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Installation Tips 2 and Preventive Maintenance-Cartridge Heaters
Evaluating 2 Your cartridge Heater Problems
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Optional Features: Cartridge Insertion Heaters:
Anti-Seize Cartridge Heaters- Anti-seize coating is available for both medium watt density cartridge heaters and high watt density cartridge heaters. Anti-Seize coating will make cartridge heater extraction more efficient while keeping work and damage to your costly tooling to a minimum. NPH now hard coats cartridge heaters in house to improve delivery. With this coating, we are still able to hold our precision NPH tolerance. If you have ever struggled to remove a cartridge heater, you understand the positive impact anti-seize coating will have on your productivity. Building a cartridge heater that lasts longer can make removal more difficult when a heater must be replaced. Removal labor often costs more than the cartridge heater itself. NPH in-house anti-seize coating is a cost effective option that can be added without impacting delivery.
Removal Aids- NPH offers knock out tabs and other removal aids that allow you to quickly and confidently remove a cartridge heater when it is a time to replace it. Knock out tabs are recommended when you are installing the heater in a through bore prone to oxidation.
Distributed Wattage- NPH has developed industry specific winding profiles to improve thermal profiles including packaging, rubber and injection molding. We have also successfully developed OEM specific winding profiles to compensate for challenging cartridge heater placement.
Cartridge heaters used as sealing bars or on rubber molds, the two ends of a cartridge heater are usually colder than the middle. To overcome this inconsistency and have a uniformly distributed heat source, cartridge heaterscould be made to have higher wattages at the ends. 35/30/35 is a common wattage distribution.
Zones and cold sections- Cartridge heaters can also be manufactured with cold sections and separate zones that can be controlled independently.
Moisture Resistance- If your application requires wash down, has high amounts of humidity in the ambient air, or has machining oil nearby, then NPH has a wide range of options to deliver moisture resistance at your operating temperature, leading to high performance for your cartridge heaters.
Right Angle Exit- To customize cartridge heaters for specific applications, NPH has redesigned the right angle exit with flat sides, making it possible to use a wrench to precisely position lead exit and break oxidation bonds when removing a heater.
Right Angle Block- The Right Angle Block has flat sides and substantial materials to provide the strength needed for highly corrosive environments such as die casting- where the cartridge heater sheath can be bonded to the bore.
Standard Flanges, Special Flanges and NPT- If your application calls for the heater to have a specific insertion depth, or to be held in place - NPH offers standard flanges for most diameters. We can also design special flanges for your application. NPT fittings can be added to your cartridge heater.
Centerless Grind Tolerance- NPH’s standard tolerance of ±.002” compares favorably to other cartridge heaters. If heat transfer is critical to your application, NPH offers premium centerless grind tolerances that are ±.0008”.
With the above range of cartridge heater performance options from NPH, you are ready to create cartridge heaters customized to your applications.
Consists of the following cartridge/insertion heater categories:Standard imperial and metric round cartridge heaters
Medium watt density cartridge heaters
High watt density cartridge heaters
Split sheath cartridge heaters
Square cartridge heaters
Small diameter/miniature pencil heaters
Bolt cartridge heaters
Custom cartridge/insertion heaters
Applications for the above include:Cartridge Heaters for-Extrusion Dies, Liquid Immersion
Metric Heaters for-Plastic Molds and Injection Molding
Insertion Heaters for-Plastics Extrusion
Custom Cartridge Heaters for-Packaging Machinery, Labeling and Sealing
Square and Round Cartridge Heaters for-Hot Plates and Platens, Hot Stamping
Cartridge Heaters for-Hot Runner Molds, Various Types of Dies
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:
Blood warmers used in medical theaters must never fail
Battery conditioners for EVA spacesuits on the International Space Station must last ten years before replacement, due to payload costs
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.
NPHs 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.
Telephone: 905-859-8225 Facsimile: 905-859-4691
Toll Free: 1-877-674-9744
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