Insertion 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.

 

Cartridge Heaters

Flanged Cartridge Heaters Cartridge heaters can be manufactured with flanged located at any point along sheath with adequate unheated area. Type W flanged can also be attached to Fig. U unheated section on 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" . Additional Variations Special Wattage Distribution. Specify percentage of overall wattage and length for each section. Typically, the entire lenght is divided into thirds with the overall wattage split into the following percentages: 40% at lead and bottom third of length with 20% in the middle, or, 35% at lead and bottom third of length with 30% in the middle.   Fiberglass Sleeving Teflon® Sleeving Formed­Consult Ogden Centerless Grinding of Sheath to Precision Diameter Passivation Special Unheated Area Ground Lead Ceramic Bead Insulation Built-in Thermostat or Thermal-Fuse

Cartridge Heaters

Stainless Steel Braided Lead Protection Swaged-in double conductor stainless steel braid is internally connected for strength and full length flexibility. See chart below for the additional dimension the Figure F and Figure G adds to the sheath length of stock items. For non-stock single conductor braided lead protection, specify Figure H for straight exit, Figure J for right angle. When ordering non-stock Fig. F, G, H or J items, specify the overall sheath length. 14" high temperature (850 F/450 C) leads with 12" braid is standard. Specify additional length. * At lead end. Standard cold sections can be increased. Consult for metric diameter dimensions. Armor Cable Leads Stainless steel Armor Cable Lead Protection Stainless steel armor cable is the best protection for use where lead wires experience abrasion. See chart below for the additional dimension the Mighty Watt Plus Figure A and D add to the sheath length of stock items. When ordering non-stock Fig. A and Fig. D items, specify the overall sheath length. 14" high temperature (850F/450C) leads with 12" cable is standard specify additional length. * At lead end. Standard cold sections can be increased. Consult for metric diameter dimensions. Non-Stock Armor Cable Protection Dia. Minimum Unheated* Cable O.D. Fig. A Fig. D 1/8" -- -- -- 1/4" 1-1/2" 1-1/2" 1/4" 5/16" 1-1/2" 1-1/2" 1/4" 3/8" 1-1/2" 1-1/2" 3/8" 1/2" 1-1/2" 1-1/2" 3/8" 5/8" 1-9/16" 1-9/16" 1/2" 3/4" 1-7/8" 1-7/8" 1/2" 15/16" 1-7/8" 1-7/8" 1/2" 1" 1-7/8" 1-7/8" 1/2" 1-1/4" 1-7/8" 1-7/8" 1/2"

 

Cartridge Heaters

Fax-Back Data Sheet

Cartridge Heaters 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 FIG. X 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"). FIG. X High Temperature Fully Flexible Leads * At lead end. Standard cold sections can be increased. Consult for metric diameter dimensions. Fig. X 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" 5/8" 11/16" 3/4" 7/8" 15/16" 7/8" 1" 7/8" 1-1/4" 7/8"

 

CARTRIDGE IMMERSION HEATER

 

Figure M is a brass, steel or stainless steel pipe fitting which allows liquid tight installation through threaded openings. Fittings are brazed. For welded fittings and other cartridge immersion heater variations, scroll along this section. Be certain the watt density and sheath material are compatible with the material being heated. Diameter Pipe Size NPT Pipe Fitting Length 1/4" 1/8-27 5/8" 3/8" 1/4-18 5/8" 1/2" 3/8-18 3/4" 5/8" 1/2-14 13/16" 3/4" 3/4-14 15/16" Stock Sheath Length Is Immersion Length Fig. M Ordering Information Select Mighty Watt Cartridge Heater from Stock, brass, steel or stainless steel pipe fitting and size, type of termination and lead length.

Right Angle Leads

Figure R 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.

* At lead end. Standard cold sections can be increased. Consult for metric diameter dimensions.

Non-Stock Right Angle Leads - Fig. R
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"

Cartridge Heaters

Flanged Cartridge Heaters Cartridge heaters can be manufactured with flanged located at any point along sheath with adequate unheated area. Type W flanged can also be attached to Fig. U unheated section on stock items. 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" . Additional Variations Special Wattage Distribution. Specify percentage of overall wattage and length for each section. Typically, the entire lenght is divided into thirds with the overall wattage split into the following percentages: 40% at lead and bottom third of length with 20% in the middle, or, 35% at lead and bottom third of length with 30% in the middle.   Fiberglass Sleeving Teflon® Sleeving Formed­Consult Ogden Centerless Grinding of Sheath to Precision Diameter Passivation Special Unheated Area Ground Lead Ceramic Bead Insulation Built-in Thermostat or Thermal-Fuse

 

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.

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PLATE HEATERS

Precision plate and component heater assemblies are designed for a wide range of extrusion, molding and packaging applications. The rugged, high performance assemblies provide exceptional performance in the heating of extrusion profile dies, blow-molding manifolds and die heads, wire cross head dies, extruder barrels, polymer pumps, and injection molds.