Cartridge Heaters

Magnum™ cartridge heaters are swaged designs, made for use in applications where high watt density, high temperatures, and long service life are critical to minimizing mold service downtime and expensive press open time. The swaged construction produces a highly compacted heater that resists shock and vibration while providing for maximum element life through efficient transfer heating. Magnum cartridge heaters last up to 20 times longer than uncompacted heating elements. UL/cUL component recognition available. Durex will also custom manufacture designs to meet your specifications.

Design Features:----Cartridge-Heater-Group.jpg

Standard cartridge heater parts list.

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1/8th Inch Style Heaters

The 1/8th Inch (3.175 mm) Magnum™ Cartridge Heater was developed for Original Equipment Manufacturers (OEMs) that required a small but high power thermal solution.

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Heaters with Integrated Sensors

Cartridge Heaters with integrated sensors are used in applications requiring high temperature and watt density heaters.

----Immersion Cartridge Heaters

Immersion Cartridge Heaters

Immersion cartridge heaters are compact, high-powered liquid heating products. They are mounted into a coupling on the side of a tank or pan.

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Bolt Heaters

Bolt 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.

Cartridge Heater Specifications & Options

Heater Specifications

Nominal Diameter 1/8" 1/4" 5/16" 3/8" 1/2" 5/8" 11/16" 3/4" 1" 6.5mm 8mm 10mm 12.5mm 16mm 20mm
Actual Diameter 0.002" (0.05") 0.122 0.246 0.309 0.371 0.496 0.621 0.683 0.746 0.996 0.252 0.312 0.391 0.489 0.627 0.784
Maximum Voltage 240 240 240 240 480 480 480 480 480 240 240 240 480 480 480
Maximum Amps 3.1 4.2 6 6.5 10.5 22 22 22 25 4 6 6 10.5 22 22
Minimum Wattage Consult Durex Industries for minimum wattage
Wattage Tolerance +5, -10% of rated wattage
Length Tolerance 2% of length, 3/32" minimum
Camber Tolerance Up to 12" long: .010" per foot Over 12" long: .015" per foot
Watt Density Total wattage divided by diameter x 3.14 x heated length


Termination Types

----Standard Lead Termination.jpgStandard Leads - Fiberglass insulated lead wires are externally connected to nickel pins. The connection area is electrically insulated with heavy-wall fiberglass sleeving. 12" leads are standard. Specify longer leads if required. Standard cold length at lead exit: 0.375". Standard cold length at disc end: 0.25".


----Swaged Flexible Leads.jpgSwaged Flexible LeadsFiberglass insulated lead wires are internally connected to nickel pins. This design allows for much greater flexibility at the lead exit point from the heater. 12" Leads are standard. Specify longer leads if required. Standard cold length at lead exit: 0.375". Standard cold length at disc end: 0.25"

----Teflon Leads and Seal.jpgTeflon Leads & SealsTeflon® insulated lead wires with Teflon® end seal swaged into the cartridge heater sheath provides a superior moisture and chemical resistance. This design requires at least a 1" cold section at the lead exit end of the heater. 12" Leads are standard. Specify longer leads if required. Specify "E" for epoxy potted end seal with 12" Teflon® insulated leads.


----Right Angle Leads.jpgRight Angle Leads - Fiberglass insulated leads exit the cartridge heater sheath at a right angle for easier access and routing. Includes stainless steel end cap and high-temperature potting. Specify the overall length of the cartridge heater.



----Straight Braid Leads.jpgStraight Braid Leads - Stainless steel braid over fiberglass insulated lead wires exits straight from cartridge heater sheath for abrasion resistance, yet is flexible enough for sharp bends. 3" additional lead beyond braid is standard. Specify longer lead if required. Standard cold length at lead exit: 0.375". Standard cold length at disc end: 0.25"

----Right Angle Braid Leads.jpgRight Angle Braid Leads
Stainless steel braid over fiberglass insulated lead wires exits at a right angle from cartridge heater sheath. Includes stainless steel end cap. 3" lead beyond braid is standard. Specify longer lead if required. Specify overall heater length when ordering.


----Straight Armor Cable Leads.jpgStraight Armor Cable LeadsArmor cable over fiberglass insulated lead wire exits straight from cartridge heater sheath for heavy duty lead protection. 3" lead beyond armor is standard. Specify longer lead if required. Specify galvanized or stainless steel armor when ordering.


----Right Angle Armor Cable.jpgRight Angle Armor Cable - Stainless steel flexible armor cable over fiberglass insulated lead wires exits at a right angle from cartridge heater sheath. Includes stainless steel cap. Galvanized or stainless steel armor. 3" lead beyond armor is standard. Specify longer leads if required. Specify galvanized or stainless steel armor and overall cartridge heater length.

 

----Right Angle Copper Elbow.jpgRight Angle Armor Cable With Copper Elbow - Armor cable leads extend at a right angle from cartridge heater with right angle copper elbow. 3" lead beyond armor is standard. Specify longer leads if required. Specify galvanized or stainless steel armor and length of cartridge heater sheath. Note: For Galvanized armor add "G" as a suffix to termination number.

 

----Internal Thermocouple Termination.jpgInternal ThermocoupleThe thermocouple provides an integral method for temperature control. Thermocouple junction (grounded or ungrounded) can be located at the end disc, center, or lead end. Please specify thermocouple type, location, and whether grounded or ungrounded. Type J or Type K is standard. Other thermocouple types are available.


----Immersion Pipe Fitting.jpgImmersion Pipe FittingThreaded NPT pipe fitting is silver soldered or welded directly to cartridge heater sheath for immersion applications, available in stainless steel or brass. Fiberglass insulated lead wires exit high-temperature cement potting. 3/4" cold required before fitting. Epoxy & Epoxylite® available for moisture applications. Other lead options are available.

----Post Terminals.jpgPost TerminalsThreaded stainless steel terminals are welded directly to nickel pin for rigid mount applications. Includes two (2) nuts and washers for each terminal.


----Mounting Flange.jpgMounting FlangeStainless steel flange welded directly to cartridge heater sheath. Fiberglass insulated lead wires are standard. Other flange sizes and hole patterns are available upon request.

 


Duraslik- Cartridge Heater Non-Stick Coating

The Duraslik non-stick coating eliminates the need for additional release agents to be applied to the cartridge heater prior to the insertion. The non-stick coating acts as a corrosion inhibitor and a solid lubricant on the inner diameter of the drilled hole when the heater is energized, allowing for reduced downtime caused by "sticky" heaters during replacement.

Benefits:

  • Reduced downtime caused by "sticky" heater removal
  • Coating is bonded directly to the heater sheath for easy handling
  • No need for secondary release agents prior to insertion
  • Superior heater transfer characteristics for increased life

Technical Data:

  • The ultra-thin Duraslik coating only adds 0.0010" to 0.0015" (0.025 - 0.037mm) to the cartridge heater diameter
  • Coating is applied up to 1/4" of lead exit
  • Coating is rated up to 1400°F (760°C)
  • Heater diameter is manufactured to within standard tolerances after the coating is applied

Special Modifications

In addition to the standard design, Durex Industries offers a variety of special modifications which are available to customize the heater for your application.

  • Distributed Wattage: Resistance windings can be concentrated in specific areas of the heater for localized heat distribution.
  • Centerless Grinding: Precision grinding of the heater sheath provides tighter diameter tolerances when required.
  • DURASLIK Coating: Duraslik coating can be provided on heater sheath for applications requiring chemical resistance or easy removal.
  • Ground Leadwire: Separate color coded ground wire can be provided when required.
  • Special Connectors: Various connectors for power leads can be provided upon request.
  • Terminal Boxes: NEMA 1, as well as moisture resistant or explosive resistant boxes, can be provided when required.

Factors for long cartridge heater life

  • Do not exceed recommended maximum watt density specified for the heater size.
  • The cartridge heater sheath must fit properly into the machined hole, a tight fit is crucial.
  • Protect the heater from contaminates such as oil, grease, and vapors.
  • Install adequate KW to accomplish workload and make up for heat losses.

Care and Maintenance

  • Store cartridge heaters in a dry area, especially during periods of high humidity.
  • Protect leads from abrasion, abuse, and exposure to contaminants such as grease and plastic drool.
  • Maintain temperature control and keep accessories in good working condition to obtain correct operating conditions.
  • All cartridge heaters have hygroscopic tendencies and can accumulate moisture in shipping and storage. Heaters with low dielectric insulation values (less than 1 megohm) can be baked in an oven for several hours or started at low voltage to eliminate moisture.

How to Order

  • Quantity
  • Nominal Diameter - see specifications for assistance
  • Overall Sheath Length - measured in inches or millimeters from end to end of heater sheath
  • Lead Length - specify in inches
  • Termination Type - see terminations
  • Voltage - specify
  • Wattage - specify
  • Other Custom Specifications - specify as required

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Typical Cartridge Heater Applications

  • Liquid Immersion
  • Plastic Molds
  • Dies
  • Labeling
  • Medical Equipment
  • Platens
  • Packaging Equipment
  • Hot Stamping
  • Sealing
  • Injection Molding
  • Other, consult Durex Industries

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Cartridge Heaters 6-9-14 - 2MB

Standard Cartridge Heater Parts List 6-9-14 - 1MB

 

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