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| Watts Current |
| Volume Seventeen, Fourth Quarter 1998 |
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News from Watlow, designer and manufacturer of industrial heaters, sensors and controls.
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Watlow Speeds Development of New Thermal Technologies for Life Sciences Industry
The responsibility of analyzing, diagnosing and caring for patient needs is changing at an exponential rate, but under the influence of opposing trends.
Thereis dramatic growth of the patient pool as a result of the general aging of the world's population. This, in addition to the increased longevity of that population, specifically in the United States, Japan and Europe, will continue to drive demand for better health care through improved technology. At the same time HMOs (health maintenance organizations), GPOs (group purchasing organizations) and government programs continue to drive lower costs on equipment, procedures and testing.
Theultimate consumer is also demanding more say in his/her quality of health care.
Atthe same time, U.S. regulatory agencies - primarily the FDA (Food and Drug Administration) - have begun to streamline the approval process for U.S. manufacturers to encourage more pre-market testing and new equipment releases in the United States.
Otheranticipated trends include:
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- The need for faster testing results.
- Miniaturization of equipment and tests for bedside and at-home use.
- More emphasis on prevention rather than cure such as DNA therapies and wellness programs.
- Greater usage of disposable items in patient care.
- Increased use of telemedicine and online equipment problem diagnosis.
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- Thick film heaters to provide high-performance, low-profile heating inside miniaturized equipment;
- Polymer heaters that permit light-weight, hermetically sealed heating for new equipment designs;
- FREEFLEX® miniature heated tubing that heats moving fluids while being routed around other system components;
- Series 96 and Series F4 controllers that offer precise equipment and process control with easy-to-use functions;
- Foam-in-place heaters featuring a tight contact fit and built-in insulation to ensure efficient, even heating; ideal for parts with complex geometries;
- Multicoil tubular heaters providing three-phase heating with an internal thermocouple to reduce the number of elements needed and assembly costs;
- RTDs and thermistors to provide optimum sensing flexibility and reliability for life science applications;
- PPC-2000 programmable process controllers that offer up to 48 PID control loops, 46 digital I/O, easy-to-use, fill-in-the blank PID setup, and optional touch screens for flexible control and monitoring; and
- Subassemblies and modules for a cost-effective means to reduce equipment part cost.
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QuickPrototyping for Fast Market Introduction
Fastresponse on prototypes, technical support and quotes is a requirement for an industry where emphasis is on speed for product development and market introductions. Watlow's response to this need has been to move prototyping capabilities closer to the customer, with both on-site engineering at a customer's location as well as prototyping labs located in particular geographic areas to support market need. This has allowed Watlow engineers to easily work on-site with customers, installing test units and gathering necessary data to make recommendations and improve the thermal component design.
HighComponent Reliability
Asa certified vendor to numerous OEMs in this industry, Watlow has the proven technology and track record to meet the consistent, repeatable and reliable thermal component quality necessary when diagnostic accuracy and patient lives are in the balance. Watlow products meet recognized agency approvals including UL®, C-UL, CE and VDE, and follow FDA procedures as needed.
GlobalSupport = Local Support
Inresponse to pricing pressures, some U.S. OEMs have been forced to manufacture off-shore. U.S. OEMs are also often forced to release new equipment first into European countries to overcome the delays of the FDA system and speed approvals. Manufacturers can still expect the same level of service and technical support from Watlow's 18 manufacturing facilities; sales offices; and distributorships located throughout the world.
Partneringwith Watlow Provides Greater Value
Newtechnologies from Watlow provide OEMs with an advantage to vault ahead of the competition. Along with expertise in heating and sensing, Watlow's engineering services also include custom controllers, system assemblies and integration capabilities. These provide a cost-effective means for the OEM to obtain the necessary components outside core competencies as well as to reduce the supplier base and inventory levels. Watlow keeps abreast of industry changes in technology and applies them to current product lines to help lower equipment and usage costs.
Thelife science market maintains a high interest in new technology as the answer to ever emerging opportunities. Watlow thermal solutions can provide the product differentiation required by the OEM serving this dynamic industry.
Watlowwill be showcasing many thermal solutions at PITTCON® '99 that are integral components for lab and analytical equipment. Featured product innovations for this market include: cable, cartridge and flexible heaters, cast-in heated parts, FREEFLEX heated tubing, thick film heater technology, temperature and multi-loop controllers, programmable process controllers, RTDs and other sensing devices. PITTCON® '99 is March 8-11 at the Orange County Convention Center in Orlando, Florida. Watlow can be found at booth 3677.
PITCON®is a registered trademark of The Pittsburg Conference on Analytical Chemistry and Applied Spectroscopy.
LifeScience Case Histories
Watlowis an essential supplier to the life sciences industry. Examples of product utilization in various applications include:
Analytical/Diagnostic
Highvolume blood sampling requires extremely even temperatures throughout the sampling chamber. Watlow fabricated two distributed wattage Kapton® heaters in an upper/lower plate assembly with zoning, holes and notches to accommodate hardware used in the assembly.
Environmentalchambers such as incubation and blood storage require controllers to handle process requirements. Watlow's Series 104 analog controller and the Series F4 ramping controller provide optimal temperature conditions for cell and tissue culture growth, protection against drying out, and help in avoiding possible contamination.
Watlowceramic fiber heaters are used in gas chromatography equipment as radiant heaters to provide high temperature chambers for inert gases. Gas chromatography is a method for separating the components of a solution and measuring their relative quantities.
Aminiature special heater assembly is used to accurately and consistently heat DNA samples for test research. The assembly consists of a 0.055 inch diameter heater with a thermistor attached to closely sense the sample temperature.
Manyresearch labs contain constant temperature baths used in testing. These baths utilize Watlow formed tubular and FIREBAR® heating elements, temperature controllers and thermocouples to maintain an environment needed for testing conditions. Temperatures can range from -130° F to 480° F (-90° C to 250° C).
Formedtubular heaters provide a fixed, warm environment for human cell growth in tissue growth chambers.
Etchedfoil silicone rubber heaters are bonded to black anodized plates for heating test tubes in laboratory equipment. Before the heaters are molded, two sensors are included to complete the assembly.
Watlow'sCLS204 multi-loop controller is utilized in conjunction with mini-cartridge heaters to heat an air stream in x-ray crystallography equipment. This equipment is used by drug research companies to analyze the arrangement of molecules in crystals to study drugs, viral receptors and other binding proteins.
Acast-in heater block and cooling plates provide necessary temperature uniformity in unique shapes for DNA analyzers. These subassemblies include heaters, tubing, connectors and RTDs in a custom box.
PatientCare
Watlowmanufactures a syringe heater of Lexan® and Mylar® to warm contrasting fluids to check for blockages. The heater is transparent and contains integrated electronics developed by Watlow. Each unit must pass strict testing prior to customer delivery.
AWatlow in-line cable heater is used to heat liquid nitrogen to form ice balls used in prostate cancer surgery. These ice balls are able to cut the tissue as effectively as a laser, but greatly reduce healing time. Liquid nitrogen passes through a tube containing a Watlow star-wound cable heater in this cryogenic application.
TheSeries 989 temperature controllers are used to maintain precise bed temperatures in patient wound care and recovery. The units control thermal devices that heat and cool air flow through a specialized mattress.
Heatis required to warm blood for intravenous patient applications. Watlow's silicone rubber heaters are used on the backside of aluminum plates to fulfill this need.
AMylar® heater with an etched foil element pre-warms blood before it is introduced to a surgery patient.
FIREROD®and tubular heaters are installed in infant care equipment including warming beds and incubators for premature babies with health problems. The heaters maintain an even ambient temperature in the enclosure, while a second heater generates moisture to maintain humidity levels.
Aspecially constructed double-wall heating element warms a solution that is circulated through the heart during open heart surgery. This heated solution maintains heart temperature and delivers medication throughout the procedure and allows the time required to operate on the heart while maintaining stability.
TheSeries 935 temperature controller is used to quickly warm refrigerated blood and fluids to body temperature in emergency room situations.
Kapton®heaters are bonded to customer supplied plates for use in kidney dialysis machines. A sensor is included to complete the assembly.
Kapton® is a registered trademark of E.I. du Pont de Nemours & Company.
Lexan® is a registered trademark of General Electric Corporation.
Mylar® is a registered trademark of E.I. du Pont de Nemours & Company.
UL® is a registered trademark of Underwriter's Laboratories.
FIREROD® Proven To Last Up To 12 Times Longer Than Competition
Theservice life of the Watlow FIREROD® cartridge heater is six to 12 times longer than other major cartridge heater brands. Accelerated life tests performed on 15 competing brands with results based on the average of four heaters per manufacturer proved the performance difference. This equates not only into savings in replacement heaters but savings in reduced downtime.
FIRERODusers have long known the benefits of the swaged cartridge heater's excellent heat transfer, uniform temperature and resistance to oxidation and corrosion, even at high temperatures, since it was patented in 1958. Watlow specializes in solving demanding cartridge heater applications through customized engineering and prototyping; the company's experience is reflected in the design of over 500,000 different FIREROD heaters for such industries as plastics processing, packaging, medical, aerospace and semiconductor processing.
Heatin a Hurry
Productavailability is industry's biggest concern in maintaining demanding production schedules. Watlow offers several FIREROD shipping programs including Ship-to-Stock and Just-in-Time that allow the OEM to reduce heater inventories. More than 150,000 configurations of stock FIREROD heaters and lead combinations are available for same day shipment as a result of Watlow's patented LA-lead adaptor-modification method.
Detailson Watlow's cartridge heater accelerated life test are available from Watlow sales engineers.
TestParameters | ]
- 1/2 inch diameter x 6 inch length units
- 120 volts
- 500 watts
- 150 W/in2
- 800°F (425°C)
Performance Capabilities
- Part temperatures to 1600°F (870°C) on Incoloy® sheath
- Part temperature to 1200°F (650°C) on optional stainless steel sheath
- Watt densities to 400 W/in2
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Thick Film Heaters Provide Low-Profile Answer For Small Areas
Watlow'sthick film heater technology is an innovative new way to heat various applications that require a tight fit. This new technology offers a high-performance, low-profile design that can be intimately fitted to flat, cylindrical and multidimensional surfaces.
Thedirect surface contact of the thick film heater offers superior heat transfer and fast thermal response, while glass-based films provide a non-porous surface that prevents moisture absorption. Because of the unique nature of the thick film circuit, this heater can be designed to vary heat output across the entire unit. This feature will correct virtually any temperature uniformity problem that customers may have with current designs.
Thickfilm heaters are produced by layering different film coatings onto a conductive surface. After each layer is printed, it is dried at 257°F (125°C) and then fired at 1560°F (850°C). This firing cycle bonds the multiple layers together and to the base material; melts glass frit materials into multiple cohesive dielectric layers, and allows metal oxides present to form the conductive lattice that carries the current and generates heat. Optional temperature sensors are available and can be directly bonded to the heated surface.
Watlowuses different dielectric and resistor ink combinations depending upon thermal expansion characteristics of the base or substrate material. The material chosen is determined by the process compatibility, operating temperature and cycle rates. A poor match will result in delamination of the heater film.
Acceleratedlife testing of thick film heaters has demonstrated significantly longer life than with infrared or other types of conduction heating technologies. "The combination of low thermal mass coupled with fast response, high watt density, compact size and conductive heat technology makes Watlow's thick film heaters an excellent solution for customers who need heat, but have minimum height clearances," stated Tom Lyons, product manager.
Watlow'sthick film heaters are manufactured to meet the requirements of NEC codes, UL® and CSA. Currently, thick film heaters are available on 400 series stainless steel, alumina, quartz, aluminum nitride and beryllium oxide. Aluminum and 300 series stainless steel substrates are currently in final testing.
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| Benefits
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Applications
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| Low profile, compact size
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Life sciences - Thermal cyclers
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| Fast response with low thermal mass
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Semiconductor - Wafer heating
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| Even thermal profile to ±5.4°F (±3°C)
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Digital printers and photocopiers
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| High watt density
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Packaging
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| 1110°F (600°C), maximum operating temperature
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Food processing
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| Corrosion resistant; long heater life
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General clamp-on applications
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| Distributed wattages available
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General applications that require high wattages and watt densities within a small area
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Solve Sensing Needs For Harsh Environments
Hybridthermocouples from Watlow Gordon are designed to meet requirements for high reliability sensing under severe conditions. Environments involving extreme physical conditions such as corrosion, electrical interference, high temperature, pressure, shock, and vibration, make Watlow's hybrid sensors the ideal solution over conventional sensors.
Thespliceless design of the hybrid sensor eliminates calibration errors caused by non-uniformity commonly found in constructions with mineral insulated cable spliced to insulated wire. The hybrid assembly is a continuous, homogenous thermoelement surrounded by high density ceramic insulation. Its integral seal prevents moisture penetration and is rated to 500°F (260°C). This thermoelement also eliminates the transition joint which is a common location of failure in sensors used in high vibration applications.
Theseattributes make Watlow's hybrid sensors perfectly suited for exhaust gas applications in diesel, gas and turbine engines, as well as test stands, die cast equipment and heat treat applications.
| Features
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Benefits
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| Homogeneous thermoelement
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Reduces calibration errors
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| Spliceless construction
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Eliminates joint failure problems
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| Integral seal
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Provides uniform sheath diameter
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| High compaction density
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Improved performance in vibration
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Save Time and Money With Easy-to-Use PPC-2000
ThePPC-2000 from Watlow Anafaze is a programmable process controller that provides flexibility with easy-to-setup multi-loop process control and programmable logic control in one complete package.
Customerscan now speed time to market with the quick, customizable options of the PPC-2000. This controller provides faster start up due to easy PID setup resulting in greater customer productivity levels and reduced process downtime.
ThePPC-2000 Saves Time:
- Reduce engineering efforts through easy-to-setup PID control parameters with "fill-in-the-blank" and pull-down menus.
- ANAWIN® software spreadsheets ease channel parameter setup. All control loops can be viewed and edited from scrollable tables.
- Pre-configured closed-loop control eliminates labor intensive ladder logic PID programming.
- Flexible hardware platform permits no-hassle changes in the input/output without rewiring the system.
- Debug faster with logic simulation on the PC test programs without PPC-2000 hardware.
- Solve downtime quickly with on-site inventory of spare modules. All modules can be used with any PPC- 2000 system small, medium or large.
The PPC-2000 saves money:
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- Combined closed-loop and programmable control eliminates the need for two separate controllers.
- Universal analog input modules support a wide variety of signals from thermocouples to transducers, and save the cost of additional modules.
- High density, flexible I/O modules minimize hardware requirements.
- Built-in auto-tuning eliminates the need to purchase special auto-tuning software.
- Modular design allows the controller to grow with the application rather than replacing the controller.
- Prolong heater life with DZC (burst-fire) outputs.
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WatlowAnafaze is expanding the PPC-2000 digital I/O capacity from 46 to 302. These additional I/O modules allow users to select from a wider variety of field I/O devices to match specific application needs. Optional touch screen displays and LCD interfaces are available for easy viewing or editing of parameters in the field.
ThePPC-2000 is a uniquely powerful and cost-effective approach for many temperature and process control applications where existing controllers are awkward, time-consuming or do not adequately solve the problem. This flexible controller is manufactured by ISO 9001 registered Watlow Anafaze and is reliably backed by a three-year warranty.
NewWATVIEW™ Software Expands Control Capability
WATVIEW™ is the new HMI (Human-Machine Interface) software that allows customers to set up and monitor Watlow controllers with ease-of-use. OEMs can now connect up to 32 Watlow or Watlow Anafaze units to a single PC for simultaneous communications. This software will be released later in first quarter 1999.
Theinitial release of WATVIEW will support the Series 96, Series 97 and MICRODIN™ controllers. Follow-up releases will add the CAS200 scanner, CLS200, MLS300 and PPC-2000 series multi-loop controllers as well as the Series F4 ramping controller during the second quarter.
Contacta Watlow sales engineer for more information.
First Quarter 1999 Trade Shows
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February 22-24
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SEMICON Korea '99
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Korea Exhibition Center (KOEX) Seoul, Korea
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3024-26
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February
23-25
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NEPCON '99
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Anaheim Convention Cente
Anaheim, California, USA
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7420
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| March 8-11
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PITTCON® '99
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Orange County Convention Center
Orlando, Florida, USA
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3677
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