cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions

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Cartridge Heaters-Frequently Asked Questions-FAQ's:

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Catridge Heaters Configuration
Catridge Heaters Configuration
Metric Insertion Heaters
Metric Insertion Heaters

Q. What sheath watt density do you build?

We warrant (with a bore nominal -0.000, +0.001") up to 160W per square inch. We will manufacture between 160W per square inch and 200W per square inch without warranty. Above 200W per square inch requires an engineering review for feasibility. In many cases a better fit required.

 

Q. Why do you use Stainless Steel 321 as opposed to Stainless Steel 316 which is more commonly used?

Stainless Steel 321 has been proven to be more resistant to corrosion and oxidation. All things being equal, a Stainless Steel 321 heater should be easier to remove. This is just one of the premium materials that are standard with a NPH cartridge insertion heater.

 

Q. What can be done to prolong the service life of a cartridge heater?

Cartridge heaters generally fail due to fit, moisture, contamination, movement improper selection, installation and high watt densities. Lower temperature heaters (below 500 degrees F) have a range of options to impede moisture, contamination and lead failure due to movement. The best thing you can do is discuss your specific application with a NPH Sales Engineer. Providing examples of failed heaters will also help us identify the root cause specific to your application.

 

 

Q. How can cartridge heater performance be optimized?

To optimize performance one must carefully consider:

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Cartridge Heater location

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Cycle time

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Fit to mating surfaces and location

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Temperature sensing method

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Material being heated

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Type of control method

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Performance goals

 

Q. How can NPH assist with engineering services and provide solutions with insertion heater application problems?


NPH Cartridge Heater Engineering services include:

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Production and product development assistance

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Thermal engineering consulting

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Solid modeling

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Design optimization for performance and energy consumption

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions FEA and Lab Simulation


The more complex the design, and the more critical heat is to design performance, the greater the impact NPH Engineering services will have on your process. Your application, performance goals and future plans create a unique opportunity to explore the power of NPH Engineering services for all heat solutions with cartridge heaters.


Q.What Cartridge Heater Solutions can NPH Provide?

NPH Cartridge Heater Solutions, your smart heat management choice.

While many companies can build a general use cartridge heater, NPH and its partners are committed to manufacturing and supplying the best cartridge heater specifically for your application. When you see the design elements beyond the obvious similarities to commodity heaters, critical engineering decisions can be made to dramatically improve durability, product quality, responsiveness and cycle time.


Every application carries with it performance requirements that must be carefully considered. Factors such as movement, moisture, dimensional tolerances, operating temperature, material being heated, and environmental conditions will impact the design of the cartridge heater.


NPH manufactures cartridge heaters with better components, materials and precision

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions High watt density cartridge heaters are built with 8” long ceramic cores, 33% longer than our competitors, resulting in fewer electrical connections on longer heaters.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Standard stainless steel sheath is SS321 for improved corrosion resistance (incoloy is also available).

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions New, compact right angle exit with flat sides to aide removal. (When cartridge heaters last as long as NPH’s do, this is important)

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Anti-seize coating applied in house for faster delivery.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Centerless grinding option to a tolerance of +/- .0008” for a better fit.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Computer controlled winding ensures the right wattage distribution profile on every heater, every build.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Technical support to understand your application and design a cartridge heater with your specific use in mind.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions Attaining and maintaining ISO 9001 since 2000.


High watt density vs. medium watt density construction

All cartridge heaters NPH manufactures are swaged (highly compacted) heaters. Customers who require precise, durable heat should accept nothing less. The compaction created during the swaging process enables the cartridge heaters to more responsively deliver heat, and provides the resistance wire with dense thermal mass improving performance and heater life greatly over loose fill cartridge heaters.


Both high watt and medium watt construction can be built as an energy saving eheat cartridge heater.


Q. What are Eheat Cartridge Heaters?

NPH eheat cartridge heaters are constructed with a special high thermal transfer sheath materialthat creates a fast responding, longer lasting, more energy efficient heater.At the same rated wattage, NPHl is a leading supplier of cartridge heaters that have measured up to 25% improved energy efficiency over traditional build cartridge heaters.


Our eheat cartridge heaters are the fast responding, energy efficient and direct replacements for your existing cartridge heaters. Extend the capabilities of your existing system with eheat cartridge heaters manufactured by NPH, or develop around its strengths to bring smart heat management capabilities to your market.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions The high thermal transfer sheath results in a cartridge heater that can perform the same work with fewer watts - saving energy and reducing total system amperage.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions For higher watt density applications such as a hot glue system, the eheat delivers heat to the application faster, resulting in more heat delivered with a lower heater core temperature. This extends cartridge heater life.

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions NPH eheat cartridge heaters reach set point faster, and can reduce cycle times of demanding applications.


High watt density cartridge heaters

The machine winding of the high watt density cartridge heater delivers the most precise distributed wattage profile. High watt density heaters supplied by NPH can be built to your specifications from 1” long to over 100”. Warranted to 160 watts per square inch.


Specify a high watt density cartridge heater if:

  • Watt density is greater than 65 watts per square inch.*
  • And/or the heater is less than 8”.*
  • And/or your application requires a precise wattage distribution.

* High watt density cartridge heaters are commonly built below 65 watts per square inch and in lengths up to 100” long for specific applications.


Medium watt density cartridge heaters

The medium watt density cartridge heater has a continuous resistance spiral throughout the heater delivering unparalleled reliability. For longer cartridge heaters there are fewer internal electrical connections. Medium watt density heaters start at 8”long and can be built to over 100”. Each medium watt density cartridge heater supplied by NPH is warranted to 65 watts per square inch.


Specify a medium watt density cartridge heater if:

  • Watt density is less than 65 watts per square inch.
  • And the heater is 8” or longer.
  • And you do not need highly precise wattage distribution.

*In the past only high watt density cartridge heaters could support an internal type J or K TC. NPH can now manufacture medium watt density cartridge heaters with an internal Thermocouple.







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Our industrial electric cartridge heaters including metric and imperial heaters...

Consists of the following cartridge/insertion heater categories:

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Standard imperial and metric round cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Medium watt density cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  High watt density cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Split sheath cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Square cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Small diameter/miniature pencil heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Bolt cartridge heaters
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Custom cartridge/insertion heaters

Applications for the above include:

cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Cartridge Heaters for-Extrusion Dies, Liquid Immersion
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Metric Heaters for-Plastic Molds and Injection Molding
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Insertion Heaters for-Plastics Extrusion
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Custom Cartridge Heaters for-Packaging Machinery, Labeling and Sealing
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Square and Round Cartridge Heaters for-Hot Plates and Platens, Hot Stamping
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Cartridge Heaters for-Hot Runner Molds, Various Types of Dies
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Insertion Heaters for- Medical Equipment and Other Industrial Applications

The square cartridge heater configuration simplifies wiring and installation while optimizing performance in a wide range of solid, liquid, and gas heating applications. Tooling applications are particularly well served by the square cartridge heater approach. Typical square cartridge heating applications include platens, molds, sealing bars, sealing plates and dies. Versatile slot style mounting simplifies installation in small tooling components such as bushings and nozzles and is particularly useful when leads must exit at a specific location on the component surface.

Some applications demand much longer heater life, that is where miniature small diameter pencil/cartridge heaters have immense application value. Life expectancies of five, seven or even ten years are not unreasonable for some mission-critical applications:


cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Blood warmers used in medical theaters must never fail
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Battery conditioners for EVA spacesuits on the International Space Station must last ten years      before replacement, due to payload costs
cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions  Here on earth, high throughput semiconductor chip testers must operate without significant      downtime for the 5 year life of the equipment. For these applications, a service life of 50,000 to      90,000 hours is a requirement that is both reasonable and attainable.

Some common issues with most standard cartridge heaters are as follows:

Heater removal: a cartridge heater will oxidize after many hours of operation and maybe difficult to remove. Consider drilling a through hole so the heater can be hammered out or choose a split sheath cartridge heater.

Lubricants: like graphite or silicone facilitate the insertion of the cartridge heater but can carbonize at higher temperature and then the heater will be really stuck.

The NPH split sheath cartridge heateris designed especially for platen, die or mold industrial heating applications where the holes are poorly drilled or worn through age. Independent expansion of each section of the split sheath cartridge heater when energized, creates intimate contact with the wall of the hole.

Through the patented split-sheath design and highly specialized manufacturing techniques, NPH split sheath insertion heaters reduce your total cost of process heating by an average of 40% over other heaters.

NPH’s split sheath cartridge heaters use a unique, patented split-sheath design that expand when energized to maximize heat transfer through greater contact with the wall of the bore. Better heat transfermeans less power is consumed to maintain the set point temperature, reducing operating costs.

Bolt cartridge heaters are used to tighten large bolts that secure heavy machinery and equipment. The shaft of the heater is inserted into the hollow bolt and energized to expand it, which allows further tightening of the nut. Manufactured with a high watt density, they heat up in just a few minutes, resulting in cost savings on reduced man hours removing nuts from bolts and studs. Large bolts can be heated to full expansion in just a few minutes. This heater design is manufactured with specific diameter sheaths to fit industry standard hollow bolts. High watt densities with special heated lengths distribute heat evenly to surrounding bolt.



cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions cartridge heaters FAQ’s, cartridge heaters, watt density, heaters solutions

Telephone: 905-859-8225        Facsimile: 905-859-4691

sales@nphheaters.com

Toll Free: 1-877-674-9744