High-Performance Custom Electric Waterproof Cartridge Heater for Industrial Use
Expertly crafted with meticulous precision, this state-of-the-art cartridge heater is encased in a robust cylindrical stainless steel tube, renowned for its exceptional corrosion resistance and durability. At the heart of this masterpiece lies an intricately engineered heating wire, skillfully wound around a high-quality ceramic core, making it the driving force behind this elite heating solution.
The coil configuration is meticulously fine-tuned to align with the heater's power demands, ensuring superior heat distribution and significantly extending the heater's lifespan. This advanced design effectively mitigates heating wire oxidation, even at elevated temperatures. Whether employed for heating solids, liquids, or gases, our cartridge heaters excel in conducting heat efficiently when in direct contact with the heat sink. Ideal for the production of plastic and rubber components in the automotive industry, these heaters prove indispensable in sectors such as food processing, chemical manufacturing, electronics, medical equipment, packaging, and even nuclear applications.
In addition to our diverse standard offerings, we specialize in the bespoke development and production of cartridge heaters, meticulously tailored to meet your specific and detailed requirements.
The cartridge heaters are designed with a resilient crimped-on or swaged-in construction, integrating a top-grade nickel-chromium resistance wire for unmatched performance and reliability.
This resistance wire is expertly wound around an exceptional-quality MgO core, perfectly centered within its stainless steel sheath, ensuring optimal performance.
Cartridge heaters are versatile and serve a wide array of heating applications, such as metal parts and liquid heating when paired with threaded bushings. These heaters can reach metal temperatures as high as 760°C, guaranteeing superior performance with the right selection of material, watt density, and fit.
Performance capabilities:
1. Capable of achieving part temperatures up to an impressive 1400°F (760°C) with an alloy 800 sheath, ensuring high thermal efficiency.
2. Watt densities can reach soaring levels of up to 40W/cm², providing powerful heating solutions.
3. Operational voltages cover a broad range, from a minimal 5VAC to a substantial maximum of 480VAC, offering versatile application.
4. The diameter is as compact and precise as 3mm, allowing for tailored customization.
5. Expanding up to a maximum diameter of 35mm, accommodating diverse industrial needs.
Benefits:
1. Installation is not only easy but also cost-effective, saving time and resources.
2. Crafted from superior, high-quality materials, ensuring durability and longevity.
3. Engineered for optimized heat transfer efficiency, maximizing energy use.
4. Maintenance is straightforward and hassle-free, minimizing downtime.
5. Ensures even temperature distribution, providing consistent performance.
6. Resistant to both oxidation and corrosion, enhancing operational longevity.
7. Designed for exceptional long-term durability, offering reliable service.
8. Endorsed by TÜV Rheinland, holding CE certification for assured quality.
Technical Details:
1. Tube diameter: Ranging from Φ3mm to Φ30mm, providing flexibility in design and application.
2. Tube Material: Choose from a variety of materials including SS304, SS316, SS321, NICOLOY800, and more, to suit diverse environmental conditions.
3. Insulation Material: Utilizes high-purity MgO for enhanced insulation and heat retention.
4. Resistance wire element: Choose from the reliable Ni-Cr or FeCr materials to ensure optimal performance.
5. Lead Connection Options: Opt for Crimped or Swaged leads to secure connections tailored to your needs.
6. Lead and Type of Connection Leads: Equipped with a 10" Fiberglass Standard Wire, and also available in High Temperature Silicone Fiberglass options.
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:
Our cartridge heaters are thoughtfully categorized by density to suit varied applications:
1. High Power Density: Delivering an impressive heat area surface power range of 10~25 W/cm².
Capable of maintaining a working temperature of up to 450°C.
2. Middle to Low Power Density: Ensures a heat area surface power range of 5~11 W/cm².
Designed to function effectively at temperatures up to 300°C.
Voltage: Versatile voltage options ranging from 12~250V, adaptable to specific requirements.
High Density Construction:
Crafted with premium stainless steel, providing robust and enduring protection in the toughest industrial settings.
Encased in a durable stainless steel sheath, achieving watt densities up to 50 W/cm² and operational temperatures soaring to 800°C.
More Photos of Our Cartridge Heaters:
Factors - How to Choose the Right Cartridge Heaters:
To ensure optimal performance, evaluate these crucial factors when selecting a cartridge heater:
1. The desired operating temperature for your application.
2. The watt density required by the heating element for efficiency.
3. Consider the sheath material based on whether the environment is corrosive or non-corrosive.
-
- Assess the temperature of the corrodent for optimal material selection.
-
- Understand the degree of aeration the exposed corrodent will experience.
-
- Evaluate the velocity of the corrodent to ensure durability.
Dimensional Data:
(The table below provides the minimum and maximum sheath lengths available for various diameters.)
| |
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 |
(The recommended maximum sheath length is mentioned; longer lengths may be offered upon request.)
Termination Options:
1. Swaged-in Flexible Leads:
For applications necessitating bending at the lead exit, swaged-in flexible leads with silicone-fiberglass insulation are ideal.
Standard supply includes 250mm
(10 in.)
leads, unless a longer length is specified.
Heaters measuring 150mm
(6 in.)
or shorter typically have a 6mm
(1/4 in.)
no-heat section. For heaters up to 250mm
(10 in.),
a 25mm
(1 in.)
no-heat section is required. Heaters exceeding 250mm might necessitate extending beyond a 25mm no-heat section. To order, please specifyswaged-in flexible leads for optimal performance.
2. Right Angle Leads:
Right angle leads are designed for applications with extensive flexing and when space is at a premium. Lead wires exit at a precise 90° angle through the heater sheath's side.
A right-angle tube might be essential for particular configurations. When placing an order, please specify the details.right angle leads and the lead length, ensuring they align perfectly with your precise requirements.
| 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 BraidPremium Stainless Steel Braid
Our exceptionally durable stainless steel braid is expertly designed to safeguard your leads from wear and tear caused by sharp edges, providing unmatched longevity and dependable performance.
For varied lead exit setups, we provide custom solutions: In straight-out lead exits, the braid is precisely swaged into the heater's no-heat area. For right-angle exits, a crimp connector firmly secures the braids, ensuring seamless performance and integration.
Unless otherwise specified, our standard leads are crafted with precision to a length of 250 mm
(10 in.)
in length. The superior braid is manufactured to an optimal length of 200 mm
(8 in.)
long. To customize your order, please specify your preference for straight or right-angle stainless steel braid, lead length, and any specific no-heat section requirements you may have.
| 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 Durable Stainless Steel Hose
Our high-quality stainless steel hose provides outstanding protection against sharp edges or abrasive equipment, making it easy to handle and install even in demanding environments.
For right-angle lead exits, the hose is expertly silver soldered to the sheath. Unless specified differently, standard leads are 250 mm(10 in.) long, with the hose precisely designed at 200 mm(8 in.). To place an order, please specify your choice of stainless steel hose, lead length, and desired 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 Galvanized Conduit Protection
Our galvanized conduit offers protection similar to that of stainless steel hose, effectively shielding against abrasion.
The conduit is connected using a 90° elbow copper coupler, which securely overlaps the heater sheath. Unless otherwise specified, we provide a standard 200 mm(8 in.) conduit, with leads extending 50 mm beyond for enhanced flexibility. To place an order, please specify galvanized conduit, lead length, and desired 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 high-temperature ceramic bead insulation provides exceptional protection for leads in environments exceeding 450°C(840°F). The ceramic beads are designed to fit over solid conductors, extending to cooler areas where flexible wires can be safely attached. To specify your order, please indicate ceramic beads and length, along with any additional lead length requirements.
7. Versatile Stainless Steel Flanges
Our versatile stainless steel flanges offer a convenient mounting method and an efficient way to precisely position heaters in your applications. Flange style and specifications are tailored to meet your exact requirements, and they can be strategically placed in any no-heat section of the heater sheath. To order, please specify flange, desired flange size, and exact location. .
Immersion Cartridge Heaters for Liquid Applications:
For optimal liquid immersion heating applications, we suggest using top-quality brass or stainless steel threaded bushings.
The size of the threaded bushing is precisely matched to the pipe diameter. Available specifications include Our selection features G thread, NPT thread, and BSPP thread, providing versatility and adaptability for your specific needs. Additionally, a variety of options ensures impeccable compatibility with your existing systems.
A Comprehensive Guide to Seamlessly Installing Cartridge Heaters:
1. Begin by crafting a precise hole in the section where heat application is required for optimal results.
2. Ream the hole to achieve smoothness and evenness, optimizing contact and enhancing heat transfer efficiency.
3. Extend the hole through the section to facilitate effortless removal of the unit when necessary.
4. If creating a through hole is not feasible, adjust the hole size while maintaining allowable tolerances.
5. Minimize vibration and flexing of the lead wires to dramatically extend the product's service life.
6. Ensure protection against liquid contamination by safeguarding the heater's terminal end effectively.
To process your order for Cartridge Heaters smoothly, please provide the following essential details :
1. Specify the type of Cartridge Heater (explore our Termination Options for a variety of selections).
2. Provide the precise diameter of the Cartridge Heater, tailored to your specifications.
3. Detail the overall length of the straight Cartridge Heaters, customized to meet your unique needs.
4. Include detailed specifications on Wattage and Voltage for your specific application.
5. Specify the type and length of Lead (options include glass fibre / PTFE) to suit your requirements.
Frequently Asked Questions
(1). Q: Can you offer a discount?
A: Absolutely, our discounts are based on order quantity. The more substantial your order, the greater the discount.
(2). Q: How can I obtain a sample?
A: Generally, we provide complimentary samples for small quantities, with shipping covered by the customer. You may also use your DHL, FEDEX, EMS, or UPS account. For larger quantities, a minimal sample fee might apply.
(3). Q: Why is your price higher than other Chinese suppliers?
A: We prioritize the creation of premium, high-performance products, aiming to foster long-lasting, amicable relationships with our customers.
While our prices may not be the lowest, we deliver unmatched value.
(4). Q: How do you ensure the quality of mass production matches the sample sent to me?
A: Our diligent warehouse team retains an identical sample marked with your company name before dispatching the original, guaranteeing consistent quality across production.
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