Customized Electric Cartridge Resistance Rod Heater with Metal Braid Wire
Our exceptional cartridge heater is crafted from a durable cylindrical stainless steel tube, offering remarkable resistance against corrosion. Within this robust casing lies a precisely wound heating wire, expertly coiled around a high-grade ceramic core, which forms the core of this top-tier heater.
The coil count is expertly calibrated to the heater's power specifications, ensuring optimal heat dispersion and extending the heater's lifespan. This meticulous design minimizes the oxidation of the heating wire even under high temperatures. Whether warming solids, liquids, or gases, our cartridge heaters provide unparalleled heat transfer through conduction, given they are in direct contact with the heat sink. Essential for manufacturing plastic and rubber parts in the automotive sector, these heaters also play a crucial role in food processing, chemicals, electronics, medical equipment, packaging, and nuclear applications.
Beyond our extensive standard selection, we excel in the custom design and production of cartridge heaters, uniquely crafted to meet your exact specifications.
Cartridge heaters boast a crimped-on or swaged-in construction, utilizing a superior nickel-chromium resistance wire for outstanding performance.
This wire is precisely wound around a premium MgO core, which is meticulously centered within a stainless steel casing.
Cartridge heaters are tailored for versatile heating applications, including metal components and liquid heating when fitted with threaded bushings. Capable of achieving metal temperatures up to 760°C, these heaters deliver peak performance when the proper material, watt density, and fit are selected.
Performance capabilities:
1. Achieve part temperatures up to 1400°F (760°C) with a robust alloy 800 sheath
2. Watt densities reaching up to 40W/cm²
3. Operating voltage range from 5VAC to 480VAC
4. Minimal diameter as small as 3mm
5. Maximum diameter extending up to 35mm
Benefits:
1. Simple and cost-efficient installation
2. Crafted with high-quality materials
3. Superior heat transfer efficiency
4. Easy and straightforward maintenance
5. Consistent temperature distribution
6. Oxidation and corrosion resistant
7. Exceptional long-lasting durability
8. Endorsed by TÜV Rheinland (CE certification)
Technical Details:
1. Tube diameter: From Φ3mm to Φ30mm
2. Tube Material: Options include SS304, SS316, SS321, NICOLOY800, among others.
3. Insulation Material: Made from high-purity MgO
4. Resistance wire element: Composed of Ni-Cr or FeCr
5. Lead Connection Options: Available in crimped or swaged leads
6. Lead and Type of Connection Leads: Experience top-notch connectivity with our 10" Fiberglass Standard leads, engineered for reliability.Wire Options: Choose between Silicone or High-Temperature Fiberglass for optimal performance under heat..
Specification of Cartridge Heaters:
| Sheath material |
SS304.321.316L,Incoloy800.840,Titanium |
| Insulation material |
High-purity MgO |
| Resistance |
Ni-Cr or FeCr |
| Maximum voltage |
480VAC |
| Wattage density |
high/middle/low(5-40w/cm2) |
| Wattage tolerances |
toloerance :+5% -10% |
| Dimensional |
Diameter: Min. dia:3mm |
| Length: |
Customized |
| Lead options |
Crimped- on / Swaged- in |
| Lead types |
Swage fiberglass insulation nickel wire ( 750°C ) |
| Crimp on silicone lead ( 250°C ) Crimp |
| Silicon insulated wire ( 200°C ) |
| Crimp fiberglass insulation nickel wire ( 450°C ) |
| Internal |
Type J or K available thermocouple |
| Lead protection options |
Stainless steel braid |
| Stainless steel flexible hose |
| other options |
Bent heaters, in no-heat section, up to 90° angle |
| mounting flange |
Feature:
Common cartridge heaters can be divided into two types based on density: For tailored heating solutions, explore our diverse cartridge heaters:
1. High Power Density: Delivers an impressive heat area surface power of 10~25 W/cm², perfect for high-demand environments.
Working temperature ≤ 450°C, ensuring stability and efficiency.
2. Middle to Low Power Density: Ideal for moderate applications with a heat area surface power of 5~11 W/cm².
Working temperature ≤ 300°C, offering a balance of performance and safety.
Voltage: 12~250V (or as per requirement), adaptable to your specific needs.
High Density Construction:
Crafted with high-quality stainless steel, ensuring robust protection in demanding industrial settings.
The stainless steel sheath enhances watt density up to 50 W/cm², withstanding temperatures up to 800°C.
More Photos of Our Cartridge Heaters:
Factors - How to Choose the Right Cartridge Heaters:
Consider the following factors to select the right cartridge heater: Ensure your selection aligns with your unique requirements:
1. Operating temperature, critical for optimal performance.
2. Watt density of the heating element, tailored to your application.
3. Sheath material (corrosive or non-corrosive), depending on environmental exposure.
-
- Temperature of the corrodent, influencing material choice.
-
- Degree of aeration of exposed corrodent, affecting longevity.
-
- Velocity of the corrodent, crucial for performance.
Dimensional Data:
(This table shows minimum and maximum sheath lengths for available diameters, guiding you to the right fit.)
| |
Diameter |
|
|
Length |
|
| Normal |
Actual |
Min |
|
|
Max |
| in. |
in. |
mm |
in |
mm |
in |
mm |
| 1/8 |
0.122 |
3.1 |
7/8 |
22.2 |
12 |
305 |
| 1/4 |
0.246 |
6.3 |
7/8 |
22.2 |
36 |
915 |
| 3/8 |
0.371 |
9.4 |
7/8 |
22.2 |
48 |
1220 |
| 1/2 |
0.496 |
12.6 |
7/8 |
22.2 |
60 |
1520 |
| 5/8 |
0.621 |
15.8 |
1 |
25 |
72 |
1830 |
| 3/4 |
0.746 |
18.9 |
1 |
25 |
72 |
1830 |
| 1 |
0.996 |
25.3 |
1 1/4 |
32 |
72 |
1830 |
(Indicates recommended maximum sheath length; however, longer lengths may be available, offering flexibility in design.)
Termination Options:
1. Swaged-in Flexible Leads:
Swaged-in flexible leads with silicone-fiberglass insulation are perfect for applications requiring bending at the exit point.
Unless a longer length is specified, 250mm
(10 in.)
leads are supplied, ensuring sufficient reach.
Heaters 150mm
(6 in.)
or shorter generally have a 6mm
(1/4 in.)
no-heat section. Heaters up to 250mm
(10 in.)
require a 25mm
(1 in.)
no-heat section. Heaters greater than 250mm may require more than a 25mm no-heat section. To order, please specifyswaged-in flexible leads.
2. Right Angle Leads:
Right angle leads are used in applications with a high degree of flexing and when space is at a premium.
A right-angle tube may be necessary for certain constructions. To order, specifyright angle leads and lead length to fit your design.
| Diameter mm |
Min No-Heat Length mm(in.) |
| 6.5 |
15 (9/16) |
| |
15 (9/16) |
| 108.0 |
17 (2/3) |
| 12.5 |
18 (11/16) |
| 16.0 |
20 (3/4) |
| 20.0 |
21 (13/16) |
3.Premium Stainless Steel Braid
Our robust stainless steel braid is meticulously crafted to protect leads from wear and tear against sharp edges, ensuring unmatched durability and unwavering reliability.
For diverse lead exit configurations, we present tailored solutions: When leads exit straight, the braid is seamlessly integrated into the no-heat section of the heater. For right-angle exits, a crimp connector securely fastens the braids, providing flawless integration.
Unless otherwise indicated, our standard leads measure 250 mm
(10 in.)
in length. The durable braid measures 200 mm
(8 in.)
in length. To personalize your order, please specify your preference for straight or right-angle stainless steel braid, lead length, and no-heat section specifications.
| Diameter |
Min. No-Heat Length |
| Straight |
Right Angle mm |
| mm |
| mm (in.) |
|
(in.) |
| |
|
| 6.5 |
30 (1 1/8) |
|
N/A |
| 8.0 |
30 (1 1/8) |
15 |
(9/16) |
| 10.0 |
30 (1 1/8) |
17 |
(2/3) |
| 12.5 |
30 (1 1/8) |
18 |
(11/16) |
| 16.0 |
30 (1 1/8) |
20 |
(3/4) |
| 20.0 |
30 (1 1/8) |
21 |
(13/16) |
4. Durable Stainless Steel Hose
Our premium stainless steel hose offers outstanding protection against abrasive elements and sharp edges. It also ensures effortless handling and streamlined wiring in challenging environments.
For right-angle lead exits, the hose is securely silver soldered to the sheath. Unless otherwise noted, our standard leads are 250 mm(10 in.)in length and the hose measures 200 mm(8 in.)in length. To customize your order, please specify stainless steel hose, lead length, and no-heat section.
| |
Min. No-Heat Length |
| Diameter |
Straight |
Right Angle mm |
| mm |
mm (in.) |
|
(in.) |
| 6.5 |
30 (1 1/8) |
|
N/A |
| 8.0 |
30 (1 1/8) |
15 |
(9/16) |
| 10.0 |
30 (1 1/8) |
17 |
(2/3) |
| 12.5 |
30 (1 1/8) |
18 |
(11/16) |
| 16.0 |
30 (1 1/8) |
20 |
(3/4) |
| 20.0 |
30 (1 1/8) |
21 |
(13/16) |
5. Galvanized Conduit Protection
Our galvanized conduit offers robust protection comparable to stainless steel hose against abrasion.
The conduit is attached with a 90° elbow copper coupler, securely overlapping the heater sheath. Unless specified, we provide a standard 200 mm(8 in.)conduit, with leads 50 mm longer than the conduit. To customize, specify galvanized conduit, lead length, and no-heat section.
| |
Min |
|
|
Galvani |
| Diam |
Dimensio |
Dimensio |
zed |
| No-Heat |
| eter |
n A |
n B |
conduit |
| Length |
| mm |
mm(in.) |
mm(in.) |
O.D. |
| mm(in.) |
| |
|
|
mm(in.) |
| |
|
|
|
| 6.5 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 8.0 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 10.0 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 12.5 |
12(7/16) |
28(1 1/8) |
30(1 3/16) |
14(1/2) |
| 16.0 |
12(7/16) |
28(1 1/8) |
34(1 5/16) |
14(1/2) |
| 20.0 |
12(7/16) |
29(1 1/8) |
36(1 7/16) |
16(5/8) |
6. High-Temperature Ceramic Bead Insulation
Our ceramic bead insulation provides exceptional protection for leads in high-temperature environments above 450°C(840°F).These ceramic beads fit over solid conductors and extend to cooler areas where flexible wires can be securely attached. To personalize your order, specify ceramic beads and length, and additional lead length needs.
7. Versatile Stainless Steel Flanges
Our versatile stainless steel flanges offer a convenient mounting method and an effective way to position heaters within various applications. Flange style and specifications can be tailored to customer requirements. These flanges can be positioned in any no-heat section of the heater sheath. To order, specify flange, flange size, and location. .
Immersion Cartridge Heaters for Liquid Applications:
For optimal liquid immersion heating, we recommend utilizing brass or stainless steel threaded bushings.
The threaded bushing size is expertly matched to the pipe diameter, with available specifications including
G thread, NPT thread, and BSPP thread , among others.
Step-by-Step Guide to Installing Cartridge Heaters:
1. Craft a precise aperture in the section to be heated for precision in performance.
2. Carefully ream a smooth hole to ensure optimal contact and enhanced heat transfer efficiency.
3. Extend the hole through the section, enabling seamless removal of the unit when necessary.
4. If a through hole cannot be created, adjust the hole size within permissible tolerances.
5. Minimize any vibration and flexing of the lead wires to maximize service life and reliability.
6. Protect the heater's end to prevent any liquid contamination and ensure longevity.
To ensure your Cartridge Heater is perfectly suited to your needs, please provide the following details :
1. Specify the Type of Cartridge Heater (refer to Termination Options for guidance).
2. State the Diameter of the Cartridge Heater for precision fit.
3. Provide the Overall Length of the straight Cartridge Heaters for accuracy.
4. Indicate the required Wattage and Voltage specifications.
5. Select the Type of Lead (glass fibre / PTFE) and specify the lead length as needed.
FAQ
(1). Q: Can you offer a discount?
A: Discounts are contingent on quantity; the larger the order, the more substantial the discount.
(2). Q: How can I obtain a sample?
A: Samples can be provided free of charge for small quantities, with shipping costs covered by the customer. Alternatively, provide your shipping account number (DHL, FEDEX, EMS, or UPS). For larger orders, a sample fee may apply.
(3). Q: Why is your price higher than other Chinese suppliers?
A: Our commitment is to high-quality, high-performance products, fostering long-term, positive relationships with our customers.
Although our prices might not be the lowest, our products offer the highest cost-effectiveness.
(4). Q: How do you ensure the quality of mass production matches the sample sent to me?
A: Our warehouse team retains an identical sample marked with your company name before dispatch, ensuring consistent quality in mass production.
){kind=link}