Cartridge heaters are cylindrical shaped heaters with resistive heating elements. The heating element is insulated to prevent the sheath from contacting the heating element and ultimately causing a short circuit or heater failure. The sheath, also known as a sleeve, or jacket, encapsulates the heater and provides a protective barrier. They are generally inserted into a heated substrate or used in immersion cartridge heaters applications; however, due to their compact cylindrical shape, they can also be used in a variety of other applications.

Selection Criteria

Important parameters to consider when specifying cartridge heaters are maximum operating or sheath temperature, AC voltage required and watt density. Other considerations include dimensions, materials of construction, RoHS / WEE compliance, and various features.

Maximum operating or sheath temperature

Maximum operating temperature is the maximum temperature that the sheath covering the cartridge heater may reach. The materials of construction, voltage requirements and watt density are design factors affecting the operating temperature of the cartridge heater. In some applications, such as molding, casting and other metal working processes, temperatures can exceed 1500°F.

Note, this is not the hottest temperature that a heated substance may reach.

AC voltage

AC voltage is the minimum alternating current (AC) volts required to operate the cartridge heater.

Watt density

Watt density is the amount of wattage per square inch that a cartridge heater can deliver. High watt density heaters should not be used with extremely viscous materials, poorly-circulated materials, or explosive/volatile materials due to risk of fire.  High watt density heaters are required for higher operating temperatures.

Dimensions

Important dimensions for cartridge heaters are the nominal diameter and cartridge length or heated length.

• Nominal diameter – The nominal diameter of the heater is actually a few thousands of an inch larger than the measured dimension. The nominal diameter is the size of the hole that the heater is designed to be inserted to. High watt density and operating temperatures require a close fit to improve heat transfer and heater life expectancy.

• Heated length – The measured length is for the heated section of the cartridge only.

Th following graph illustrates the required hole fit tolerance between the cartridge heater and the heated substrate for various temperatures and watt densities.

Materials

Sleeve (sheath) material

Sleeves, jackets or sheaths are used as a protective outer covering for heating elements. Typically, cartridge heaters use sleeve materials made of aluminum, brass, copper, iron, nickel alloy, stainless steel, or steel.

Options include:

Insulation options

Heater insulation isolates the heating element. Typically, suppliers carry cartridge heaters with ceramic, fiberglass, magnesium oxide, mica or mineral insulation, or a fluoropolymer. Each type of insulation offers different features. Some heaters may be available with multiple insulation options.

• Ceramic insulation consists of nonmetallic minerals, such as clay, that are permanently hardened by high-temperature firing. Most ceramics resist heat and chemicals.
• Mica insulation consists of colored or transparent mineral silicates that are crystallized in monoclinic forms and readily separated into very thin leaves. Mica is valued for its electrical insulating properties and resistance to heat and acids.
• Fluoropolymer insulation is used in applications requiring superior chemical resistance. Fluoropolymers have several unique chemical systems including polytetrafluoroethylene (PTFE) and polyvinylidene fluoride (PVDF).
• Fiberglass insulation is strong, durable, and impervious to many caustics and extreme temperatures. Fiberglass fabrics are used widely in industry.
• Magnesium oxide insulation has a high melting point (2800°C) and heat resistance (1700°C in the reducing and 2300 °C in oxidizing atmospheres.) 

Electrical Connection / Termination

Most devices can be configured with many different termination options. Choices for termination type include: bare leads, insulated leads, armor cable leads, metal braided leads, flexible conduit leads, screw terminals terminal boxes, quick disconnects and plugs.

Mounting / Installation

Cartridge heaters may be mounted or installed using different methods. Some products have multiple mounting options, such as threaded pipe fittings, mounting flanges and locating rings.

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RoHS / WEEE Compliance

RoHS Compliant

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Restriction of Hazardous Substances (RoHS) is a European Union (EU) directive that requires all manufacturers of electronic and electrical equipment sold in Europe to demonstrate that their products contain only minimal levels of the following hazardous substances: lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyl and polybrominated diphenyl ether. RoHS became effective on July 1, 2006.

WEEE Compliant

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Waste Electrical and Electronics Equipment (WEEE) is a European Union (EU) directive designed to encourage the reuse, recycling and recovery of electrical and electronic equipment. WEEE is also designed to improve the environmental impact and performance of this equipment. The WEEE directive establishes requirements and criteria for the collection, treatment, recycling and recovery of electrical and electronic equipment. It also makes producers responsible for financing these activities. Retailers and distributors must provide a way for consumers to return used or obsolete equipment without charge.

Features

Features common to cartridge heaters include corrosion resistance, explosion proof, UL approved, internal temperature detectors and grounding wires.

• Corrosion resistant heaters are made of corrosion-resistant materials and suitable for use in a corrosive or chemical environment.
• Explosion-proof heaters are designed to withstand explosions and protect the materials within. Some suppliers include heaters with housings that can withstand sparking and flames.
• The heater is equipped with a grounding wire that allows you to connect the electrical wiring to a common ground in order to dissipate the load in the event of a short circuit.
• The heater contains an integral temperature detector that is used to sense the temperature of the heater while it is in use.
• UL approved trace line heaters are approved by Underwriters Laboratories (UL). Typically, documentation of UL certification is available from the cartridge heaters manufacturer.

Electric Cartridge Heaters Resources

How to install cartridge heater

Common Cartridge Heater Configurations

High Density Electric Cartridge Heaters For Your Industrial Heating Need

For manufacturers of ovens, furnaces, lehrs, dryers, dehumidifiers, tanks, paint booths, custom machinery, etc.

For in-plant installations that include plastics softening, material drying, embossing heaters, fuel fired equipment conversion, dryer and oven rebuilds, upgrading existing heating equipment, light duty electric heater replacement, and add-on heat zones.

Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd Folded and Formed heating elements are ribbon type elements that were developed to meet the need for higher temperatures and improved temperature control demanded in today’s heat processing operations.

First patented in 2004, Xinshengfa Electrical Heating Tech Co.‘s Folded and Formed heating elements have a unique element configuration that is sometimes imitated — never duplicated. Here are some of the performance advantages the Folded and Formed heating elements provide for your electrically heated process equipment:.

• Greater direct radiation to the workload.

• More rapid heat dissipation, at lower watt density than conventional elements.

• Faster heat-up and cool-down.

• Maximum heating efficiency at lower element surface temperatures
to prolong element life and minimize burnouts.

• Trouble-free, cost-effective, applied heat to meet your most
demanding application.

Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd Folded and Formed heating elements are backed by more than 75 years experience in electrically heated equipment design and manufacture.

Why choose Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd electric heating elements?

1ST… because it starts as flat ribbon. And no other heating element dissipates heat more readily over more heating area! Compare a ribbon element 1” wide by .0159: thick, with a rod element of the same cross sectional area.

The rod would be 9 times thicker than the ribbon — with less than one-fourth the radiating surface area. Result? Much of the heat is stored in the rod, instead of being dissipated. And that causes element burnout! Not so with ribbon elements. Its low mass will not allow heat to concentrate within the element. So it radiates optimum heat at low watt density. Ribbon is a more efficient heating element.

2ND… because it’s FOLDED. TRENT makes the most of the ribbon element by folding it to expose maximum flat radiating surface where it is needed most — the work zone of the equipment being heated. Other ribbon elements do not offer this important advantage. Wound ribbon elements, for example, expose radiating surfaces to one another — with only the element edges facing the work chamber. One element tends to heat the other. They hold heat. Too often they operate at higher surface temperatures than necessary — and that costs money. Folded ribbon improves air recirculation, too. Heat is picked up more readily from the flat radiating side of the ribbon — with only minimal airflow resistance from the edge of the element. In addition, folded ribbon heats up and cools down more quickly. There is practically no residual heat when the equipment is de-energized — a significant advantage in maintaining close tolerances between process control set-points and actual temperatures.

3RD… because it’s FORMED. Greater structural strength is one obvious advantage. Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd‘s unique forming process makes FOLDED and FORMED heating elements virtually self-supporting. And they maintain their structural strength and stability over extended periods of use — even at high temperatures where ordinary elements sag. Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd Folded and Formed heating elements require less heat absorbing support material. That not only makes them a more efficient and cost-effective heat source — it makes them much easier to replace in your equipment when necessary. And note the concave surface of the FOLDED and FORMED element. It exposes even more radiating surface — and directs more heat to the work chamber than flat ribbon.

Why settle for less? Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd Folded and Formed heating elements are utilized in heater racks, plug heaters, electric ovens, electric furnaces, electric jackets, kettles, melters and hot plates. Talk to Shenzhen Xinshengfa Electrical Heating Tech Co., Ltd Electric Heating Elements Experts on 86-0755-29835076 today.

• Up to 1.297″ Dia.
• Up to 60″ Lengths
• Up to 11,500 Watts
• 120 and 240 Volt
• Up to 1400°F Max. Working Temp.
• Modification Available to Fit Custom Applications

Type CIR cartridge heaters are most frequently used for heating metal parts by insertion into drilled holes. For easy cartridge heater installation, the heaters are made slightly undersize relative to their nominal diameter.

Determining Fit — At high watt densities cartridge heater, a close fit is important. The fit is the difference between the minimum diameter of the heater and the maximum diameter of the hole. For example, 1/2″ diameter Type CIR cartridge heater is actually 0.498″ plus 0.000″ minus 0.005″. If this heater is placed in a hole which has been drilled and reamed to a diameter of 0.503″, then the fit would be 0.01″ (0.503″ 0.493″ = 0.01″).

Determining Watt Density — Watt density refers to the heat fl ow rate or surface loading. It is the number of watts per square inch of heated surface area. For calculation purposes, CIR stock cartridge heaters have 1/4″ unheated length at each end. Thus, for a 1/2 x 12″ heater rated 1,000 watts, the watt density calculation would be as follows:

Watt density = W/ p x D x HL

Where:

• W = wattage = 1,000 W D = diameter = 0.5 in.
• HL = heated length = 11.5 in.
• Watt density = 1,000 / 3.14 x 0.5 x 11.5 = 55 W/In ²

Selecting Sizes and Ratings — The calculation of total heat requirements for an application.

Determining, Quantity, Size and Rating — Once total heat requirements are established, the quantity, size and rating of cartridge heaters can be decided. Plan for enough heaters to permit even temperatures through the part during heat-up and operation. The sensor for the temperature control should be placed close to the working surface for accurate control.

Calculate Watt Density and Fit — After the wattage for each heater has been established, the watt density and fit must be calculated. Then, use Graph G-235 to be sure that the watt density is within allowable limits. For example, a 1/2 x 12″ CIR heater rated 1000 watts has a watt density of 55 W/in ² . If it were used in a part with an operating temperature of 1000°F with a fit of 0.01″, the allowable watt density from the graph would be 90 W/in ² . Thus, the actual watt density of 55 W/in ² is well below the maximum allowed. A substantial safety margin would exist and high reliability can be expected.

If the electric heater selected had a watt density higher than that allowed by the graph, consider the following changes.

1. Using more heaters of lower watt density.
2. Using longer or larger diameter heaters.
3. Improving the fit.
4. Reducing heat requirements by reducing heat losses or by allowing for longer heat-up time.

Using the Maximum Allowable Watt Density Graph — This graph is useful for choosing Type CIR cartridge heaters. The curves should be considered as guides and not precise limits.

The graph is based on a 1600°F resistance wire temperature inside the cartridge heater, when the heater is installed in an oxidized mild steel block. Watt density values from the graph should be lowered by about 10% or more when other materials are used which have a lower thermal conductivity or lower emissivity than oxidized mild steel. Contact your Local Chromalox Sales office. 8Q3AW236VJ7D

Quality Heating Elements Manufacturer

Heatingelementsinc have built an unrivaled reputation for electric heating elements quality and reliability over the past 7 years. We formulate highly skilled and experienced personnel working with the finest raw materials. The electric heater, cartridge heater and heating tube we manufacture undergo strict quality control and detailed product testing routines.

If your Kenmore Elite Dryer is running but not heating, it may be time to change the electric heating element. Changing out the heating element is not a difficult task if you have a few basic tools and a little bit of expertise.

Instructions

1. Unplug the dryer. Locate and remove the front service panel on the bottom of the Kenmore dryer, located at the bottom of the dryer. The entire panel will pop off.

2. Remove 1 wire that runs from the heating element and test it by using a volt/ohm meter. You only need to remove 1 wire. This will provide enough ohms for a correct reading. If you are getting a zero reading, then the heating element is bad and should be replaced.

high density electric cartridge heater

3. Take the heat shield off by pulling off the wires and removing the screws that secure the heating element in place. This will free the element. Remove the heating element.

4. Replace the heating element with a new element. Make sure it is securely in place and then screw the element back into the housing and reinstall the wires.

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5. Reassemble the dryer by putting the front service panel back on. Plug the dryer back in, push it back into place and turn it on. Allow it to run for a few minutes to test the new element.

 

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Type CIR High Watt Density

Advanced Internal Construction Plus Swaged Leads — The challenge to Chromalox engineers was to design a cartridge heater that would out perform any brand cartridge heater — under any given set of conditions, and to assure that the customer receives and continues to receive the most heater performance and life possible for his investment.

Type CIR Cartridge Heater — Includes several signifi cant advances in cartridge heater technology. Its high performance characteristics have been proven, not only in the laboratory, but also on Customers’ equipment on selected problem applications, at 1500°F and higher operating temperatures.

Type C-LD, C-HD & C-DE

Medium Watt Density

Type C Large Diameter Cartridge Heater — For medium and low watt density Cartridge Heater applications. The tightly compacted refractory insulation provides excellent heat transfer to the heavy wall stainless steel sheath. This means the resistance wire runs at a lower temperature than competitive units with loose-fill insulation; the result is much longer life. This heavy-duty construction also provides high dielectric strength as well as shock and vibration resistance required for many industrial applications.

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Type CBH Electric Stud Heater — Used to wrench-tighten bolts or studs to “shrink fit” tightness.

Type SCB Small Space Heater — Edison screw base installs in standard porcelain lamp socket to heat very small spaces.

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Go to our accessories and cartridge heaters applications pages for high temperature wire and connection supplies .

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Cartridge heaters can be easily specified to meet the demands of special applications. Simply select from a variety of standard options and features to customize the heater to your specific needs. For customized engineering or alternative options, contact your Chromalox sales representative for fast turnaround on your specifications.

• Leadwire Types
• End Seal Options
• Lead Options
• Mounting Options
• Built-In Thermocouple

Leadwire Types

Seal Options

End Seal Temperature Limits

End Seal Options

Hermetic Seal
Ceramic-to-metal seal is good for element temperatures up to 1000°F. Specify heater length beyond the seal. Metal portion of the seal overlaps the heater sheath ”. For washdown conditions.

Lead Options

Right Angle Flexible Leads

Strain Relief
Strain Relief supports leads to reduce bending, crimping, and breakage.

Flexible Stainless Steel Conduit
Flexible Stainless Steel Conduit provides leadwire protection from abrasion and sharp edges, and facilitates easier handling in harsh environments. Available in both straight and right angle confi gurations.

Protective Spring
Available in both straight and right angle configurations, the Protective Spring gives strong, yet flexible leadwire protection from bending, fatigue and flexing.

Metal Braid
Stainless Steel metal braid protects leadwire from abrasion and sharp edges, yet maintains flexibility and ease of installation. Metal braid is available in both straight and right angle configurations.

Ceramic Beads
Ceramic Bead insulation can be specified to protect leadwires from high ambient tem peratures up to 1200 F (649C). To order, specify ceramic beads length and additional lead length.

Threaded Post Terminals
Post Terminals provide a strong, secure connection to buss bars or ring/fork connectors. Available only on 5/8 and 3/4” diameter heaters.

Mounting Options

Threaded Fittings
Threaded fittings allow the heater to be easily installed into a threaded hole for immersion applications. Available with single or double threaded fi ttings. The fitting overlaps the cartridge heater sheath by 1/4″. Specify “brass”

Mounting Flange
The mounting flange option allows for easy mounting and specific positioning

Wire Pull
The Wire Pull assists in heater removal.

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Instructions

1. Choose the right heater for your space and heating needs. The capacities of space heaters range from 10,000 Btu to 40,000 Btu per hour. If the area you want to heat is small, you may want to choose one in the low range. Look for a general sizing table in the floor sample manual. Most space heaters work by convection, which means they follow the natural circulation of air in the room to heat it. Some space heaters are radiant, which means they emit heat outward from the source.

2. Buy the latest model heater. This will ensure that all safety features are included and current. A quality space heater will have the Underwriter’s Laboratory (UL) label attached. Keep in mind that less expensive usually means less efficient.

3. Arrange the heater appropriately. Knowing where and how to arrange the heater can maximize benefit and keep costs low. If you plan to use a room for a few hours only, it’s best to use a radiant heat space heater. That way, it can heat your immediate surroundings and you can avoid a higher bill by not heating the entire room. Always shut off heaters when you leave a room unattended. Some heaters are equipped with a timer and/or a “tip over switch” that will turn the heater off if it falls over.

4. Plug the heater directly into the wall outlet and use a quality cord.

Mica insulate layer Heating Frame

Tips and Warnings

Consider the risks and always put safety first. Consumers should always be mindful of portable heating devices. Many residential fires are caused by space heaters, leading to injury or, in some cases, death.

Electric Heaters and Cartridge Heaters Resource

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1. On moving machinery, anchor the leads securely. As little movement as possible should be allowed close to where the leads emerge from the heater. A loop in the lead wire will frequently extend lead life. If application conditions result in continual lead flexing, terminate the cartridge heater leads at a terminal block which moves with the heated assembly. Flexing is transferred to the extension leads which can be economically replaced.
2. For rapidly vibrating equipment, employ the terminal block described above. Keep leads from heater to block short and well supported to prevent lead movement due to vibration.
3. Protect leads from spray, oil and abrasion. Contaminating liquids and vapors can enter unsealed electric cartridge heaters and cause insulation breakdown.
4. Avoid tape on leads where they emerge from the cartridge heater. The adhesive on some tapes can enter the heater and turn to carbon which is electrically conductive. Where glass tape cannot be avoided, a tape with a silicone based adhesive is suggested.
5. Design the installation so that the leads are in an ambient temperature which doesn’t exceed the rating on the lead insulation (842°F for standard leads). Where temperatures require it, use nickel or nickel-plated copper wire with fluoropolymer insulation, silicone impregnated Fiberglas ^® or Rockbestos ^® insulation to extend leads.
6. Graphite and other lubricants to help insert the cartridge heater into the hole are generally not recommended. These are electrically conductive and can get on the lead end of the heater unless extra care is taken. Use Chromalox heat transfer and release coating.
   

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7. As operating temperatures rise, thermal insulation on the heated part becomes more desirable to conserve heat. Thermal insulation results in lower wattage requirements and therefore lower watt density on the heaters. Other benefits are more even work temperatures and greater operator safety and comfort.
8. Leads must not extend into the hole containing the cartridge heater. Generally, the lead end of the heater sheath should be flush with the surface of hole or extended by 1/16 inch.

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