Cartridge Heaters Configurations Styles and Terminations

Products:

Cartridge Heaters-Lead Configurations, Exits, Mounting Styles and Lead Protection Options:

Cartridge Heaters - All applications must consider fit tolerance, the correct watt density and appropriate terminal connections. Cartridge Heaters are uniquely designed to fit into metal blocks, dies, platens, molds etc.

Features Include:

precisely concentrate the heat where it is needed
ideally suited to digital temperature control systems
low capital cost
wide selection of: diameters and lengths, up to 60" long, wattages and watt densities and terminations

Cartridge Heaters, Metric Insertion Heaters-Configurations

(Configuration 1)

Cartridge Heater with Crimped-On Leads

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.

(Configuration 2)

Cartridge Heater with Swaged-In Leads

High 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 Braid

(Configuration 3)

Cartridge Heater with Stainless Steel Braid

High 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)

(Configuration 4)

Cartridge Heater 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 Leads

(Configuration 5)

Cartridge Heater with Right Angle Fiberglass Leads

High 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 Braid

(Configuration 6)

Cartridge Heater with Right Angle Stainless Steel Braid

Stainless 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.

(Configuration 6B)

Cartridge Heater 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)

(Configuration 7)

Cartridge Heater 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.

Heater Diameter	Minimum Unheated Length
1/8"	Not Available
1/4"	1"
5/16"	1 1/2"
3/8"	1 1/2"
1/2"	1 1/2"
5/8"	1 9/16"
3/4"	1 7/8"
15/16"	1 7/8"
1"	1 7/8"

(Configuration 8)

(Configuration 8A)

(Configuration 8B)

Cartridge Heaters with Single or Double Threaded Fittings - Brass or Stainless Steel NPT Fittings Single 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

Heater Diameter	NPT Size	X Dimension	Y Dimension	Y1 Dimension
1/4"	1/8 - 27	3/8"	3/16"	1/4"
3/8"	1/4 - 18	1/2"	3/16"	1/4"
1/2"	3/8 - 18	9/16"	1/4"	1/4"
5/8"	1/2 - 14	5/8"	1/4"	5/16"
3/4"	3/4 - 14	3/4"	1/4"	3/8"
7/8"	1 - 11 1/2	3/4"	1/4"	3/8"
1"	1 - 11 1/2	3/4"	1/4"	3/8"
1 1/4"	1 1/4 - 11 1/2	7/8"	5/16"	1/2"

(Configuration 9)

Cartridge Heater with Mounting Flange

Mounting 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.

(Configuration 10)

Cartridge Heater with Teflon End Seal

A 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.

(Configuration 11)

Cartridge Heater with Screw Terminals

Threaded 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.

(Configuration 12)

Cartridge Heaters with Double Ended Terminals

These 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

(Configuration 13)

Cartridge Heater with Terminal Boxes

Terminal boxes are permanently attached to the heater sheath to provide excellent protection in a variety of environments.

Available Boxes
- General purpose sheet metal
- Moisture proof
- Cast aluminum explosion resistant

Cartridge Heater with Internal Thermocouples

Internal 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 End

(Configuration 14)

Cartridge Heater with Grounded Thermocouple at Disc End

The 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 End

(Configuration 15)

Cartridge Heater with Ungrounded Thermocouple at Disc End

The 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 Center

(Configuration 16)

Cartridge Heater with Grounded thermocouple at Center

The 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 Center

(Configuration 17)

Cartridge Heater with Ungrounded Thermocouple at Center

The 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.

Custom Cartridge Heaters with Screw Terminals

(Configuration 18)

Cartridge Heaters with High Temperature Ceramic Beads on Leads

Ceramic 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.

(Configuration 19)

Pelletizer and Hot Water Cartridge Heaters

All 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.