Application Examples - Custom Component Sales, LLC

The Heatron HEATROD offers a wide range of application advantages. With watt densities ranging over 200 watts per square inch and a
multitude of lead configurations, the HEATROD offers solutions where fast, efficient heat transfer is requires. The incorporation of controlled heat profiles and thermal controls reduce temperature variations. Innovative ideas including out patented Non-Stick coating, Quick
Turn Service, and Minimum unheated sections are a few of the results of our continuous search for products and services which benefit our
customers. New applications for HEATROD heaters are being discovered everyday by Heatron and its valued customers. For applications requiring other heating methods, consult Heatron.
Application Examples
Non-Stick Heater—Heatron developed and patented a Non-Stick
coating to prevent cartridge heaters from seizing inside molds.
The factory applied coating resists scraping and eliminates the
need for applying release agents. Quick installation and easy removal has resulted in cost savings for our customers. A major
manufacturer of dies eliminated costly machining steps when
they switched to Non-Stick.
Medical Heater - An international manufacturer of kidney
dialysis equipment uses a HEATROD with an internal
thermal fuse to meet agency approval for over temperature
protection. The heater incorporates passivation and electro
polish to inhibit corrosion of the sheath, low leakage construction to meet medical standards for leakage current,
and computer serialization to meet tracking requirements.
“Heater in a Jacket” - Designed and constructed to
serve the photo processing industry. The incorporation of over temperature thermostats and thermal
fuses prevent the unit from over heating. The
stainless steel construction resists corrosion. The
internal HEATROD transfers heat to the liquid as it
flows across the surface.
Packaging Industry—Customers in the packaging industry
needed to minimize temperature variation when sealing
food products. A HEATROD with Controlled Heat Profile (CHP) was designed to provide uniform temperature
across the surface to within 1% of set point. An epoxy
seal was incorporated to allow the HEATROD to be used
in wash down applications.
Semi-Conductor - Heatrod Immersion Heater was used to help
control process water for the semi-conductor industry within
0.5°C. Heatron incorporated a moisture resistant seal, 316L
stainless steel sheath construction and passication. Solution
heating rates were increased by determining the optimum
heated section location within the overall heater length.
Heatrod Cartridge Heaters
Application Advantages
- UL and CSA recognition
- Utilization of internal over temperature controls
- Controlled heat profiles along length of heater
- Diameters from 1/4” to 3/4” and 8mm to 20mm
- Patented Non-Stick coating
- Low current leakage
- Any length from 1 to 60 inches
- High watt density construction
Heatrod Construction Features
Nickel Chrome Alloy Resistance Wire. This wire is machine wound around an MGO core and centered in the unit. The heaviest wire
gauge is used consistent with thermal design to maximize resistance wire strengths.
Hi Purity Solid Nickel Connector Pins. These solid Grade A pins run the length of the heater to connect with the resistance wire at the
end of the core. The design achieves the best possible pin/wire connection location for both temperature and amperage, assuring the
longest healthiest life.
Controlled MGO Granulation & Compaction. Heatron’s swaging process provides optimum thermal transfer and electrical dielectric
strength. High purity magnesium oxide (MGO) grain electrically insulates the thin space between the resistance windings and the heater
sheath, for maximum heat transfer into the part being heated. During the swaging process, the MGO is evenly compacted so that the heat
transfer and dielectric strength is consistent throughout the length of the heater.
Corrosion Resistant Sheath. The wall thickness and diameter of the sheath material is custom designed by Heatron to give optimum
swage configuration. This tubing provides the best combination of corrosion resistance, strength, and thermal transfer. Various alloys
are available for special applications.
Welded End Disc. To protect the heater from external moisture or contaminants, the end disc is welded in place. During swaging, this
disc is concave, thus maintaining equivalent MGO compaction density at the heater tip.
UL & CSA Approved flexible lead wire has insulations which allow operations up to 450°C.
Innovative Lead Construction provides minimal lead end cold section and allows a variety of custom lead configurations to meet all
delivery needs.
Agency Approvals
Heatron’s HEATROD Cartridge heaters are Underwriters Laboratories, (UL), recognized components under file #E91597.
Heatron has most extensive UL option list in the heater industry. Consult with the Heatron technical staff to discuss your particular requirements. Because Heatron has been through the UL approval process numerous times, early involvement by Heatron can save your
company time and money.
Heatron’s HEATROD Cartridge heaters are certified by the Canadian Standards Association, (CSA), under file #LR66355-1.
Many of the same options available under UL are also available under CSA. Heatron also has significant experience with European and
other international approval agencies. Please consult Heatron for further information.
Heatron has TUV approval under test specifications EN60335-1/A11 and EN61010-1A2 (certificate number B 99 04 17816 003
report number Dl1E9016601). This approval gives Heatron the option of CE marking its elements.
Heatrod High Density Cartridge Heaters
Standard Lead Options
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 inside the heater to provide a flexible alternative to crimped–on leads and 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.
Swaged-in Stainless Steel Metal Braid provides the best combination of abrasion protection and lead flexibility. The stainless steel braid is held securely inside the heater using a
unique Swage Ring connection. This internal connection method prevents the braid from
pulling out and can even be used to help remove a seized heater.
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 using the Swage
Ring connection and incorporates a protective metal cap spot welded to the heater sheath.
This unique design allows the braid to be fastened internally, rather than connected with
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. The caphose assembly is then placed over the leads and spot welded to the heater sheath.
Many competitors braze the hose directly to the heater sheath at temperatures approximately
1200°F, thereby weakening the lead wire insulation and moisture barrier. Our unique preassembled Right Angle Cap avoids this potential lead wire damage.
Additional Options
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. Where vibrations can cause
heaters to work loose into open air, a flange at the lead end is ideal to secure the heater.
Custom flanges are available, consult Heatron for standard flange and locating ring
sizes.
Rubber Over molds protect the heater from moisture and excessive flexing, such as in
food service or refrigeration equipment. Rather than molding the heater lead connection
inside the rubber overbold, Heatron swage-connects the S.J.O. cord inside the heater.
The over mold then acts as an additional strain relief and moisture barrier, not as a lead
connection. The temperature near the rubber should net exceed 220°F.
BX Conduit Lead Protection is and inexpensive alternative to Heatron’s standard
stainless steel flexible hose. Specify BX Conduit when ordering.
Watertight Stainless Steel Hose Lead Protection is ideal for areas where leads can be
subject to liquids or contamination. Specify Watertight Hose when ordering.
High Temperature Ceramic Beads cover the solid nickel pins in high temperature applications (above 500°F). The beads should extend to a point where the temperature is acceptable to attach flexible leads.
Internal Thermocouple Junctions can be located in three specific areas inside the heater.
Style 8 (high temperature fiberglass leads) is standard. If Style 9 (Teflon TM leads) is
required, please specify along with thermocouple location.
Location A is recommended for sensing temperatures of materials flowing past the heater
tip, such as in various plastic molding applications. The thermocouple junction
is always grounded to the sheath with the A location, and the “end disc” is flat to
provide better sensing ability.
Location B places the thermocouple junction against the inside wall of the heater sheath
at any point along the heater length. This location is used to monitor the heater
sheath or the approximate temperature of the part being heated. The
thermocouple junction is typically grounded to the heater sheath, specify if a
guaranteed ground is required.
Location C provides for the thermocouples junction in the center of the heater core at any
point along the heater length. This location is used to sense the heater’s hottest
internal temperature and is used for prototype testing and research. The thermo
couple junction is NOT grounded.
Thermocouple Material Available
J type is standard for all locations
J type Iron(+) magnetic white lead & Constantan (-) non-magnetic red lead
K type Chromel (+) non-magnetic yellow lead & Alumel (-) magnetic red lead
Other type thermocouples are available on request. Consult Heatron.
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. Conduit boxes can be mounted to a flange or threaded fitting welded to the heater. Various
NEMA boxes are available.
Bolt Heaters are used for the preheating of large studs and drilled bolts. The heater is inserted
inside a hollow bolt or stud before tightening. Once the nut is tightened the heater is removed,
causing the bolt to be contract for a tight fit. Custom heater diameters and lengths can be manufactured. Standard bolt heaters are supplied with post terminals. Extension cords can be provided
as an option.
Plugs can be provided with the heater for applications that require quick convenient connections.
The plugs can be attached to S.J.O. cord, flexible leads with sleeving, stainless steel metal hose or
braid. Specify any agency requirements.
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. Specify with a sketch or dimension of No Heat when
ordering.
Lead Wire Strain Relief Springs can be swaged into the lead end of 3/8” (10mm) and larger
cartridge heater diameters. Specify Spring Strain Relief when ordering.
Additional Engineering Options
Consult Heatron Engineering for the following options. The feasibility of each option depends upon detailed application specifications and
requirements.
Sub assemblies - Heatron can provide turn key heater assemblies which reduce labor, inventory and overall cost. Consult Heatron for specific applications.
Lead connectors and terminals can be specified with various quick disconnects, spade or lug terminals in male or female configurations,
either insulated or bare. Ask for a list of stocked terminals. Heatron has both hand tools and tape and reel capability, depending on the
terminal and quantity required.
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 polish protection. To protect HEATROD cartridges and heat exchangers against corrosive environments,
Heatron maintains in house facilities for passivation or electro polish finishes. This is particularly useful in medical, photo processing, or
immersion heater applications.
Sheath materials - Heatron stocks 304SS in all English and Metric diameters, 316L and Incology TM in most other English diameters.
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. This allows for different
process steps requiring different wattages.
Ground wires are available on most designs as a safety feature. The ground may be added internally or externally, depending on the heater
style and size.
Three phase cartridge heaters can be designed depending on the wattage, amperage, and size of the heater. The lead style will vary depending on these factors.
Leads out each end may be used when the application requires this design. Cement potting is the standard lead end seal rated to 1000°F.
Bare 3” long pins are standard and longer cold sections are required.
Center less grinding provides for precision diameters that may be needed for high watt density heaters that require a close fit between
heater and part. Lead length is restricted to 12”. Longer leads would require an external connection.
Self regulating cartridge heaters can be manufactured to change resistance as the temperature increases.
Incoloy TM is registered trademark of Inco Alloys International.
Lead Wire Material Options
Lead wire materials are available to match a variety to applications. Heatron HEATROD leads should be selected to withstand
the maximum ambient temperature for the intended service. Moisture and contaminants are also important considerations. Various lead
wire insulations are available from stock or may be special ordered, examples include:
Insulation Material
Teflon or Tefzel
Silicone rubber
PVC
SJO or SJT cord
TGGE (Teflon, Glass, Enamel)
MGE (Mica, Glass, Enamel)
Temperature Rating
105°C, 150°C, or 200°C
150°C or 200°C
105°C
60°C or 90°C
250°C
450°C
Depending on the application, many of the insulation materials available are UL and CSA listed or certified constructed to meet
Military Specification. Contact Heatron Engineering for specific construction ratings.
Heatrod Heat Exchanger Assembly
Application Advantages
-Reduced Space
-Reduced cost/less assembly
-Ease in gaining safety agency approvals
-Faster/more efficient heat up times
-Better/more accurate heat control
Characteristics
HEATROD high watt density Cartridge Heater
Heavy Wall construction for reliable welds. Standard units are pressure tested to ensure trouble free operation up to 60
psi.. Corrosion resistant materials available such as 316L and 304 stainless steel.
Heatron maintains in house facilities for electro polish and passivastion finishes.
A variety of lead wire and end seal options for moisture protection.
Optional internal over temperature safety devices.
Thermal wells with fittings for mounting RTD’s, thermistors, thermocouples, or other temperature controlling devices.
Internal thermocouples available (Type J standard)
Mounting pads for 1/2” disc thermostats can be welded to the heat exchanger, (contact Heatron for other thermostats).
Mounting brackets can be provided per customer specifications.
Ports located and configured to accept existing customer fittings in any location.
Ports can be flared to ensure secure clamped connections.
Ground wire can be internally connected in heater, or a ground lug (8-32 thread, 1/4” long) can be welded to the heat
exchanger for wiring convenience.
Heatrod Patented Non-Stick Coated Cartridge Heaters
Heatron developed and patented the original Non-Stick coating for cartridge heaters. Confirmed in actual customer applications,
this revolutionary coating eliminates the seizing of heaters in molds. This cost effective product alleviates the expense related to removal of heaters and potential damage to equipment.
Application Advantages
-Revolutionary improvement in cartridge heater technology. Eliminates costly heater
removal downtime.
-Exclusive Heatron formulated and factory applied barrier release coating eliminates the
time consuming and messy process of applying release agents before installation.
-Non-Stick coating specially bonded to heater sheath. Resists scraping, unlike other
anti-seize compounds.
-Non-Stick coating improves heat transfer. Extends heater life.
-Patented process provides non-stick protection at high temperatures up to 1200°F.
-Higher watt density capabilities. Longer life at less cost than “split sheath” type cartridge heaters.
-Non-Stick cartridge heaters fit same hole sizes required for standard heater cartridges.
Special diameter bores not required.
US Patent No. 5, 136, 143 Canadian Patent No. 2071024
Heatron’s Controlled Heat Profile (CHP)
Cartridge Heater
Application Advantages
Heatron developed the Controlled Heat Profile (CHP)
cartridge heater to let customers specify a heat profile for their
application. In many cases industry standard cartridge heaters
provide inadequete temperature uniformity. By eliminating cold
and hot spots, designed so the wattage ans heat vary along the
length of the heater, both quality and yield improve, resulting in
lower production costs. For example, the faster sealing of potato
chip bags-with fewer air leaks-will result in higher productivity.
Heatron’s engineering staff will work closely with you to economically develop the proper CHP design for your
unique application. This process usually involves evaluating your existing process to determine the temperature profile.
Using computer aided design and winding techniques, Heatron will design and build CHP prototype that can be tested in
the Heatron lab or in your actual application.
The final CHP design will result in better quality parts, faster cycle times and fewer rejects-guaranteed.
Application Examples
Heatron’s CHP is proven to provide even heat profile for the following applications:
Packaging-Seal Jaws
Extrusion-Die Heads
Marking-Hot Stamping
Plastic-Heat Fusion & Staking
Molding-Injection
-Transfer
-Composites
-Blow Molding
Mold Components-Sprues
-Distribution Tubes
Electronics-Patens
-Component Fabrication
Heatrod Temperature Controlled Cartridge Heaters
Application Advantages
To meet the needs of original equipment manufactuars,
Heatron developed HEATROD Cartridge Heaters with
internal Over Temperature Control. Internal thermostats or
thermal fuses offer space savings over conventional methods and eliminate the need for additional mounting and
hook-up. Units can be designed for over temperature protection, temperature control, or automatic heater start-up.
Heatron’s engineering staff will work closely with you to
economically develop the proper temperature setting for
your application. This process simply involves testing a
heater with a thermocouple located in a “dummy” thermostat or thermal fuse to determine the proper temperature
setting. Heatron stocks devices to make this prototype
testing process as easy and fast as possible.
Characteristics
Flanges or Threaded Fittings
Mounted in Heat Exchanger (see page 8)
Self Regulating Resistance Wire
Low Leakage Current to meet UL Medical 544 and IEC 601.1
Electro polished & Passivated Heater Sheaths
Moisture Resistant End Seals
HEATRODS can also be designed with internal sensors such as RTD’s, thermocouples, or thermistors.
Thermostats and thermo fuses with UL, CSA, and TUV?VDE available. Consult Heatron for further information.
Heatrod Immersion Heaters
Heatron Heatrod Immersion Heaters are ideal for heating water, water soluble solutions, or other liquids. Using
watt densities over 200 watts per square inch allow the designer to minimize space requirements without sacrificing product performance. This compact heater with an integral bushing provides versatility in the final product
design, minimum assembly time, and ease of service. Bushing materials, moisture resistance end seals, low leakage current, and specifications can be customized for each application.
Factors such as liquid type, temperature requirements, flow rates and scale build up potential, play roles in providing the correct design for the application. Fittings are available in 304SS, brass and double threaded fittings.
Other alloys available upon request.
Heatron Packaging Machine Punch Heaters
Heatron was the first to develop a cartridge heater with a built in punch. This built in design allows for more efficient transfer of heat to the punch tip. A heat punched hole forms a bead which adds strength to the hole when the
plastic film package is hung for display. This Works particularly well with polypropylene films.
Internal thermocouples (Type J or K) can be provided at the tip of the punch. The thermocouples used in conjunction with an electronic temperature control allow for accurate temperature control for faster production cycles and
protects the heater from overheating if
the machine stops. (Some form of
temperature control should be used to
prevent the heater from overheating.)
Common Punch Heater configurations
utilize 1/4” diameter heaters with
5/16” or 3/8” diameter punches. Select 3/8” diameter heaters to provide a uniform diameter for the complete
punch heater.
Lead End Seals for Moisture and Contamination Protection
Teflon TM Seal-rated for continuous operating temperatures up to 400°F (205°C).
Teflon TM leads are supplied as standard, other typed leads are available on request.
Epoxy Potting-rated for continuous operating temperatures up to 350°F (177°C).
Specify type lead wire required. No-heat section can vary on depending on the cartridge heater design.
Silicone Potting or End Plug-rated for continuous operating temperature up to 400°F (205°C).
Specify type lead wire required. No heat section can vary depending on the cartridge heater design
Silicone Rubber Over molds-rated for 220°F (104°C).
The over mold protects from moisture contamination.
Moisture Retardant Coating-rated for continuous operating temperatures up to 600°F (316°C).
Can be applied to ceramic, lava, or mica end plugs with all standard or optional lead wires.
Heatron Bent Heatrods
Bent HEATRODS are designed to offer extra
protection where the leads may be exposed to
high temperature or potential abrasion. The area
of the bend must be in a no-heat section
Low Density Cartridge Heaters
Applications
Where watt densities of less than 45 watts/square inch can be used
Examples
Including but not limited to Dies, Heat Sealing, Labeling, Packaging, Molding
Characteristics
304 stainless steel sheath and end disc material
High nickel content element for effective heat transfer
Ceramic cores providing high dielectric qualities
Fiberglass leads rated up to 250°C
Diameters from 3/8” to 3/4”
Standard Lead Configurations
Internally connected leads with 12” of fiberglass lead
wire.
Tin plated copper braid protects fiberglass leads from
abrasion. The braid is silver soldered in place.
Galvanized conduit protects fiberglass leads from sharp
objects. The hose is silver soldered in place.
High temperature beads cover internally connected pins.
Right angle hose protects leads from sharp objects or
small amounts of contaminants in areas where space is
limited.
Right angle braid offers lead flexibility and abrasion
protection where space is limited.
Post terminals are designed for applications requiring a
fast connection using leads, spade terminals, or bus
bars. 1/2”, 5/8”, and 3/4” diameters available.
Consult Heatron for other available lead configurations.
Tolerances
Wattage: +5%, -10%
Diameter: +0.000”, -0.009”
Minimum Length: 2”
Maximum Length: 40” (longer lengths –consult Heatron)
Length: +/- 1/16” 4” and under
+/-1/8” over 4”
Wattages below 240Watts are not available at 440Volts or 480Volts
3/8” and 1/2” diameter by 2” long available at 120 Volts only
Consult Heatron for wattages that exceed recommendations.