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1. ENGINEERED SOLUTIONS FOR HEATING AND SENSING
ENGINEERED SOLUTIONS FOR HEATING AND SENSING
Heaters
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EMAIL
EMAIL
sales@marathonheat.com
PHONE
PHONE
+91-8003395150
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Cartridge Heater
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Cartridge heater often considered as component
heater has a heating coil wounded on a ceramic
core and are cylindrical-shaped, heavy-duty Joule
heating element. Electricity flows through coil
when two or three-phase voltage is applied. The
electricity heats the coil and, subsequently, the
cartridge sheath. The watt density (in Watt/inch²)
depends on the number of spirals or turns per
inch. The sheath comes in contact with the surface
being heated. Insulation in the cartridge heater ensures that the heating wire never comes in contact
with the sheath and protects the sheath from melting in case of any mishap. The leads that come out of
the heater terminal have metal conduit, or silicon sleeves to protect from high temperature. Lead wires
are often fiberglass or silicon rubber.
These heaters provide a suitable, reliable and competent method of applying concentrated heat to solid
metal components to high temperatures, particularly where compact, insert type heating is desirable.
Swaged construction provides minimal air gaps, which lead to high efficiency and improved heat
transfer. Distinguished for long trouble free service, cartridge heaters have precise dimensions and
tolerances. Heating elements are kept close to the material being heated for maximum heat transfer,
minimum core temperature, and faster heating. Use of stainless steel sheaths provides non oxidizing
surfaces. The surface watts density and operating temperature of a cartridge is dependent on hole
clearance. The larger the hole clearance the lower the recommended watt density. For temperature
sensing, a thermocouple should be positioned in the heater but its life is reduced by slow “ON/OFF”
cycling of power controllers. So PID auto tuning controllers with solid state relay or thyristor output are
suggested.
TECHNICAL SPECIFICATION:
Sheath Material Stainless steel, INCOLOY
Watt Density Up to 400 W/in
Design temperatures Up to 760°C (1400° F).
Voltage Up to 480V AC
Length Up to 72 inches
Leads Stranded/ Swaged in/ Pin leads/ Crimped on/ Customized
Controls Thermocouple/ RTD
Sheath Length tolerance ±3% (standard), special tolerance available on request
Wattage length +5%, -10%
Resistance tolerance +10%, -5%
Note- For custom design requirements please contact sales@marathonheat.com
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STANDARD SPECIFICATION:
Nominal
diameter
Minimum
diameter
Maximum
diameter
Std.
Lead
wire
gauge
Max
amps
with
std.
Max
lead
wire
gauge
Maximum
amps
Maximum
volts
2
Applications Features & Benefits Video
Process Heater
Component Heater
Cartridge Heater
Ceramic Band Heater
Mica Band Heater
Strip Heater
Finned Strip Heater
Silicone Rubber Heater
Blower Assembly
Air Heater
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Heat Sensing &
Control
Heat Tracing
Solutions
Specifications
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2. Lead
wire
1/8” 3.022 3.14 24 3.6 24 3.6 240
1/4″ 6.19 6.32 24 6 22 9 300
6 mm 5.82 5.97 24 6 22 9 300
6.5 mm 6.35 6.47 24 6 22 9 300
5/16” 7.77 7.89 24 6 22 9 300
8 mm 7.84 7.97 24 6 22 9 480
3/8“ 9.37 9.49 22 9 18 15 480
10 mm 9.86 11.96 22 9 18 15 480
12 mm 11.83 12.48 22 9 18 15 480
12.5 mm 12.34 12.67 22 9 18 15 480
1/2″ 12.55 12.97 22 9 18 15 480
13 mm 12.85 13.46 22 9 18 15 480
17/32” 13.33 15.84 22 9 18 15 480
14 mm 13.84 13.97 18 15 14 26 480
5/8” 15.72 15.84 18 15 14 26 480
16 mm 15.84 15.97 18 15 14 26 480
17 mm 16.84 16.96 18 15 14 26 480
11/16” 17.32 17.44 18 15 14 26 480
19 mm 18.84 18.97 18 15 14 26 480
3/4” 18.89 19.02 18 15 14 26 480
25 mm 24.84 24.96 18 15 14 26 480
1” 25.24 25.37 18 15 14 26 480
Material Maximum Operating
Temperatures
Maximum Watt
Density
°F °C As mentioned
above W/cm
INCOLOY 1400 760 400 62
Stainless
Steel
1000 538 400 62
Lead wire options:
Wire Type Temperature
Rating
Maximum
Recommended
Temperature
Comments
Ultralead 250°C 450°C Excellent, durable wire, good for
high-temperature application
Teflon 250°C 450°C Good dielectric strength
2
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3. Silicon
Rubber
250°C 450°C Good moisture resistance
Braided
Silicon
rubber
250°C 450°C Inexpensive wire, good for non-
abrasive applications.
MGT 250°C 450°C Superior high-temperature
resistance
SJO cord 94°C 90°C Rubber Jacket, resistance to oil and
moisture. For use on 3/8” diameter
and larger.
Thermocouple: Cartridge heaters can also accommodate internal thermocouple which helps in
controlling temperature of heater more accurately. Thermocouples can be of type “J” or type “K”,
grounded or ungrounded, and can be attached at the disc end or middle of the heater. Thermocouple
lead wire is 24 gauge unless specified, thermocouple leads are of the same length.
Termination Options:
1. Swaged in Leads
Swaged in Leads are ideal for application where there is excessive movement or leads are required
to bent sharply upon exiting the heater.
In heaters under 3” long, leads wire goes directly into the core whereas in heaters over 3” long,
leads are connected to power pins in unheated section.
Also remember, if the leads are required to be inserted completely into the hole, they are exposed
to the block temperature ( maximum temperature for standard leads is 550°C ).
Unless otherwise specified, all heaters will be supplied with Swaged in Leads.
2. Right angle Leads
Right angle leads are ideal for application with tight spaces.
Leads are covered with a silicon impregnated fiberglass sleeve where they exit the heater.
3. Distributed wattage
Distributed wattage hotrods( with a higher watt density on the ends rather than the rest of the
heater) can be used to compensate for end losses in blocks.
Distributed wattage hotrods are available in all diameters.
4. Right angle stainless steel conduit
They offers the same advantages as swaged in stainless steel conduit but allows use in tight spaces.
End Seal options:
1. Teflon Seal
Teflon seal is used where an effective sealing is required against moisture and oil contamination.
Teflon lead wire is used in conjunction with Teflon seal to provide an effective barrier.
2. Epoxy Seal
Epoxy potting forms a good moisture seal with more mechanical strength than a silicon rubber seal.
Regular Epoxy is rated at 350°F (177°C) and epoxy lite is rated at 600°F (316°C).
3. Silicon Rubber Seal
High temperature silicon rubber seal in conjunction with silicon rubber lead wires provides an effective
moisture seal up to 400°F (200°C).
It is the most impervious seal of all the other moisture seals.
4. Cement
Provides protection against some thicker liquids and dust, however it is not waterproof.
It is also somewhat brittle and subject to cracking in high impact or high vibration application.
Used for temperatures up to 2600°F (1425°C).
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