Insertion Cartridge Heaters Catalog
STANDARD CARTRIDGE HEATER CONFIGURATION CHART
____________________________________________________________________
Split Cartridge Heaters
Maximize Heat Transfer
The unique split-sheath design of the Watt-Flex Cartridge Heater allows the independent, bilateral expansion of each half of the heater outward against the walls of the surrounding bore.
Ideal for Use in Oversized Bores
The unique bi-lateral expansion of the cartridge heaters eliminates the need for tight fits and makes them well-suited for use in oversized bores where conventional cartridge heaters cannot be used effectively.
Heaters Eliminate Bore Seizure
The split-sheath design cartridge heater reduces your heater change-out costs by preventing heater bore seizure.
____________________________________________________________________
Square Cartridge Heaters
The square heater assembly consists of an element wound on shaped ceramic cores and securely connected to internal lead conductors. This assembly is centrally located within shaped tubing and voids are filled with ceramic insulation. The heater assembly is swaged to the final square cross-sectional dimensions to metallurgically bond the element wire to the lead conductors and to compact the internal ceramic core and ceramic insulation to near theoretical density. The densely compacted assembly provides the optimum heat transfer and insulation dielectric essential to heater performance and reliability and maximizes the heaters resistance to vibration, shock and physical abuse.
As an alternative to traditional round cartridges and their costly, time consuming deep hole drilling requirements, square cartridges utilize simple, cost effective surface milled slot mounting systems. This approach provides close fits between the cartridge and tooling maximizing heat transfer and performance while still allowing easy heater removal for maintenance and cleaning. Lead channels added during the slot machining process provide total protection for the heater power leads while allowing routing of the leads to connectors or terminal strips at any desired location on the tool. A square cartridge forming option further simplifies heating of special shapes and can be utilized in heating both large and small tooling components.
External / Internal Connected Leads
Fax-Back Data Sheet
Externally Connected Flexible Leads
This is the foundation of all the variations shown on the following pages. A heavy duty double crimp connects lead wires to solid nickel pins. Connections are insulated with sleeving. Maximum temperature at the lead area is 400 F/200 C. Standard lead length is 12". Specify additional length. This is the standard design for all diameters (except 1/8").
Internally Connected Flexible Leads High Temperature
Fully Flexible Leads 
This series is the foundation of all the variations shown on the following pages. A heavy duty double crimp connects lead wires to solid nickel pins. Connections are insulated with sleeving. Maximum temperature at the lead area is 400 F/200 C. Standard lead length is 12". Specify additional length. This is the standard design for all diameters (except 1/8").
High Temperature Fully Flexible Leads
DIA. |
Standard Unheated Area |
1/8” |
3/8” |
1/4” |
1/2” |
5/16” |
1/2” |
3/8” |
9/16” |
1/2” |
5/8” |
3/4” |
7/8” |
15/16” |
7/8” |
1” |
7/8” |
1-1/4” |
7/8” |
* At lead end. Standard cold sections can be increased. Consult for metric diameter dimensions. |
CARTRIDGE IMMERSION HEATER
 |
Cartridge Immersion Heater
Available in brass, steel, or stainless steel pipe fitting which allows liquid tight installation through threaded openings. Fittings are brazed to the heater. Be certain the watt density and sheath material are compatible with the material being heated. (Available in both NPT and Straight thread with O-Ring) See chart for sizes available.
Cartridge Immersion Heaters
DIA. |
Pipe Size NPT |
Pipe
Fitting
Length |
1/4” |
1/8-27 |
5/8” |
3/8” |
1/4-18 |
5/8” |
1/2” |
3/4-18 |
3/4” |
5/8” |
1/2-14 |
13/16” |
3/4” |
3/4-14 |
15/16” |
|
Cartridge Immersion Heaters Straight Thread
DIA. |
S.A.E. O-Ring Boss |
Pipe Fitting Length |
1/2” |
08
3/4-16 THD |
3/4” |
1/2” |
10
7/8-14 THD |
3/4” |
5/8” |
10
7/8-14 THD |
3/4” |
|
|
Right Angle Leads is used when spacing requirements are limited. See chart below for the additional dimension the heater adds to the sheath length of stock items. When ordering non-stock Fig. R, specify the overall sheath length. High temperature (850° F/450° C) leads are fully flexible from the exit of the sheath. 12" lead wire is standard. Specify additional length.
| Non-Stock Right Angle Leads
|
| Dia. |
Minimum Unheated* |
| 1/8" |
-- |
| 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" |
| 1-1/4" |
1-7/8" |
Flanged Cartridge Heaters
Flanged Cartridge Heaters
Cartridge Heater can be manufactured with flange located at any point along sheath with adequate unheated area.
Water Pelletizer Cartridge Heater
Conduit Coupler Connector
Flexible conduit is attached with a copper coupler over-lapping the heater by 1/4". Leads are 14" long and cable 12" unless specified. 
Fig. 1B and 1C can be attached to stock items.
* Standard cold sections can be reduced or increased
| Diameter |
Minimum Unheated* |
| Fig. 1B |
Fig. 1C |
| 1/4" |
1/8" |
1/8" |
| 3/8" |
7/8" |
7/8" |
| 1/2" |
7/8" |
7/8" |
| 5/8" |
7/8" |
7/8" |
| 3/4" & larger |
7/8" |
7/8" |
| Diameter |
A |
B |
Cable O.D. |
| 1/4" |
3/4" |
7/8" |
1/4" |
| 3/8" |
3/4" |
15/16" |
3/8" |
| 1/2" |
1" |
1-3/16" |
3/8" |
| 5/8" |
1-1/16" |
1-7/16" |
1/2" |
| 3/4" & larger |
1-5/16" |
1-7/8" |
1/2" |
|
The square heater assembly consists of an element wound on shaped ceramic cores and securely connected to internal lead conductors. This assembly is centrally located within shaped tubing and voids are filled with ceramic insulation. The heater assembly is swaged to the final square cross-sectional dimensions to metallurgically bond the element wire to the lead conductors and to compact the internal ceramic core and ceramic insulation to near theoretical density. The densely compacted assembly provides the optimum heat transfer and insulation dielectric essential to heater performance and reliability and maximizes the heaters resistance to vibration, shock and physical abuse.
As an alternative to traditional round cartridges and their costly, time consuming deep hole drilling requirements, square cartridges utilize simple, cost effective surface milled slot mounting systems. This approach provides close fits between the cartridge and tooling maximizing heat transfer and performance while still allowing easy heater removal for maintenance and cleaning. Lead channels added during the slot machining process provide total protection for the heater power leads while allowing routing of the leads to connectors or terminal strips at any desired location on the tool. A square cartridge forming option further simplifies heating of special shapes and can be utilized in heating both large and small tooling components.
