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Normal Resistance Heating Elements

Normal-resistance elements are widely used across industrial heating because they are reliable, predictable and relatively simple to control.

Unlike elements whose resistance changes significantly as they heat up, a normal-resistance element has a comparatively stable resistance from cold to operating temperature. This produces a consistent electrical load and makes it well suited to thyristor power control.

Where Are Normal-Resistance Elements Used?

They are commonly found in:

  • Industrial ovens and dryers
  • Cartridge and band heaters
  • Immersion heaters
  • Heated tanks and vessels
  • Packaging and sealing machinery
  • Heated platens and tooling
  • Air-heating systems
  • General process-heating equipment

Typical industries include plastics, food and drink, packaging, chemicals, pharmaceuticals and general manufacturing.

Why Use a Normal-Resistance Element?

Normal-resistance elements are popular because they offer:

  • Predictable current draw
  • Stable heating performance
  • Simple electrical design
  • Good temperature repeatability
  • Wide availability
  • Compatibility with single-phase and three-phase systems

They are particularly effective where the process requires dependable, repeatable heat without the high cold-start currents associated with specialist elements such as silicon carbide or molybdenum disilicide.

What Is the Best Way to Control Them?

For most normal-resistance loads, zero-cross burst firing is the preferred control method.

The thyristor controller switches complete mains cycles on and off in response to the heating demand. This provides accurate power control while keeping electrical noise and harmonic disturbance low.

Key benefits include:

  • Smooth and repeatable temperature control
  • Reduced electrical interference
  • No mechanical contact wear
  • Fast, silent switching
  • Longer service life than contactors
  • Reduced maintenance and downtime

Faster cycle control may be used for low-mass heaters or processes requiring a quicker response. Phase-angle control is generally only needed where there is a specific requirement for soft start, voltage limiting or very rapid power adjustment.

Recommended CD Automation Controllers

REVO S

REVO S is ideal for straightforward normal-resistance heating applications requiring reliable solid-state switching.

It is well suited to:

  • Contactor replacement
  • Standard heating zones
  • OEM machinery
  • Ovens, tanks and dryers
  • Logic or analogue control

REVO C

REVO C is recommended where the application requires more advanced control, monitoring or communications.

It offers options including:

  • Zero-cross and phase-angle firing
  • Current and power measurement
  • Heater-break detection
  • Current or voltage limiting
  • Load diagnostics
  • Analogue control
  • PLC and fieldbus integration

Select the Right Controller for Your Heater

Correct selection depends on the supply voltage, number of phases, heater current, control signal and required diagnostics.

Send us the following details:

  • Supply voltage
  • Single-phase or three-phase
  • Heater current or kW
  • Number of heating zones
  • Control signal
  • Any monitoring or communication requirements

Need Help Selecting the Right Solution?

Our power-control specialists can help you size the controller, select the correct firing mode and identify the most suitable REVO product for your application.

Call 01323 811 100 or send us your application details today.

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and shift from reactive to predictive maintenance.