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Cartridge Heaters

Matrusree Designs & Manufactures Cartridge Heater to suite a wide range of industrial applications as percustomer requirements. These also act as component heaters that are used to heat up many differentapplications. Primarily used in moulds& Dies heating by snug fit inside the holes or cavity of the mould andhelps to heat solids by reaching high temperatures.

Cartridge heaters have the versatility of being able to carry thermocouple inside to help control temperatures ofthe heater more accurately. Various diameters allow for it to be used in any cavity and can be custom designedwith any cold section. Lead wires extend from the end to your controls. Depending on surface loading of thecartridge heaters elements we offer

  Low Watt Density Cartridge Heaters

  High Watt Density Cartridge Heaters

 

LOW WATT DENSITY CARTRIDGE HEATER

The heater design consists of helically wound resistance coil made from High Temperature Resistance Wirewhich is evenly stretched and strung through holes in a cylindrical ceramic insulator. The element assembly isinserted into a SS300 series tubes. This alloy provides the best combination of physical strength and resistanceto heat oxidation. Then a Premium Quality Magnesium Oxide with Specially selected grain size and high purity (Mgo) is used to fillall remaining space inside the ceramic insulator to increase thermal conductivity, dielectric strength, andprovide longer operating heater life to the heater.

APPLICATION

  Heating Of Manifolds

  Heating Of Dies & Platens

  Heating Of Hot Stamping

  Packaging Machines

  Injection Moulding Machine

  Extrusion Machines

  Heat Sealing

  Labeling Machines

  Glue guns and Wax pots

  Heating of gases and liquids

FEATURES

  Unique winding design allows faster heating and longer life

  High purity magnesium oxide (Special grain MgO) fills any voids around the resistor wire to optimize heattransfer, dielectric strength and life of the heater.

  Stainless steel sheath 300 Series for oxidation resistance.

Resistor wire is joined to the leads by placing each end into high temp lead wires which, upon crimping, affordsa positive and consistent junction.

Features

Low Density

Max. Surface Load

4 w/cm2

Wattage Tolerance

10%

Std. Dia Range

8mm to 40mm

Diameter Tolerance

0.2mm

Std. Length

Min. 50mm

Length Tolerance

2mm

Max. Sheath Temperature

350 C

ORDERING INFORMATION:

  Diameter

  Length

  Wattage

  Voltage

  Connection Wire Length

  Quantities

 

HIGH WATT DENSITY CARTRIDGE HEATERS

Hi-Density cartridge heaters are manufactured in a complete range of standard physical dimensions, electricalratings and variety of lead terminations. In high-density cartridge heaters the resistance wire loops arepositioned as close as possible to the outside shell. Because the MgO powder insulation around these loops iscompacted by swaging and transformed into a very hard medium, heat transmission is very efficient. Cartridgesare usually supplied with lead wires.

The construction of high temperature High Watt Density cartridge heaters starts with aa premium grade high temperature resistance wire that is wound around a high purity magnesium oxide core with Numerically controlled machinery precision. It is inserted into a Stainless steel or Incoloy tubing locating the resistance wire close to the sheath. The core is centrally positioned within the tube and Machine Filled with Special Grade High Mgo. Nickel pins pass through the centre of the core making contact with the resistance wire at both ends. The whole is assembly is highly compacted by a swaging operation and thus ensuring excellent heat transfer to the external sheath. One end of the heater is closed with a welded metal end-disc and wire leads exit at the opposite end which is typically closed with a lava seal. A variety of wire leads and lead protection options are available. Heaters can be supplied with internal thermocouples, mounting fittings and many other options.

 

APPLICATIONS

  Heating of Mould

  Heating of Dies and platents

  Packaging Industry

  Marking & Sealing Machinery

  Hot Runner Bushings

  Medical & Laboratory Apparatus

  Leather & Resins Manufacturing

 

FEATURES

  NC controlled Resistance winding & Computer Calculated design allows faster heating and longer life

  Incoloy sheath for oxidation resistance.

  Swazed construction enhance the Life of heaters and dependability

  Swazed construction allows operation in machines & environment with high Vibrations

  High purity special grain size MgO fills any voids around the resistor wire to optimize heat transfer, dielectricstrength and life of the heater.

  Unique construction design & Materials allow high watt densities & Higher Operating temperatures

v  Built in Thermocouple 'J' or 'K' types designs available

v  Rugged & durable construction with excellent heat transfer capabilities

 

TECHNICAL FEATURES:

Features

High Density

Max. Surface Load

14 w/cm2

Wattage Tolerance

10%

Std. Dia Range

6.5mm ( ) to 25.4mm (1)

Diameter Tolerance

- 0.02 mm to - 0.06 mm

Std. Length

Min. 25mm

Length Tolerance

2mm

Max. Sheath Temperature

700 C

 

High Watt Density Cartridge Heaters Are Available In Above Standard Diameters & Sizes, Any Other Non Standard Intermediate Diameters Are Also Possible As Per Customer Requirement Standard Cable length Fibreglass cable 300mm long.




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.

 

Hole / Bore clearance is the gap between the heater O.D and the bore I.D should be very close. These close fits insure rapid heat transfer from the heater and also help keep the unit as cool as possible, which contributes to long life.

 

Enter the chart with either known variable, part fit in hole dimension or W/in2. Then find the application Temperature by reading up or over on the chart. If the fit of the heater in the hole dimension is not known, it is easily determined. Subtract the minimum diameter of the HD cartridge heater (nominal diameter minus tolerance) from the maximum hole diameter.

WATT DENSITY VS FIT IN HOLE SIZE FOR High Watt Density CARTRIDGE HEATERS


MAXIMUM RECOMMENDED 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

 

The graph shows the recommended maximum watt density for High Density Cartridge Heaters at different operating temperatures and fit, when the heater is installed in an oxidized mild steel block. The thermocouple is located 12.5 mm from the heater. When heating other materials, the data needs to be extrapolated based on the thermal conductivity of the material.

 

HOLE TOLERANCE

< 80mm length + 0.1 mm

81 to 200mm length + 0.15mm

> 201 mm length + 0.2mm

For cartridge heaters with surface loads up to 20 W/cm2 the holemust be drilled according to ISA H7 with peak to valley height assmall as possible

For higher load press fitting is required

Fit = Max.hole diameter Min.heaterdiamete

 

To determine Fit :

Fit = Maximum Hole I.D Minimum Heater O.D

Consider a Heater O.D = 12.5 mm ( 0.06mm std. tolerance)

Hole I.D = 12.6 mm ( 0.02mm hole tolerance)

Min heater O.D = 12.44 mm

Largest hole I.D = 12.62 mm

Fit = 12.62 - 12.44 = 0.18 mm (max permissible clearance)

 

HIGH WATT DENSITY CARTRIDGE HEATERS ARE AVAILABLE IN THE FOLLOWING DIAMETERS,

Anyother Intermediate diameter sizes are also manufactured as per customer specification.

Metric Sizes mm

5

6.5

8

10

12.5

16

20

22

25

Inch Sizes mm

3/16

1/4

5/16

3/8

1/2

5/8

3/4

7/8

1

 

Standard Cable length Fibreglass cable 300mm long.

 

Terminal lead options as designated under

1. Fibre glass or Teflon wire crimped or welded to terminals

2. Fibre glass wire with SS metal braiding

3. Wires protected with SS or GI flexible conduits

4. All wires are available in straight or right angle exit

5. Drawing or sample required for special type terminals

HIGH WATT DENSITY CARTRIDGE HEATERS

Standard Termination Options Available are

Important points to be observed when using High Watt Density Cartridge Heaters

 

  For cartridge heaters with surface loads up to 20 W/cm2 the receiving hole must be drilled according to ISA H7 with peak tovalley height as small as possible.

  For cartridge heaters with surface loads exceeding 20 W/cm2 a sliding fit is necessary which can be obtained by individualattention being paid to each cartridge heater.

  The drilled receiving bores of cartridge heaters must be cylindrical. Crossing bores and shrinkages cause a localization ofheat and shorten the useful life of the heating elements.

  To facilitate the insertion and the removal of the heating elements the receiving bores should be drilled in a continuousmotion (to avoid a stepped bore).

  The maximum working temperature of the cartridge heaters stated in the leaflet does not apply to the connection leads.These must be selected according to the operating conditions.

  When using several cartridge heaters the distance between two consecutive cartridges should be at least equal to thecartridge diameter.

  The end of the cartridge heater with the connection leads should be protected against liquid and pasty media (lubricants, oil,synthetic materials, etc.) as well as their vapours because otherwise leakage currents and, possibly flashover could occur atthe outlet connection terminals.

  The connection leads should be protected against mechanical vibrations close to the outlet of the cartridge heater. If they areheated with the cartridge, the resulting vapour must have the ability to escape.

  If possible, control of the operating temperature should be achieved by means of continuous regulators, controllers withpulse width modulation or electronic power control devices. A control system with long time lag often causes thermaloverload of the heating elements. For this reason also the temperature sensor must be fitted in close proximity to thecartridge heater (about 10 mm apart).

  If heating elements are to be stored for long periods they should be housed in absolutely dry rooms or enclosed in plasticbags which are hermetically sealed. If cartridge heaters are moist, they can be dried by heating at 180C for 8 hours.

  If the heaters are not supplied with a separate earth lead the installation has to provide a safe ground connection.

 

Ordering information - Please specify

 

1. Dia& length of the heater

2. Wattage and Voltage

3. Type of termination

4. Cold zone length & hot zone length

5. Quantity

6. Any special option required like different termination or custom flanges please send drawing or sample