Hi-Density Cartridge Heaters

The Electrical Termination is located at one end of the heater and exits straight out from the heater.

The Electrical Termination is located at one end of the heater and exits at a right angle from the heater.

Each end has one Electrical Termination.

If your filter selections do not return your desired results from our standard configurations, please continue to select your Specifications. When you are finished, save your selections in the Wish List (using the button at the right of this page) and follow the steps to submit them to Tempco.

Standard Termination for Hi-Density and Hi-Density Metric Cartridge Heaters. Flexible stranded lead wires have fiberglass insulation and are connected to 1-1/4″ (32 mm) long solid conductors. Silicone rubber coated fiberglass sleeving insulates the pin/lead wire connection.

Standard Termination for Low-Density Cartridge Heaters. The fiberglass lead wires are internally connected to the terminal pins. This lead termination provides flexibility, permitting the lead wires to be sharply bent as they exit the heater.

A liquid barrier used for low temperature applications primarily in refrigeration or food service applications. The seal bonds to both the heater and the leads.

Potted end seals help to protect the heater from moisture or contamination from plastic material, cleaning solvents, or oils. The bottom end disc seal is welded in.

Standard Termination for Hi-Density Miniature Cartridge Heaters. A moisture resistant Teflon® seal that is swaged in during the manufacturing process with Teflon® insulated lead wire.

A liquid-proof stainless steel corrugated metal hose is silver brazed to the end of the cartridge heater. The end disc of the heater is also welded or brazed. This termination provides a positive seal against moisture and contamination entering the heater.

The leads are reinforced with a steel spring for applications with extreme flexing. The spring is mechanically fastened or silver brazed.

Stainless steel braid over fiberglass leads offers sharp bending not possible with armor cable, as well as abrasion protection.

Stainless steel braid over fiberglass leads offers sharp bending not possible with armor cable, as well as abrasion protection. In addition, Type W3 offers contamination resistance due to the Teflon® seal required for holding the wire braid.

The armor cable is directly attached to the cartridge heater, eliminating the coupling, to maintain an overall diameter equal to or smaller than the cartridge diameter.

Armor cable provides the maximum in protection for abrasive, jagged environments. The coupling between the cartridge and the armor cable is mechanically fastened or silver brazed. *Limited to C1B: SS Cable, Mechanically Fastened for 1/8″ Miniature Cartridge Heaters

This termination is used when space is limited. The copper elbow is mechanically fastened or silver brazed.

This termination is used when space is limited. Not suitable for abrasive environments. The plain leads are internally connected and they offer flexibility. Various lead end finishes are available as listed below:

The leads are reinforced with a steel spring for applications with extreme flexing. The spring is mechanically fastened or silver brazed.

Stainless steel braid over fiberglass leads for abrasion protection, mechanically crimped to the cartridge sheath at 90°. Wire braid offers extreme flexibility not possible with armor cable. Various lead end finishes are available as listed below.

Armor cable provides the maximum in protection for abrasive, jagged environments. The copper elbow between the cartridge and the armor cable is mechanically fastened or silver brazed.

Use this termination when space is limited and maximum protection is required. The armor cable is tack welded or silver brazed to the cartridge sheath at 90°. The sheath extension is potted with cement. Various lead end finishes are available as listed below.

For use with leads, crimp terminals, or bus bars. Includes washers and nuts.

The ultimate in high temperature lead protection. Allows for the attachment of flexible leads to the heater away from the high heat area. Used when the ambient temperature exceeds 842°F (450°C).

High temperature flexible leads are connected away from the high heat area.

For those applications in which wiring from both ends is an advantage. Various seals are available:

For applications in which it is an advantage to wire from both ends. The leads are internally connected and can be bent sharply as they exit the potted ends. Various seals are available:

A Double-Ended heater with quick change wiring screw terminals. Includes zinc plated washers and nuts.

If your filter selections do not return your desired results from our standard configurations, please continue to Refine Results for your specifications. When you are finished, save your selections with the Save Results for Quote button (at the right of this page) and choose Request for Quote for further assistance.

Strain relief clip for leads subject to tension and stress. A “T” type strain relief is silver brazed to the sheath.

Strain relief clip for leads subject to tension and stress. A “T” type strain relief is silver brazed to the sheath and bent at a 90° angle.

General purpose Stainless Steel NEMA 1 electrical enclosure designed to provide protection from electrical shock. The boxes have a 5/8″ conduit knockout and are welded or brazed to the cartridge sheath.

NEMA 4 aluminum electrical enclosures provide protection from splashing or hose directed water, external condensation and water seepage. The box is mechanically attached to the cartridge sheath.

General purpose Stainless Steel NEMA 1 electrical enclosure designed to provide protection from electrical shock. The box is welded or brazed to the cartridge sheath.

General purpose steel NEMA 1 electrical enclosure designed to provide protection from electrical shock. The box is welded to the cartridge sheath.

NEMA 4/7 electrical enclosures provide protection from contaminants, moisture, and hazardous conditions. These housings are screwed onto a heater with a single or double ended Brass or Stainless Steel fitting. A threaded fitting mounting termination must be specified. See pages 2-50 and 2-51. Other terminal box configurations available upon request.

Various types of crimp terminals can be attached to the heater leads to make wiring into applications quick and easy. Non-insulated and insulated with nylon (221°F/105°C) or PVC (194°F/90°C).

Various types of crimp terminals can be attached to the heater leads to make wiring into applications quick and easy. Non-insulated and insulated with nylon (221°F/105°C) or PVC (194°F/90°C).

Various types of crimp terminals can be attached to the heater leads to make wiring into applications quick and easy. Non-insulated and insulated with nylon (221°F/105°C) or PVC (194°F/90°C).

Various types of crimp terminals can be attached to the heater leads to make wiring into applications quick and easy. Non-insulated and insulated with nylon (221°F/105°C) or PVC (194°F/90°C).

Allows for the quick and easy replacement of the heater. The plug can be attached to galvanized armor cable, stainless steel armor cable, or wire braid.

When required, high temperature lead wire can be used on most cartridge heaters. The stranded wire is insulated with mica tapes and then a treated fiberglass overbraid.Maximum temperature rating: 450°C (842°F)

Maximum temperature rating: 200°C (392°F)

Either the galvanized or stainless steel armor cable can be covered with moisture proof heat shrink Polyolefin tubing.

When required, high temperature lead wire can be used on most cartridge heaters. The stranded wire is insulated with mica composite and then a treated fiberglass overbraid. Available wire gauge sizes: 10-18 Maximum temperature rating: 550°C (1022°F)

For effective thermal and mechanical protection, the lead wires can be covered with uncoated fiberglass sleeving.

FSA: Uncoated Fiberglass sleeving on each lead separately

FSB: Uncoated Fiberglass sleeving on both leads together Specify length when ordering. Maximum temperature rating: 1112°F (600°C)

For added protection, strength, and resistance to various chemicals, the lead wires can be covered with silicone rubber sleeving.

SRA: Silicone rubber coated fiberglass sleeving on each lead separately

SRB: Silicone rubber coated fiberglass sleeving on both leads together Specify length when ordering. Maximum temperature rating: 200°C (392°F)

If your filter selections do not return your desired results from our standard configurations, please continue to select your Specifications. When you are finished, save your selections in the Wish List (using the button at the right of this page) and follow the steps to submit them to Tempco.

A single threaded pipe fitting is attached to the end of a cartridge heater to allow for installation into a threaded hole. This mounting option, available with many terminations, can also be offset from the lead end of the sheath. This option is useful when the lead wires need to be kept away from the heated area. Brass fittings are silver brazed and stainless steel fittings are heli-arc welded. Available with the potting seals listed in the table.

A double threaded pipe fitting is attached to the end of a cartridge heater to allow for installation into a threaded hole. Brass fittings are silver brazed and stainless steel fittings are heli-arc welded.

This heater has a header cap as an integral part of the fitting. Leads exit through small holes which are sealed with epoxy for moisture protection.

A 5/8-18 UNF fitting is attached to the end of the cartridge heater to allow for mounting the heater to the wall of a tank or enclosure. Brass fittings are silver brazed and stainless steel fittings are heli-arc welded. Includes a copper washer and jam nut. The lead wires are internally connected. Available with the potting seals listed in the table.

Recommended for applications where excessive vibration exists and may cause the heater to back out of its mounting hole. The 16 ga. 304 SS flange is used as a means of securing the cartridge heater in place. The default position of the flange is flush with the lead end. Specify the position of the flange when ordering.

A hex shape allows the possibility of using a wrench when removal is tight. The 16 ga. 304 SS flange is used as a means of securing the cartridge heater in place. The default position of the flange is flush with the lead end. Specify the position of the flange when ordering.

The sheath extension is welded to the cartridge at a 90° angle. The standard sheath extension is 3/8″ long. Specify when ordering if a longer sheath extension is required. If abrasion resistance is required, armor cable or stainless steel wire braid can be attached to the sheath extension. Available with various lead wire types and potted end seals.

The heater sheath itself is bent to 90°. The bend is through a required unheated section. The standard sheath extension past the bend is 1″. Specify when ordering if a longer sheath is required.

A locating ring can be attached to the heater to aid in positioning the heater for the application. The default position of the ring is 1/4″ from the lead end. Specify the position of the ring when ordering.

A nickel wire rope is silver brazed to the lead end of the cartridge heater sheath to assist in removing the heater.

The standard sheath material for all Hi-Density Cartridge Heaters except 1″ diameter is 321 stainless steel; standard for 1″ diameter is 304 stainless steel. The incoloy sheath option is available on all diameters except 1/8″, 5/16″, 8 mm and 20 mm. To assist you in selecting the proper sheath material, corrosion resistant ratings and chemical properties of various heater sheath materials are given in the Engineering Section of the site.

If your application requires a specific alloy sheath material, consult Tempco with your requirements.

Passivating is a chemical process accomplished by dipping the heater in a solution of nitric acid. The process removes surface contamination, usually iron, so that the optimum corrosion resistance of the stainless steel is maintained.

If a special length tolerance different than the standard length tolerance specified on page 2-4 is required, consult Tempco with your requirements.

Electro-Polishing is an electro-chemical process that removes surface imperfections and contaminants, enhancing the corrosion resisting ability of the heater sheath.

For applications requiring high precision fit and tolerance, the sheath can be centerless ground. Tolerance: ±0.0005 inches (0.013 mm) Specify diameter when ordering.

The thermocouple junction is grounded to the sheath at the disc end and packed with MgO. The concave end disc is filled with silver solder and ground flat. When inserted into a flat end blind hole, it will provide fast responsive temperature readings. Widely used in Hot Runner mold probes.

The thermocouple junction is ungrounded, located at the end of the heater section, 1/8″ behind the end disc and packed with MgO. Only provides reference temperature reading of the part being heated – slower response.

The thermocouple junction is ungrounded and is located in the center of the length and diameter of the cartridge heater. It provides internal temperature readings of the heater core. Generally used for research applications and is not recommended for controlling process temperatures.

The thermocouple junction is grounded to the sheath in a 1/2″ unheated section located in the center of the cartridge length unless otherwise specified. It provides good temperature readings with quick response.

The thermocouple junction is grounded to the sheath at the lead end. A minimum of 3/8″ of cold section is required. It provides good temperature readings with quick response.

Cartridge heaters can be designed to vary the wattage along the length of the heater. Specify number of zones and the required watts and length per zone starting from the disk end. Leads can be connected externally or internally. Picture shows a heater with Type N externally connected leads. Heaters with other terminations may require a longer cold section at the lead end.

In order to minimize the gauge of the wiring on high wattage cartridge heaters, 3-phase elements can be designed.

3/8″ and 1/2″ diameter heaters may require a larger diameter transition area at lead end. Cartridge heaters can be designed using 3-wire series/parallel circuits for dual voltage applications. Whether the heater is run on the high or low voltage, the wattage will be the same. DV1 120/240 volts DV2 240/480 volts

Independent resistance elements can be designed in a single cartridge heater for added versatility

3/8″ and 1/2″ diameter heaters may require a larger diameter transition area at lead end. Multiple independently operated sections of the heater with a common wiring connection can be designed for increased flexibility.

For DC applications where the electrical circuit is negative grounded, the cartridge heater can be designed with one side of the element winding grounded to the sheath and a single lead wire exiting the cartridge heater.

For those applications requiring a separate ground lead attached to the cartridge heater sheath. Standard ground lead wire is a 10″ long insulated stranded conductor. Optional insulated and color coded leads are available.

Thermal fuses can be built into cartridge heaters to act as a high limit for the heater in applications where the temperature must be limited to avoid dangerous situations. When the trigger point is reached, the thermal fuse will open, cutting the electrical current to the cartridge heater. Once the thermal fuse opens, it cannot be reset. Many different trigger temperatures are available.

Cartridge heaters with built-in thermostats are very efficient and economical for heating and controlling temperatures. Available with NPT or special type mounting fittings, they provide a self-contained heater mainly recommended for immersion applications. They can also be used as over-temperature safety devices. The thermostats are factory preset for the trip temperature; therefore, prototyping and testing is required to determine the exact fixed setpoint. Maximum temperature—302°F (150°C). Maximum Amps—8@120 Volts. A minimum 2-1/2″ cold section is required to house the thermostat. Consult Tempco with your requirements.

Tempco has the ability to custom design cartridge heaters with built-in temperature sensors such as thermistors and RTDs. For specific applications that have a limited or single set point range, thermistors or RTDs in conjunction with simple electronic controllers can be an economical choice. NOTE: For thermocouples see page 2-58.

Tempco has the ability to custom design cartridge heaters with built-in temperature sensors such as thermistors and RTDs. For specific applications that have a limited or single set point range, thermistors or RTDs in conjunction with simple electronic controllers can be an economical choice. NOTE: For thermocouples see page 2-58.

Standard Electrical Tests and Optional Test Reports 1. Resistance test — measures ohms at room temperature. 2. IR (insulation resistance) test — measures the insulation resistance to the flow of current. Standard test is done at 500VDC. 3. Hipot (high potential) test — a high voltage is applied between a product’s current carrying conductors and its metallic enclosure to verify that the insulation is sufficient to protect the operator from electrical shock. 4. Leakage current test — measures the current that flows from any conductive part to ground. 5. Heaters can be serialized and test reports can be sent with each shipment if required. Contact Tempco with your requirements.

This non-destructive testing can detect imperfections in weld joints. For critical applications, each individual heater’s weld joints by end cap and fittings can be tested. Certified test reports will be sent with each shipment. Consult Tempco for details.

Cartridge heaters with attached pipe fittings can be pressure tested to your specifications at Tempco. Our in-house testing capabilities can ensure that your products meet your exact specifications. Contact Tempco with your requirements.