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Supply Voltage
HEATROD cartridge heaters are available for operation with nearly any DC or AC supply voltage – single phase or three phase.  Certain restrictions will apply depending on the size of the heater and with requirements for agency approvals.

Wattage Output
The power output of HEATROD cartridge heaters is a function of supply voltage and available space inside the heater to wind resistance wire. Wattage tolerances are +5%/-10%.

Sensors
HEATROD cartridge heaters can be supplied with internal thermocouples.  The thermocouples can be located in one of three locations:

A thermocouple can be located at the tip of the heater (Location A) is recommended for sensing temperatures of materials flowing past the heater tip. The thermocouple junction is always grounded to the sheath with the A location, and the “end disc” is flat to provide better sensing ability.

A thermocouple can be located against the inside wall of the heater sheath at any point along the heater length (Location B). This location is used to monitor the heater sheath or the approximate temperature of the part being heated. Specify if a guaranteed ground is required.

Finally, a thermocouple junction can be located in the center of the heater core at any point along the heater length (Location C). This location is used to sense the heater’s hottest internal temperature and is used for prototype testing and research. The thermocouple junction is not grounded.

Thermostats and thermal fuses can also be installed in the lead end of the HEATROD cartridge heater.

Lead Connections
Heatron offers several standard Lead Options for the HEATROD cartridge heater.

High Temp (450°C) Leads are crimped onto the conductor pins outside the heater. The crimps are covered with 200°C, 600V rated silicone rubber coated fiberglass sleeving. Recommended for applications where flexing and vibration do not occur.

Swaged-in Flexible High Temp (450°C) Leads are recommended for applications that require the heater leads to flex or bend sharply as they exit the heater. Flexible leads are securely joined to the pins inside the heater to provide a flexible alternative to crimped-on leads or solid pins.

Right Angle Leads are available for applications where space is limited. Crimped-on leads are standard. Swaged-in leads are available as an option.

Right Angle Swaged-In Stainless Steel Metal Braid offers lead flexibility and abrasion protection where space is limited. The braid is fastened inside the heater and incorporates a protective metal cap welded to the heater sheath. This unique design eliminates connections that use bulky crimps or potting compounds that can fail easily.

Swaged-in Stainless Steel Metal Hose allows for flexibility, while protecting the lead wires against sharp objects or small amounts of contaminants. The hose is swaged securely inside the heater to eliminate bulky fittings or couplers that might prevent full insertion of the heater.

Right Angle Stainless Steel Metal Hose is recommended to protect leads from sharp objects and contaminants in areas where space is limited. In our unique Right Angle Cap construction, the flexible hose is brazed to the metal cap before assembly to the heater. Many competitors braze the hose directly to the heater sheath exposing the lead wire insulation to very high temperatures, thereby weakening the lead wire insulation and moisture barrier. Our unique preassembled Right Angle Cap avoids this potential lead wire damage.

Additional Construction Options
Sub assemblies – Heatron can provide turnkey heater assemblies which reduce labor, inventory and overall cost. Consult Heatron for specific applications.

Various custom lead wire insulations and lead connections are available from stock or may be special ordered. Ground wires are available on most designs.

Sheath materials – Heatron stocks 304SS in all English and Metric diameters, 316L and Incology TM in most other English diameters.

Threaded Fittings allow for installation into a threaded hole, particularly in immersion heater applications. Brass and stainless steel fittings are available in single or double threads.

Mounting Flanges or Locating Rings can be placed at any point along the heater for convenient mounting or locating in various applications.

Rubber Over molds protect the heater from moisture and excessive flexing, such as in food service or refrigeration equipment. Heatron can also swage-connect an S.J.O. cord inside the heater.

Watertight Stainless Steel Hose Lead Protection is ideal for areas where leads can be subject to liquids or contamination.

Post Terminals are designed for applications requiring a fast connection using leads, spade, terminals, or bus bars. Not available for sizes under 1/2″ diameter (12.5mm).

Conduit Box Housings are available for applications that require protection of the lead terminal area.

Plugs can be provided with the heater for applications that require quick convenient connections.

No Heat Sections can be designed anywhere along the length of the cartridge heater. A typical application for an extra no heat section is to allow the heater leads to operate in cooler temperatures, farther away from the heated section.

Low leakage construction is usually required for medical, aircraft, or other critical applications, where UL or other agency requirements for leakage current are very stringent. This construction is designed to customer specifications depending on the individual application or agency requirements. Typically heaters 3/8″ (10mm) diameter and above will be acceptable. Consult Heatron for your application.

Passivation or electro polished finishes are available to protect against corrosion.

Dual voltage cartridge heaters can be engineered to operate on two separate voltage ratings.

Dual wattage cartridge heaters can be engineered to operate at two different watt ratings within a single heater.