Sensetek
High Density Cartridge Heaters

HIGH WATT DENSITY CARTRIDGE HEATERS

Elmec High Watt Density Cartridge Heaters are manufactured with most advanced technology and quality raw materials, enables usage with high watts in small spaces and advanced manufacturing process ensures our heaters are vibration proof and thus ensures excellent reliability in heavy duty working conditions (Like Plastic Processing, Printing, Packaging and automobile industries where the heaters are subjected to heavy vibrations). The high performance is achieved by correct installation of the cartridge heaters. The perfect fitness of the heater in the hole facilitates good heat exchange between the surfaces of heater and mass to be heated thus increases the heater life and reduces energy loss.

Technical specifications:

Cartridge Heater

High Watt Density Cartridge Heaters With Built In Thermocouple

Cartridge heaters can be produced with built in ‘J’ or ‘K’ type thermocouples to provide heat control to increase heater life and to save energy

High Density Cartridge Heaters With Built In Thermocouple

Junction at the bottom, ungrounded suitable to avoid disturbances to sensitive controllers.

Junction at center gives faster response. The control of the heat transfer in the application is possible.

Types Of Thermocouple

Code Positive Colour Negative Colour Temperature Range
J Iron (+) White Constantan (-) Red -20°C to + 750°C
K Chromel (+) Yellow Alumel (-) Red -20°C to + 1260°C

TERMINAL LEAD OPTION

RIGHT ANGLE TYPE

STRAIGHT TYPE


High watt cartridge heaters

CABLE PROTECTION

CABLE TYPE

TOLERANCE
Diameter - 0.02 to - 0.08 mm
Length   Up to 100mm + 2mm
      Over 100mm + 1% to 3%
Wattage - 10% to + 5% (+ 5% available upon request)
Resistance + 10% to - 5% (+ 5% available upon request)
     Maximum working temperature allowed on sheath 750°C
MAXIMUM RECOMMEDED SURFACE LOAD
High Watt Density Max.150 W/Sq.inch
Max. 25W/Sq.cm
Medium Watt Density Max. 65 W/Sq.inch
Max. 10W/Sq.cm
Low Watt Density Max. 25W/Sq.inch
Max. 4W/Sq.cm

WATT DENSITY VS FIT SIZE FOR CARTRIDGE HEATERS

Operating temperature of heater and fit size are major factors in determining the life expectancy of cartridge heaters. Select closest possible fit size for installing cartridge heaters for heating metal parts ref Fig-1 and Fig-2.

 
HOLE TOLERANCE
< 80mm length + 0.1 mm
81 to 200mm length + 0.15mm
 > 201 mm length + 0.2mm
Hole tolerance H7 up to 20W/Sq.cm
For higher load press fitting is required
Fit = Max.hole diameter – Min.heater diamete
Example
Heater Dia 15.8 (Maximum Tolerance – 0.08mm)
Hole Dia 15.9
Clearance 15.9 – 15.72 (15.8-0.08mm=15.72) = 0.18mm
We recommend tightest possible fit.

HIGH WATT DENSITY CARTRIDGE HEATERS ARE AVAILABLE IN THE FOLLOWING DIAMETERS

Metric Sizes Ømm 5 6.5 8 10 12.5 16 20 22 25
Inch Sizes Ømm 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1

Standard Cable length – Fibreglass cable 300mm long.

We also manufacture any non-standard Diameter; Length & Terminal lead option as per customers’ requirement.

APPLICATIONS  
Plastic Processing Machineries Shoe Machinery
Injection Moulding Machine Packaging Equipment
Blow Moulding Machine Moulds & Dies
Plastic Extruder & Extrusion Dies Rubber Industry
Hot Runner Moulds Chemical Industry
Hot Stamping Heating Liquids
Food Processing Power Plants
Medical Equipment Automobile Industries and many more applications.

Wherever there is a requirement of high watts in less space.

ADVANTAGES

  • High watt density cartridge heaters make it possible to have high watts in less space without sacrificing lifetime.
  • Proof against shock and vibration.
  • Excellent heat transfer.
  • Maximum operating temperature 1400°F (750°C) on heater surface.
  • Our heaters are cylindrically ground to have better surface contact and minimum hole tolerance.
  • Leak proof Tig welded end cap prevents heater contamination due to the entry of any foreign materials.

INSTALLATION RECOMMENDATION

  • The tightest possible fit is recommended
  • Prevent damages to hole surface while removing the heater.
  • Excellent heat transfer.
  • For easy fitting and removing the heater and to improve heater conductivity, a very thin layer of assembly get should be used on heater surface and should not be in contact with cables to avoid short circuit.
  • Protect cables from physical damage, excess temperature and excess flexing etc.
  • Use suitable temperature controllers like PID controller with SCR, Thyristor, mercury relay or solid-state power controls to increase the heater life.
  • The sensor should be placed as close as possible to the heater (15mm).
  • Use largest possible number of heaters to reduce watt densities.