 12 18 24
Type ultra-rapid fuse 230 V to 16 A (3680 Watt), individually switchable
Connections hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Heater/Sensor 24-pole Wieland
In/Output 9-pole D-Sub
Machine/Alarm potential free relay contact 250 V DC 1A (4-pole HTS), Wieland 3-pin outlet and PE
Digital Input hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Number 4, 24 V DC (optional 8 for tool coding)
Digital Output hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
Number 3, 24 V DC (500 mA)
Interfaces hotcontrol cDT 06 hotcontrol cDT 12 hotcontrol cDT 18 hotcontrol cDT 24
RS 485 9-pin D-Sub
CAN 9-pin D-Sub
Ethernet RJ 45 socket

60
4
07/2014+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
61
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
62
 Product-
Range
hotcontrol

Coil Heater
hotspring
Thermocouples – RTDs

General information for all thermocouples and RTDs

hotslot
L All dimensions are subject to general tolerances according to DIN 2768-m. Our tolerances in most cases exceed DIN 2768-m
standards. Exact tolerances for your item are available on request.
L All thermocouples can be produced with ANSI color code. Other standards are available on request.
L All dimensions for mineral insulated thermocouples are subject to tolerances according to EN 61515.

Mineral Insulated Thermocouples

hotflex
Technical key features Options
Lead cross-section 0.22 mm2 L Measuring point grounded
Minimum bending radius 5.0 x sheath diameter or ungrounded
Classification tolerance Class 1 or 2 (DIN 60584) (grounded just possible

hottube
Standard, Special (ANSI 96.1) for MIT < 3.0 mm)
L Bend protection spring
Performance Range
Dia- Number
meter Connection Lead of thermo-

hotrod
[mm] Types head [mm] Options couples
0.5 J, K, L Ø 6 x 30 GLS/GLS/MB 1x
0.75 J, K, L Ø 6 x 30 GLS/GLS/MB 1x
1.0 J, K, L Ø 3.2 x 23 Kapton/Kapton 1x

hotform
GLS/Kapton
GLS/GLS Lead Types
1.0 J, K, L Ø 4 x 22 any 1x
Lead Types Max. Temperature
1.5 J, K, L Ø 3.2 x 23 Kapton/Kapton 1 x
GLS/Kapton PFA/PFA 260 °C 500 °F

hotcast
GLS/GLS GLS/GLS (MB*) 400 °C 750 °F

ZD
1.5 J, K, L Ø 4 x 22 any 1x Kapton/Kapton 350 °C 600 °F
2.0 J, K, L Ø 4 x 22 any 1x GLS/Kapton 350 °C 600 °F
2.0 J, K, L Ø 6 x 30 GLS/GLS/MB 2x PFA/Kapton 260 °C 500 °F

hotcast
PFA/PFA PFA/PFA/MB 260 °C 500 °F

MH
3.0 J, K, L Ø 6 x 30 any 1 x or 2 x Material information from the inside to the outside.
4.5 J, K, L Ø 6 x 30 any 1 x or 2 x Duplex MIT available with MB/GLS/GLS and PFA/PFA.
* Glass silk insulated leads with glass silk insulated casing
6.0 J, K, L Ø 8 x 50 GLS/GLS/MB 1 x or 2 x and metal braided protection sleeve.

hotcontrol
Controller
Thermocouple Type Specifications
Type Material Standard Lead Colors [+/-] Sheath Material Measurement Range
J Fe-CuNi IEC 60584 black/white 1.4541/AISI 321 -40 to +750 °C -40 to 1380 °F
L* Fe-CuNi DIN 43710* red/blue 1.4541 -40 to +750 °C -40 to 1380 °F hotcontrol
TC/RTD
K NiCr-Ni IEC 60584 green/white 2.4816/Alloy 600 -40 to +1100 °C -40 to 2010 °F
K* NiCr-Ni DIN 43710* red/green 2.4816 -40 to +1100 °C -40 to 2010 °F
J Fe-CuNi ANSI MC 96.1 white/red 1.4541 -40 to +750 °C -40 to 1380 °F
Automotive

K NiCr-Ni ANSI MC 96.1 yellow/red 2.4816 -40 to +1100 °C -40 to 2010 °F

hotcontrol

* Obsolete standard, usually for existing installations. Other materials on request.

Connection Type Range

Isolite
Z-System

BLANK LEAD LEMO Standard Mini

Open ends Connection head LEMO connector (female) male/female connector, male/female connector,
(260 or 400 °C / 500 max. 250 °C / 480 °F max. 200 °C / 390 °F max. 200 °C / 390 °F
Projects

or 750 °F) and cable

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2017+ SM 63
1
 hotcontrol
Thermocouples – RTDs

Mineral Insulated Thermocouples

Stock range
All with bend protection spring, lead length 2000 mm, measuring point ungrounded, Connection type LEAD
Dimensions Connection head (260 °C / 500 °F)
Stock ID Type [mm] [mm] Lead Type
8512090 J Ø 1.0 x 90 Ø 4 x 22 GLS/GLS MB
8512091 L Ø 1.0 x 90 Ø 4 x 22 GLS/GLS MB
8512150 J Ø 1.0 x 150 Ø 4 x 22 GLS/GLS MB
8512151 L Ø 1.0 x 150 Ø 4 x 22 GLS/GLS MB
8501090 J Ø 1.5 x 90 Ø 4 x 22 GLS/GLS MB
8501091 L Ø 1.5 x 90 Ø 4 x 22 GLS/GLS MB
8501150 L Ø 1.5 x 150 Ø 4 x 22 GLS/GLS MB
8501151 J Ø 1.5 x 150 Ø 4 x 22 GLS/GLS MB
8501240 J Ø 1.5 x 240 Ø 4 x 22 GLS/GLS MB
8501241 L Ø 1.5 x 240 Ø 4 x 22 GLS/GLS MB
8511091 K Ø 1.5 x 90 Ø 4 x 22 GLS/GLS MB
8511150 K Ø 1.5 x 150 Ø 4 x 22 GLS/GLS MB

64 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
2
 Product-
Range
hotcontrol

Coil Heater
hotspring
Thermocouples – RTDs

Mineral Insulated RTDs

hotslot
Technical key features
Lead cross-section 0.22 mm2
Minimum bending radius 5.0 x sheath diameter
Classification tolerance Class A or B

hotflex
Wire circuit 2-wire-circuit: class B
3- and 4-wire-circuit: class A or B

Options

hottube
L Bend protection spring

hotrod
Performance Range Lead Types
Diameter Connection Lead Number Max.
[mm] Types head [mm] Options of RTDs Lead Types Temperature
2.0 PFA/PFA 260 °C 500 °F

hotform
3.0 Pt 100 Ø 6 x 30 GLS/GLS (MB*) 400 °C 750 °F
any 1x
4.5 Pt 1000 Silicone/Silicone 180 °C 355 °F
6.0 Ø 8 x 50 Material information from the inside to the outside.
* Glass silk insulated leads with glass silk insulated casing
and metal braided protection sleeve.

hotcast
ZD
hotcast
Type Specifications

MH
Type Material Standard Lead Colors [+/-] Sheath Material Measurement Range
Pt 100 Platinum DIN EN 60751 red/white 1.4404 -50 to +600 °C -50 to 1120 °F
Pt 1000 Platinum DIN EN 60751 red/white 1.4404 -50 to +600 °C -50 to 1120 °F

hotcontrol
Controller
Other materials on request.

hotcontrol
TC/RTD
Automotive
hotcontrol

Connection Type Range

Isolite
Z-System

BLANK LEAD LEMO Standard Mini

Open ends Connection head LEMO connector (female) male/female connector male/female connector
(260 or 400 °C / 500 max. 250 °C / 480 °F max. 200 °C / 390 °F max. 200 °C / 390 °F
or 750 °F) and cable
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2017+ SM 65
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 hotcontrol
Thermocouples – RTDs

Compression Fittings for Mineral Insulated Thermocouples and RTDs

PTFE Clamping ring Stainless Steel Clamping ring
max 200 °C / 390 °F max. 500 °C / 930 °F
max pressure 10 bar max. pressure 40 bar
removable not removable after tightening

Stock Range
Applicable for Clamping ring Screw
Stock ID sheath diameter [mm] material thread
8531010 1.0 PTFE M8 x 1
8531015 1.5 PTFE M8 x 1
8531020 2.0 PTFE M8 x 1
8531030 3.0 PTFE M8 x 1
8531045 4.5 PTFE G 1/4 inch
8531060 6.0 PTFE G 1/4 inch
8532010 1.0 Stainless steel M8 x 1
8532015 1.5 Stainless steel M8 x 1
8532020 2.0 Stainless steel M8 x 1
8532030 3.0 Stainless steel M8 x 1
8532045 4.5 Stainless steel G 1/4 inch
8532060 6.0 Stainless steel G 1/4 inch

Male and female connectors (single part)

Available on request:
L Standard/Mini connectors for single or duplex thermocouples (J, K), 200 °C / 390 °F
L High temperature male/female connectors, 350 °C / 660 °F
L Ceramic male/female connectors, 425 °C / 795 °F
L Standard/Mini connectors for RTDs (2, 3, 4-wire-circuit), 200 °C / 390 °F
L LEMO according to customer request

66 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
4
 Product-
Range
hotcontrol

Coil Heater
hotspring
Thermocouples – RTDs

Angle RTD PWF 1

hotslot
Technical key features
Temperature range 0 to 350 °C / 32 to 660 °F
Sensor structure Ermeto-fitting M10x1, rectangular exit,
bend protection spring,

hotflex
immersion depth 10 to 35 mm / 0.39 to 1.38 inch
Sensor type Pt 100 with 2-wire-circuit
Lead structure GLS/GLS/MB
Lead cross-section 0.22 mm2

hottube
Measuring point at bottom
Classification tolerance Class B

Stock range
Lead length 2000 mm

hotrod
Stock ID type standard dimension [mm] leads
8700203 Pt 100 DIN EN 60751 Ø 6,0 x 60 red/white

hotform
Insert Surface Thermocouple TEF 2
Insert Surface RTD PWF 2
Technical key features TEF 2 PWF 2
Temperature range 0 to 400 °C / 32 to 750 °F 0 to 400 °C / 32 to 750 °F

hotcast
ZD
Diameter 3, 3.5, 4, 5, 6 mm 3, 3.5, 4, 5, 6 mm
Length max. 500 mm max. 500 mm
Sensor type type J, K, L Pt 100 with 2-, 3-
or 4-wire-circuit*

hotcast
Lead options GLS/GLS, GLS/GLS/MB*, GLS/GLS, GLS/GLS/MB*,

MH
PFA/PFA PFA/PFA, silicone/silicone*
Lead cross-section 0.22 mm2 0.22 mm2
8 Ø5
Measuring point at bottom, at bottom
grounded or ungrounded

hotcontrol
3.5

Controller
Classification tolerance Class 2 (DIN), Standard (ANSI) Class A or B, B is standard 11
Material also available in ANSI. * Depending on diameter of the tube.
15

Stock range hotcontrol

Lead length 2000 mm, GLS/GLS, with GLS sleeving, TEF: Measuring point grounded, PWF: 2-wire-circuit TC/RTD

Stock ID Type Standard Dimension [mm] Leads Mounting plate

8600200 L Fe-CuNi DIN 43710 Ø 3.5 x 30 red/blue
Automotive
hotcontrol

8600210 J Fe-CuNi IEC 60584 Ø 3.5 x 30 black/white

8600201 L Fe-CuNi DIN 43710 Ø 3.5 x 30 red/blue yes
8600211 J Fe-CuNi IEC 60584 Ø 3.5 x 30 black/white yes
8600202 L Fe-CuNi DIN 43710 Ø 3.5 x 40 red/blue yes
8600212 J Fe-CuNi IEC 60584 Ø 3.5 x 40 black/white yes
Isolite

8600203 L Fe-CuNi DIN 43710 Ø 3.5 x 40 red/blue

8600213 J Fe-CuNi IEC 60584 Ø 3.5 x 40 black/white
8600204 K NiCr-Ni DIN 43710 Ø 3.5 x 30 red/green
8600214 K NiCr-Ni IEC 60584 Ø 3.5 x 30 green/white
8600207 K NiCr-Ni DIN 43710 Ø 3.5 x 30 red/green yes
Z-System

8600217 K NiCr-Ni IEC 60584 Ø 3.5 x 30 green/white yes

8700200 Pt 100 DIN EN 60751 Ø 3.5 x 30 red/white
8700201 Pt 100 DIN EN 60751 Ø 3.5 x 30 red/white yes
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2017+ SM 67
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 hotcontrol
Thermocouples – RTDs

Thermocouple with Bayonet Cap TEF 4

RTD with Bayonet Cap PWF 4
Technical key features TEF 4 PWF 4
Temperature range 0 to 400 °C / 32 to 750 °F 0 to 400 °C / 32 to 750 °F
Sensor structure bayonet cap Ø i = 14.2 mm, bayonet cap Ø i = 14.2 mm,
compression spring compression spring
200 mm / 7.87 inch 200 mm / 7.87 inch
immersion depth 25 to 200 mm / immersion depth 25 to 200 mm /
0.98 to 7.87 inch 0.98 to 7.87 inch
Sensor type type J, K, L Pt 100 2-, 3- or 4-wire-circuit
Lead structure GLS/GLS/MB GLS/GLS/MB
Lead cross-section 0.22 mm2 0.22 mm2
Measuring point bottom, grounded/ungrounded bottom
Classification tolerance Class 2 (DIN), Standard (ANSI) Class A or B, B is standard
Material also available in ANSI.

Stock range
Lead length 2000 mm, TEF: Measuring point grounded, PWF: 3-wire-circuit

Stock ID type standard dimension [mm] leads

8600400 L Fe-CuNi DIN 43710 Ø 8.0 x 12 118° red/blue
8600401 J Fe-CuNi IEC 60584 Ø 8.0 x 12 118° black/white
8700205 Pt 100 DIN EN 60751 Ø 8.0 x 10.5 118° red/red/white

Thermocouple with Bayonet Cap TEF 16

RTD with Bayonet Cap PWF 16
Technical key features TEF 16 PWF 16
Temperature range 0 to 400 °C / 32 to 750 °F 0 to 400 °C / 32 to 750 °F
Sensor structure bayonet cap Ø i = 12.2 mm, bayonet cap Ø i = 12.2 mm,
compression spring compression spring
200 mm / 7.87 inch 200 mm / 7.87 inch
immersion depth 25 to 200 mm / immersion depth 25 to 200 mm /
0.98 to 7.87 inch 0.98 to 7.87 inch
Sensor type type J, K, L Pt 100 2-, 3- or 4-wire-circuit
Lead structure GLS/GLS/MB GLS/GLS/MB
Lead cross-section 0.22 mm2 0.22 m2
Measuring point bottom, grounded/ungrounded bottom
Classification tolerance Class 2 (DIN), Standard (ANSI) Class A or B, B is standard
Material also available in ANSI.

Stock range
Lead length 2000 mm, TEF: Measuring point grounded, PWF: 2-wire-circuit

Stock ID type standard dimension [mm] leads

8601600 L Fe-CuNi DIN 43710 Ø 8.0 x 12 118° red/blue
8601601 J Fe-CuNi IEC 60584 Ø 8.0 x 12 118° black/white
8700209 Pt 100 DIN EN 60751 Ø 8.0 x 12 118° red/white
8701216 K NiCr-Ni DIN 43710 Ø 8.0 x 12 118° red/green
8701233 K NiCr-Ni IEC 60584 Ø 8.0 x 12 118° green/white

68 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 Product-
Range
hotcontrol

Coil Heater
hotspring
Thermocouples – RTDs

Thermocouple with Bayonet Cap TEF 20

RTD with Bayonet Cap PWF 20

hotslot
Technical key features TEF 20 PWF 20
Temperature range 0 to 400 °C / 32 to 750 °F 0 to 400 °C / 32 to 750 °F
Sensor structure bayonet cap Ø i = 12.2 mm, bayonet cap Ø i = 12.2 mm,
comp. spring 200 mm / 7.87 inch comp. spring 200 mm / 7.87 inch

hotflex
immersion depth 25 to 200 mm / immersion depth 25 to 200 mm /
0.98 to 7.87 inch 0.98 to 7.87 inch
Sensor type type J, K, L Pt 100 2-, 3- or 4-wire-circuit
Lead structure GLS/GLS/MB GLS/GLS/MB

hottube
Lead cross-section 0.22 mm2 0.22 mm2
Measuring point bottom, grounded/ungrounded bottom
Classification tolerance Class 2 (DIN), Standard (ANSI) Class A or B, B is standard
Material also available in ANSI.

hotrod
Stock range
Lead length 2000 mm, TEF: Measuring point grounded , PWF: 2-wire-circuit
Sensor cylinder
Stock ID type standard upper part lower part leads
8602000 L Fe-CuNi DIN 43710 Ø 5.0 x 19 mm Ø 4.0 x 6.0 mm red/blue

hotform
8602001 J Fe-CuNi IEC 60584 Ø 5.0 x 19 mm Ø 4.0 x 6.0 mm black/white
8700207 Pt 100 DIN EN 60751 Ø 5.0 x 19 mm Ø 4.0 x 6.0 mm red/white

hotcast
ZD
Screw-in Adaptors
for Thermocouples and RTDs with Bayonet Cap

hotcast
MH
Stock range
TEF PWF TEF PWF TEF PWF Screw Thread Bayonet Total Outside
Stock ID 4 4 16 16 20 20 Thread Length Cap Length Hexagon
8700400 x x R 3/8 inch 10 mm 14 mm 30 mm x

hotcontrol
Controller
8700401 x x R 1/4 inch 10 mm 14 mm 30 mm x
8700402 x x M14 x 1,5 10 mm 14 mm 30 mm x
8700410 x x M12 x 1 8 mm 14 mm 40 mm
8700404 x x x x M12 x 1 10 mm 12 mm 25 mm
hotcontrol
8700408 x x x x M12 x 1 10 mm 12 mm 40 mm TC/RTD
8700411 x x x x M12 x 1 10 mm 12 mm 60 mm
Automotive
hotcontrol
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2017+ SM 69
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 hotcontrol
Thermocouples – RTDs

Angle Thermocouple TEF 12

Technical key features

Temperature range 0 to 400 °C / 32 to 750 °F
Sensor structure semicircular probe with screw-in fitting M8 x 1,
bend protection spring
immersion depth 10 to 15 mm / 0.39 to 0.59 inch
Sensor type type J, K, L
Lead structure GLS/GLS/MB
Lead cross-section 0.22 mm2
Measuring point at bottom, grounded or ungrounded
Classification tolerance Class 2 (DIN), Standard (ANSI)
Material also available in ANSI.

Stock range
Lead length 2000 mm, Measuring point grounded

Stock ID type standard dimension [mm] leads

8601200 L Fe-CuNi DIN 43710 Ø 6.0 x 10 red/blue
8601201 J Fe-CuNi IEC 60584 Ø 6.0 x 10 black/white

Ring Thermocouple TEF 13

Technical key features

Temperature range 350 °C / 660 °F
Sensor structure washer Ø 14 mm with bore hole M4, GLS sleeve
Sensor type type J, K, L
Lead structure GLS/GLS/MB
Lead cross-section 0.22 mm2
Measuring point at washer, grounded
Classification tolerance Class 2 (DIN), Standard (ANSI)
Material also available in ANSI.

Stock range
Lead length 2000 mm, Measuring point grounded, ferrules uninsulated

Stock ID type standard dimension [mm] leads

8601300 L Fe-CuNi DIN 43710 14 x 10 red/blue
8601301 J Fe-CuNi IEC 60584 14 x 10 black/white
8701213 K NiCr-Ni DIN 43710 14 x 10 red/green
8701232 K NiCr-Ni IEC 60584 14 x 10 green/white

70 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
8
 Product-
Range
hotcontrol

Coil Heater
hotspring
Thermocouples – RTDs

Surface Thermocouple TEF A

hotslot
Technical key features
Temperature range 0 to 400 °C / 32 to 750 °F
Sensor structure 15 x 30 x 0.5 mm, bent Ø 100 mm ±5 mm,,
bend protection spring

hotflex
Sensor type type J, L
Lead structure GLS/GLS/MB
Lead cross-section 0.22 mm2
Measuring point at bottom, grounded or ungrounded
Classification tolerance Class 2 (DIN), Standard (ANSI)

hottube
Material also available in ANSI.

Stock range
Lead length 2000 mm, Measuring point grounded

hotrod
Stock ID type standard dimension [mm] leads
8608815 L Fe-CuNi DIN 43710 Ø 6.0 x 40 red/blue
8608816 J Fe-CuNi IEC 60584 Ø 6.0 x 40 black/white

hotform
hotcast
ZD
Clamping Band Thermocouple TEF SP

hotcast
MH
Technical key features
Temperature range 0 to 350 °C / 32 to 660 °F
Sensor structure with clamping band, width 9 mm, bend protection spring

hotcontrol
Controller
Sensor type type J, L
Lead structure GLS/GLS/MB
Lead cross-section 0.22 mm2
Measuring point grounded or ungrounded
Classification tolerance Class 2 (DIN), Standard (ANSI)
hotcontrol
Material also available in ANSI. TC/RTD

Stock range
Lead length 2000 mm, Measuring point grounded
Automotive
hotcontrol

Stock ID type standard Clamping range [mm] leads

8609925 L Fe-CuNi DIN 43710 25 to 40 red/blue
8609926 J Fe-CuNi IEC 60584 25 to 40 black/white
8609940 L Fe-CuNi DIN 43710 40 to 60 red/blue
8609941 J Fe-CuNi IEC 60584 40 to 60 black/white
Isolite
Z-System
Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 03/2017+ SM 71
9
 hotcontrol
Thermocouples – RTDs

Flange Mounted Thermocouple TEF 68

Technical key features
Temperature range 0 to 400 °C / 32 to 750 °F
Diameter 4 mm
Length 12, 20, 35, 80 mm
Sensor structure tip: conical (standard for grounded)
and round (standard for ungrounded) are possible,
mounting probe 90° to the block 8 x 8 mm, bend protection spring
Sensor type type J, K, L
Lead structure GLS/GLS/MB
Ø 4.5
Lead cross-section 0.22 mm2

4
Measuring point at bottom, grounded or ungrounded

8
Classification tolerance Class 2 (DIN), Standard (ANSI)

4
Material also available in ANSI. 7

20

Stock range
Lead length 2000 mm, Measuring point ungrounded
Sensor
Stock ID type standard dimension [mm] leads
red/blue
8606800 L Fe-CuNi DIN 43710 Ø 4.0 x 12
8606801 J Fe-CuNi IEC 60584 Ø 4.0 x 12 black/white
8701223 K NiCr-Ni DIN 43710 Ø 4.0 x 12 red/green
8701234 K NiCr-Ni IEC 60584 Ø 4.0 x 12 green/white

Ring Thermocouple TEF 30

Technical key features

Temperature range 0 to 260 °C / 32 to 500 °F
Sensor structure ring
Sensor type type J, K, L
Lead structure PFA/PFA/MB
Lead cross-section 0.22 mm2
Measuring point at washer, grounded or ungrounded
Classification tolerance Class 2 (DIN), Standard (ANSI)
Material also available in ANSI.

Stock range
Lead length 1000 mm, Measuring point ungrounded, ferrules uninsulated

Stock ID type standard dimension [mm] bore hole leads

8603080 L Fe-CuNi DIN 43710 Ø 14.0 x 8.0 M4 red/blue
8603081 J Fe-CuNi IEC 60584 Ø 14.0 x 8.0 M4 black/white
8603082 J Fe-CuNi ANSI MC 96.1 Ø 14.0 x 8.0 M4 white/red

72 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
10
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
74
 Product-
Range
hotcontrol

Coil Heater
hotspring
Automotive Thermocouples – RTDs

General information for all thermocouples and RTDs

L All dimensions are subject to general tolerances according to DIN 2768-m.

hotslot
Our tolerances in most cases exceed DIN 2768-m standards. Exact tolerances for your item are available on request.
L All thermocouples can be produced with ANSI color code. Other standards are available on request.
L All dimensions for mineral insulated thermocouples are subject to tolerances according to EN 61515.

hotflex
Mineral Insulated Thermocouple
Mineral Insulated RTD
General applications
L Engine compartment

hottube
Union nut with internal thread M10x1
L Catalytic converter
L Exhaust pipe

hotrod
Sealing cone

hotform
Mineral Insulated Screw-in Thermocouple
Mineral Insulated Screw-in RTD
General applications

hotcast
ZD
L Engine compartment
Hollow bolt with nut M4x0.7
L Turbocharger
L Oil pan
L Exhaust pipe

hotcast
MH
6

8.5

hotcontrol
Controller
Options
L Bend protection spring hotcontrol
L Protection tube TC/RTD
L Support pipe
Automotive
hotcontrol

Technical key features Mineral Insulated Thermocouple Mineral Insulated RTD

Mineral Insulated Screw-in Thermocouple Mineral Insulated Screw-in RTD
Lead cross-section 0.22 mm2 0.22 mm2
Minimum bending radius 5.0 x sheath diameter 5.0 x sheath diameter
Classification tolerance Class 1 or 2 (DIN60584) Class A or B
Isolite

Wire circuit – 2-wire-circuit: class B

3- and 4-wire-circuit: class A or B
Measuring point Ungrounded or grounded –
Z-System

(grounded just possible for MIT < 3.0 mm)

Projects

Please observe operating instructions and safety information!

03/2017 SM · Errors
Pleaseand
observe operating
technical changes instructions and safety information!
reserved · www.hotset.com 75
· Errors and technical changes reserved · www.hotset.com
· 03/2017 SM
2 3
 hotcontrol
Automotive Thermocouples – RTDs

Performance Range
Dia- Number Dia- Number
meter Connection Lead of thermo- meter Connection Lead of thermo-
[mm] Types head [mm] Options couples [mm] Types head [mm] Options couples
Thermocouple Thermocouple
0.5 K Ø 6 x 30 GLS/GLS/MB 1 x 3.0 K Ø 6 x 30 any 1 x or 2 x
0.75 K Ø 6 x 30 GLS/GLS/MB 1 x 4.5 K Ø 6 x 30 any 1 x or 2 x
1.0 K Ø 3.2 x 23 Kapton/Kapton 1 x 6.0 K Ø 8 x 50 GLS/GLS/MB 1 x or 2 x
GLS/Kapton
GLS/GLS
1.0 K Ø 4 x 22 any 1x
1.5 K Ø 3.2 x 23 Kapton/Kapton 1 x Diameter Connection Lead Number
GLS/Kapton [mm] Types head [mm] Options of RTDs
GLS/GLS RTD
1.5 K Ø 4 x 22 any 1x 2.0
2.0 K Ø 4 x 22 any 1x 3.0 Pt 100 Ø 6 x 30
any 1x
2.0 K Ø 6 x 30 GLS/GLS/MB 2x 4.5 Pt 1000
PFA/PFA 6.0 Ø 8 x 50

Type Specifications
Type Material Standard Lead Colors [+/-] Sheath Material** Measurement Range
Thermocouple
K NiCr-Ni IEC 60584 green/white 2.4816/Alloy600 -40 to +1100 °C -40 to 2010 °F
K* NiCr-Ni DIN 43710* red/green 2.4816 -40 to +1100 °C -40 to 2010 °F
K NiCr-Ni ANSI MC 96.1 yellow/red 2.4816 -40 to +1100 °C -40 to 2010 °F
RTD
Pt 100 Platinum DIN EN 60751 red/white 1.4404 -50 to +600 °C -50 to 1120 °F
Pt 1000 Platinum DIN EN 60751 red/white 1.4404 -50 to +600 °C -50 to 1120 °F
* obsolete standard, usually for existing installations, ** Other materials on request

Lead Types Thermocouple Lead Types RTD

Lead Types Max. Temperature Lead Types Max. Temperature
PFA/PFA 260 °C 500 °F PFA/PFA 260 °C 500 °F
GLS/GLS (MB*) 400 °C 750 °F GLS/GLS (MB*) 400 °C 750 °F
Kapton/Kapton 350 °C 660 °F Silicone/Silicone 180 °C 356 °F
GLS/Kapton 350 °C 660 °F Material information from the inside to the outside.
* Glass silk insulated leads with glass silk insulated casing
PFA/Kapton 260 °C 500 °F and metal braided protection sleeve.
PFA/PFA/MB 260 °C 500 °F
Material information from the inside to the outside.
Duplex MIT available with MB/GLS/GLS and PFA/PFA.
* Glass silk insulated leads with glass silk insulated casing
and metal braided protection sleeve.

Connection Type Range

BLANK LEAD LEMO Standard Mini

Open ends Connection head LEMO connector (female) male/female connector male/female connector
(260 or 400 °C / 500 max. 250 °C / 480 °F max. 200 °C / 390 °F max. 200 °C / 390 °F
or 750 °F) and cable

76
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technical changes instructions and safety information!
reserved · www.hotset.com · Errors and technical changes reserved · www.hotset.com
· 03/2017 SM
6 3
 Product-
Range
hotcontrol

Coil Heater
hotspring
Automotive Thermocouples – RTDs

Wire Thermocouple
Technical key features

hotslot
Temperature range 0 to 260 °C / 32 to 500 °F
Sensor structure Insulated thermo wires
joined by welding
Sensor type Type K
Lead structure PFA/PFA
Conductor cross section 2 x 0.07 mm2

hotflex
Connection See “Connection Type Range”
on preceding pages
Classification tolerance Class 1

hottube
General applications
L Difficult accessible areas with limited space
and/or if fast response times are necessary,
e. g. engine compartment

hotrod
hotform
hotcast
ZD
Self-Adhesive Surface Thermocouple
Technical key features

hotcast
Temperature range 0 to 260 °C / 32 to 500 °F

MH
Sensor structure Insulated thermo wires
joined by welding
Sensor type Type K
Lead structure FEP/FEP, GLS/GLS

hotcontrol
Controller
and Kapton/Kapton
Conductor cross section 2 x 0.2 mm2
Connection See “Connection Type Range”
on preceding pages
Classification tolerance Class 1
hotcontrol
TC/RTD
Adhesive pad PTFE impregnated fiberglass pad,
L: 25 mm
Temperature resistance 180 °C / 255 °F
(Short time load 260 °C / 500 °F)
L
Automotive
hotcontrol

General applications
L Quick, space-saving and uncomplicated temperature
L
measurement on surfaces, e. g. on auto interior and boots
Isolite
Z-System
Projects

Please observe operating instructions and safety information!

03/2017 SM · Errors
Pleaseand
observe operating
technical changes instructions and safety information!
reserved · www.hotset.com 77
· Errors and technical changes reserved · www.hotset.com
· 03/2017 SM
4 3
 hotcontrol
Automotive Thermocouples – RTDs

Spring Thermocouple (Brake Disc)

Technical key features
Temperature range 0 to 850 °C / 32 to 1560 °F
(at the flat surface)
Diameter 8 mm
Sensor structure Spring loaded measuring point,
fixed on a flat surface
M12x1
Sensor type Type K
Lead structure PFA/PFA, Silicone/Silicone
Conductor cross section 2 x 0.22 mm²
Connection See “Connection Type Range”
on preceding pages
Measuring point At bottom, grounded
Classification tolerance Class 2

Flat surface Hollow bolt

General applications
L Temperature recording on the brake disc
or other rotating surfaces Ø

Nuts Spring

Friction Thermocouple (Brake Disc)

Technical key features
Temperature range 0 to 850 °C / 32 to 1560 °F
(at the flat surface)
Sensor structure Bent mineral insulated thermocouple,
Ø 0.5 mm, fixed on the flat surface
Sensor type Type K
Lead structure Mineral insulated thermocouple with
free ends and metal braided sleeving
Contact pressure Variably adjustable
Connection Compensation connector
or mini compensation connector
Measuring point At bottom, ungrounded
Classification tolerance Class 1

General applications Mineral insulated M3 x 8 M3 Mounting hole

L Temperature recording on the brake disc thermocouple screw nut for M5 screw

or other rotating surfaces

Flat surface

78
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Pleaseand
observe operating
technical changes instructions and safety information!
reserved · www.hotset.com · Errors and technical changes reserved · www.hotset.com
· 03/2017 SM
6 5
 Product-
Range
hotcontrol

Coil Heater
hotspring
Automotive Thermocouples – RTDs

Insert Thermocouple (Brake Disc)

Technical key features

hotslot
Temperature range 0 to 850 °C / 32 to 1560 °F
(at the flat surface)
Diameter 3 mm
Length L 3 mm
Sensor type Type K
Lead structure GLS/GLS (high temperature resistant,

hotflex
max. Temp. 600 °C / 1110 °F)
Conductor cross section 2 x 0.2 mm²
Connection See “Connection Type Range”
on preceding pages

hottube
Measuring point At bottom, grounded
Classification tolerance Class 2

General applications Flat surface

L Temperature recording in the brake disc

hotrod
(For installation into the brake disc)
Ø

hotform
L

hotcast
ZD
Terminal Strip
Technical key features

hotcast
Temperature range of

MH
the female connectors 0 to 200 °C / 32 to 390 °F
Housing material Aluminum
Number of
female connectors 4 (2 or 4 pins)

hotcontrol
Controller
8 (2 or 4 pins)
16 (2 pins)
Sensor types Thermocouples: Type J, K
RTDs: all types
Lead structure FEP/FEP, FEP/MB*/FEP,
hotcontrol
TC/RTD
PFA/PFA, PFA/MB*/PFA
Lead cross-section 0.22 mm²
Connection See “Connection Type Range”
on preceding pages
* metal braided
Automotive
hotcontrol

168
General applications
13

L Consolidates several connection leads

to reduce wiring effort and save space
45

Isolite

1 2 3 4 5 6 7 8
L (Lead)
Z-System

*** Dimensions on request ***

Projects

Please observe operating instructions and safety information!

03/2017 SM··Errors
Please observe
and operating
technical changes instructions and safety information!
reserved · www.hotset.com 79
· Errors and technical changes reserved · www.hotset.com
· 03/2017 SM
6 3
80
 Product-
Range
Isolite

Coil Heater
hotspring
High temperature lubriciant with boron nitride

L Excellent lubricant high temperature resistance up to 900 °C

L Protection against oxidation
L Electrical insulating

hotslot
L Excellent release properties in contact with molten
metals, glass and slags as well as plastics and rubber
L Aids installation and removal of cartridge heaters
L Protects hotcast sealed heaters screw nut (die-casting)
L Release agent for molten metals, glass, slag, plastics and rubber

hotflex
L For soldering and welding
L For stamping or drawing tools
L Protects screw joints in high temperature environment
L Spray or composite avaliable

hottube
L Composite for air freight and shipping suitable –
no hazardous material

Technical key features Isolite Spray

hotrod
Substance boron nitride, ethanol, power gas, auxiliaries
Packaging spray can
Package unit 1 or 12 spray cans
Content 500 ml
Safety instruction F+ extremely flammable

hotform
Xi irritand
Application spray
Temperature resistance 900 °C
Drying time approx. 3 minutes

hotcast
ZD
Technical key features Isolite Composite
Substance boron nitride, water, auxiliaries
Packaging Box
Package unit 1 piece

hotcast
Content 200 ml

MH
Safety instruction none
Application brush
Temperature resistance 900 °C

hotcontrol
Controller
Drying time approx. 10 minutes

Stock range
Content Package Description
Stock ID [ml] unit hotcontrol
9400002 500 1 or 12 spray cans TC/RTD
9400004 200 1 composite box
Automotive
hotcontrol
Isolite
Z-System

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com 05/2017 SM
Hotset America Corp. · 713 Kite Road · Swainsboro, GA 30401 · USA · Office +1 912 289 1844 · Fax +1 866 496 4123 · usa@hotset.com
Projects

Hotset Singapore Pte Ltd · 362 Upper Paya Lebar Road · Unit 07-02 · Da Jin Factory Building · Singapore · Office +65 6777 7993 · Fax +65 6777 7656 · hspl@hotset.com
Hotset Heating Elements (Suzhou) Co. Ltd · Luzhi Innovation Park · Suzhou · China · Office +86 512 6502 6218 · Fax +86 512 6502 6238 · szsales@hotset.com
HIPL India Pvt Ltd · Toyota Kirloskar Motor Company Road · Bidadi · Karnataka · India · Office +91 99 00 266 271 · rraghavendra@hotset.com 81
Hotset GmbH (HQ) · Hueckstraße 16 · 58511 Lüdenscheid · Germany · Office +49 2351 4302-0 · Fax +49 2351 4302-25 · DEsales@hotset.com
82
 new

Product-
Range
Z-System

Coil Heater
hotspring
Partial dynamic temperature control

L Partial, dynamic cavity heating

with up to 60 Kelvin/second (K/s)
L No cycle time extension

hotslot
L Cycle time savings are possible
by lowering the basic temperature of the tool
L Minimum energy costs
(with sample tool "ice scraper" Ø 100 W) conventional Z-System
L No licence costs temperature-controlled temperature-controlled

hotflex
L Easy operation and integration
into the production environment
L Trademark rights are registered

Application examples

hottube
L Weld lines
L Jetting Example from the Z-System: Preventing weld lines

L Thin-wall technology
L Partial optimization of the impression 180 60

hotrod
L Surface defects (e.g. dullness) 160 50
140 40
The Z-System is a collaborative project
120 Temperature [°C] 30
of the company Hotset Heizpatronen und Zubehör GmbH
and the Plastics Institute (KIMW) in Lüdenscheid, Germany. 100 20

hotform
80 Heating rate [K/s] 10
Your contact partner 60 0
Hotset Heizpatronen und Zubehör GmbH
40 -10
Mr. Andreas Filler
Phone: +49 173 5228001 20 -20

hotcast
E-Mail: afiller@hotset.com 0 -30

ZD
2 4 6 8 10 s
Possible project procedure Heating rate

Development of The system's

Tool modification/ Varying preliminary temperature,

hotcast
Confidentiality tool concept, energy consumption Heating and cycle times
Construction

MH
Agreement possible simulation. 0.9
Design of the heating system of the Z-System
Energy consumption in kWh

0.8
Customer KIMW hotset KIMW hotset Customer hotset
Average: 100 W
0.7
(for "ice scraper" tool)
0.6

hotcontrol
Controller
Offer for Delivery of the
Kick-Off meeting heating system/regulation ready-to-install 0.5
and engineering Z-System 0.4
Customer KIMW hotset hotset hotset 0.3

0.2
Transfer of the hotcontrol
TC/RTD
Support 0.1
tool and/or article Feasibility
for installation and
data to hotset/ analysis 0
start-up
KIMW 1:00 2:00 3:00 1:00 5:00 6:00 7:00 8:00 9:00
Time in h
Customer KIMW hotset Customer KIMW hotset
Energy requirement
Automotive
hotcontrol

Example „ice scraper“ Simulation Practice

Isolite
Z-System

Comparison of simulation and practice for example tool „ice scraper“

Projects

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com · 11/2016+ SM 83
 new
Z-System
Partial dynamic temperature control

Fluid
Tool integrated
temperature
heating
applies control

Integrated
applies in part

Z-System
Ceramic

inductor
does not apply

Steam
Water
Technical limits
Heating of closed tool possible
Very high temperatures possible - suitable for all thermoplastics
Suitable for amorphous thermoplastics
Suitable for temperature control of large area moulded parts
Suitable for 2.5D contours
Suitable for 3D contours
Suitable for high gloss surfaces
Tool and cooling
Conventional temperature control channels are sufficient
No special tool designs required
Can be retrofitted for existing tools
Economic aspects
Low system costs
Low additional costs for tools
Low energy and operating costs
Low additional costs for safety relevant measures
Short or cycle-parallel heating time
Low or no cycle time extension
Heating universally applicable for all other tools
Safety
Low safety-technical risks
Procedural applications
Partial prevention of visible weld lines
Partial flow medium (integral hinge, thin segments)
Partial micro-structures
Foam injection moulding of thermoplastics
Full-area heating
Technical performance
Maximum attainable temperature [°C] 200 160 >> 200 >> 200 >> 200
Maximum attainable temperature [°F] 392 320 >> 392 >> 392 >> 392
Heating speed [K/s] 4-7 10-15 20 20-50 25-60
Pressure [bar] 18-20 7-6 0 0 0
General conditions
Structural requirements specification generally depending on generally depending on generally
(power supply, safety devices) available performance available performance available

84 03/2017+ SM · Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com
6
 Product-
Range
Coil Heater
Projects

hotspring
L Custom Designed Heating Solutions
Analysis Conception
L Design of heated machine components
L Optimizing and design of heating systems

hotslot
for industrial applications
L Engineering and development service

hotflex
Competences
Prototype Testing Solution
L Experienced Engineering Staff
L Integration of new technology with proven componentry
L Effective distribution and control of process heat
L Performance, Reliability, Durability of final product

hottube
L Technology adaptation from other industrie applications
L Control Systems Technology

Development Process

hotrod
L Thorough understanding of customer requirement
prior to design
L commercial rating of technical options
L Engineering – Design – Fabrication
L Prototype bench test to technical specification

hotform
L System test with customer
L Production release

hotcast
References

ZD
e. g. Homogeneous Temperature Control
Temperature anomaly within a production process
caused a lack of quality. Hotset designed and
manufactured a ready to plug-in system.

hotcast
This was implemented into the conveyer system

MH
of the production device. The result was an absolute
homogeneous heat transfer to the product material.

More Examples

hotcontrol
Controller
L Water proofed sealing devices for Plain surface Heating System Surface coating carburetor
the packaging industry for homogeneous temperature control

L Medical device carburetors

L Packaging system for pallet shipping of
sensitive electric devices hotcontrol
L Heating systems for vacuum applications TC/RTD
L Packaging transform devices
L Heated sprue nozzle to reduce cycle time
within die-casting
Automotive
hotcontrol

L Surface coating gas heater

Contact
Andreas Filler, Customer Project Manager Application specific control device Infrared thermography
Isolite

Phone: +49 2351 4302-441

E-Mail: afiller@hotset.com
Z-System

Please observe operating instructions and safety information! · Errors and technical changes reserved · www.hotset.com 11/2017+ SM
Hotset America Corp. · 713 Kite Road · Swainsboro, GA 30401 · USA · Office +1 912 289 1844 · Fax +1 866 496 4123 · usa@hotset.com
Projects

Hotset Singapore Pte Ltd · 362 Upper Paya Lebar Road · Unit 07-02 · Da Jin Factory Building · Singapore · Office +65 6777 7993 · Fax +65 6777 7656 · hspl@hotset.com
Hotset Heating Elements (Suzhou) Co. Ltd · Luzhi Innovation Park · Suzhou · China · Office +86 512 6502 6218 · Fax +86 512 6502 6238 · szsales@hotset.com
Please observe
HIPL India Pvt Ltdoperating instructions
· Toyota Kirloskar Motor and safetyRoad
Company information!
· Bidadi · ·Karnataka
Errors and· technical
India · Offichanges
ce +91 99 00 266· 271
reserved · rraghavendra@hotset.com
www.hotset.com · 04/2016+ SM 85
Hotset GmbH (HQ) · Hueckstraße 16 · 58511 Lüdenscheid · Germany · Office +49 2351 4302-0 · Fax +49 2351 4302-25 · DEsales@hotset.com
86
 Projects

87
Projects Z-System Isolite hotcontrol hotcontrol hotcontrol hotcast hotcast hotform hotrod hottube hotflex hotslot hotspring Product-
Automotive TC/RTD Controller MH ZD Coil Heater Range
 04/2018 DV

www.hotset.com