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Cartridge Heaters Configurations Styles and Terminations
Construction of Cartridge Heaters and Features
Optional Features-Cartridge Heaters
Mounting Options-Cartridge Insertion Heaters
Electrical Terminations Cartridge Heaters
Diameter, Tolerances, Actual vs Nominal Diameter-Cartridge Heaters
Installation Tips 2 and Preventive Maintenance-Cartridge Heaters
Evaluating 2 Your cartridge Heater Problems
Heat Calculations Watt Density Catridge Heaters-2
Order Form-How to Order Cartridge Heaters
Split Sheath Cartridge Heaters
Square Cartridge Heaters
Small Diameter, Miniature Pencil Heaters
Bolt Cartridge Heaters
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Cartridge Heaters with Crimped-On LeadsA high temperature double crimp connects the MGT (450ºC) leads to solid nickel pins. This construction is recommended for applications with elevated temperatures. Due to the rigid nickel pins, this construction is not recommended in applications where movement or flexing is encountered, or if sharp bends are required adjacent to the heater exit.
Cartridge Heaters with Swaged-In LeadsHigh temperature MGT (450ºC) wire is internally connected and swaged in place. This construction is recommended for applications in which the leads must be bent at the exit point from the heater and where mild flexing may be found. For applications with continuous or more severe movement, we would recommend metal braid or armor cable.
Cartridge Heaters with Stainless Steel BraidHigh temperature MGT (450ºC) wire is internally connected and swaged in place. This construction offers protection against abrasion and sharp edges. This is a very strong construction which offers full length flexibility. This construction is recommended in applications with flexing and where the leads must pass through metal openings or routed along metal components.
Cartridge Heaters with Stainless Steel Hose (Armor Cable)High temperature MGT (450ºC) wire is internally connected and swaged in place. This construction is recommended for applications in which the leads are subjected to abrasion or run the risk of being pinched. This is the strongest lead protection available and works well in moving or flexing applications.
Cartridge Heaters with Right Angle Fiberglass LeadsHigh temperature MGT (450ºC) leads exiting at right angle to the sheath. This construction offers a compact design where space is limited. This construction is not recommended where abrasion or flexing is present.
Cartridge Heaters with Right Angle Stainless Steel BraidStainless steel braid over high temperature MGT (450ºC) wire exiting at right angle to the sheath. This construction is recommended in applications with flexing and where the leads must pass through metal openings or routed along metal components. This construction is desirable when space is limited and it is not feasible to bend standard leads.
Cartridge Heaters with Copper Elbow
Armor cables are less flexible than stainless steel braids, but provide contamination resistance in addition to superior protection against abrasion. A copper elbow braised to the cartridge externally, provides a 90° transfer.
Cartridge Heaters with Right Angle Stainless Steel Hose (Armor Cable)Stainless steel hose over high temperature MGT (450ºC) wire exiting at right angle to sheath. This is the strongest lead protection for use in applications where severe abrasion is present. These leads offer good flexibility and are good for moving or flexing applications.
Cartridge Heaters Diameters and Minimum Unheated Lengths
Cartridge Heaters with Single or Double Threaded Fittings - Brass or Stainless Steel NPT FittingsSingle or double threaded fittings attached to sheath to allow for installation into threaded holes.
Fitting Materials- Brass, Steel and Stainless Steel
Leadwires- Fiberglass for high temperature applications
- Teflon for moisture protection
- Stainless Braid or Hose for flexing applications
and abrasion protection.
Terminal Boxes- General purpose and moisture resistant housing
Cartridge Heaters Outside Diameter vs Appropriate NPT Size Fittings with X, Y and Y1 Dimensions
Cartridge Heaters with Mounting FlangeMounting flanges are recommended for applications where vibration or movement may cause the heater to be dislodged from its hole. Stainless steel flanges are available in a variety of sizes and configurations. The standard flange is round and is supplied with two mounting holes. For heaters 5/8" diameter and under, the flange would be 1 1/2" in diameter. For larger diameter heaters the standard flange would be 2.00" in diameter
Cartridge Heaters with Teflon End SealA Teflon plug is swaged in place along with Teflon leads. This construction resists oil and water to 250°C/480°F. There is a minimum of a 1.00" unheated length at the lead end. Longer cold sections may be required if the watt density or operating temperature is high
Cartridge Heaters with Screw TerminalsThreaded stud terminals are supplied complete with high temperature nuts and washers. Standard screw is #8-32. Available in 5/8", 3/4", 1", 16 mm and 20mm diameters heaters.
Cartridge Heaters with Double Ended TerminalsThese terminations are ideal for applications where wiring form both ends is required. A minimum cold section of 1" is required for these leads.
Available Terminations- Solid nickel pins
- Lead Wires
- Threaded Studs
Cartridge Heaters with Terminal BoxesTerminal boxes are permanently attached to the heater sheath to provide excellent protection in a variety of environments.
- General purpose sheet metal
- Moisture proof
- Cast aluminum explosion resistant
Cartridge Heaters with Internal ThermocouplesInternal thermocouples are built into the heater assembly to monitor the internal or sheath temperatures. These are useful as high limit devices or in applications where space is at a premium. The power and sensor leads exit the sheath together and can be ordered with a variety of lead protections. Not all thermocouple configurations are available on smaller diameter heaters. Type J and K calibrations are standard for the shown constructions.
Cartridge Heaters with Grounded Thermocouple at Disc EndThe thermocouple junction is grounded to the disc end of the heater. This construction is commonly used in hot runner applications. The disc end can be filled with silver solder and ground flat. This will ensure good contact when inserted into a flat end blind hole.
Cartridge Heaters with Ungrounded Thermocouple at Disc EndThe thermocouple junction is ungrounded and is located just behind the disc end. This will give a reference temperature of the part being heated.
Cartridge Heaters with Grounded thermocouple at CenterThe thermocouple junction is grounded to the sheath along the length of the heater. The standard location is at the center of the heater, but can be located anywhere along the length of the sheath. This construction will provide a quick response.
Cartridge Heaters with Ungrounded Thermocouple at CenterThe thermocouple junction is ungrounded and is centered in the diameter of the sheath. The standard location is at the center of the heater, but can be located anywhere along the length of the sheath. Typically used as a high limit in air or vacuum applications.
Cartridge Heaters with High Temperature Ceramic Beads on LeadsCeramic bead insulation protects the leads from high temperature environments (above 842°F / 450°C). The beads fit over the solid conductors which extend far enough to reach a cooler area where flexible wires can be attached. A high temperature double crimp connects the MGT (450ºC) leads to solid nickel pins. This construction is recommended for applications with elevated temperatures. Due to the rigid nickel pins, this construction is not recommended in applications where movement or flexing is encountered, or if sharp bends are required adjacent to the heater exit.
Pelletizer and Hot Water Cartridge HeatersAll pelletizer cartridge heaters are 1" in diameter with a 2-1/2" insertion length below the 1-1/2” diameter flange. All heaters are 240 Volt 600 Watts. Other styles beside those listed can be custom manufactured.
Small Diameter, Miniature Pencil Heaters
Bolt Cartridge Heaters
Split Sheath Cartridge Heaters
Square & Rectangular Cartridge Heaters
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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