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Miniature Cartridge Heaters, Cartridge Heaters, Small Diameter Cartridge Heaters, Pencil Heaters, Miniature Heaters for the Plastics, Injection Molding, Tool & Die, Food Service and Packaging Industries

Small Diameter Miniature Pencil Heaters

 
 
 
1/8" Small Diameter, Miniature Cartridge/Pencil Heaters
 
 
Small Diameter 1/8" OD Miniature Pencil/Cartridge Heaters:

Available 1/8" OD Cartridge Heaters Terminations:
 
 
 
 
                                                                                     Type N - External Pins with Leads                                          
 
                                                                              Standard Termination
                                                                              24 ga ultralead leads, 482F (250C)
                                                                              10" Leads are standard
                                                                              Leads externally crimped to nickel pins
                                                                              Minimum 1/4" cold section at lead end is required
 
        
  Type M - Teflon End Plug Seal
    
                                                                            Moisture resistant swaged Teflon seal
                                                                            24 gauge Teflon® insulated leads, 392F (200C)
                                                                            10" leads are standard
                                                                            Minimum 1/2" cold section at lead end is required
 
        
 
     Type F - Internally Connected Flexible Leads
 
                                                                             Provides flexibility
                                                                             High temperature fiberglass leads 842F (450C)
                                                                             10" leads are standard
                                                                             Minimum 1/2" cold section at lead end is required
 
    
 Type R4 - Bent Cartridge
 
                                                                            Heater Sheath is bent up to 90
                                                                            Bend is through a required cold section
                                                                            Standard sheath extension past the bend is 1"
                                                                           10" plain leads are standard
 
  Type MFR - Mounting Flange
 
                                                                           1" diameter flange, 2 x 9/64" Mounting holes is standard
                                                                           Other sizes available
                                                                          10"plain leads are standard
 
 Type W - Stainless Steel Braid Mechanically Fastened
 
                                                                        Offers sharp bending and abrasion protection
                                                                        10" braid over 12" Leads are standard
                                                                        Minimum 1/4" cold section is required
 
 
Type C1B - Stainless Steel Cable Mechanically Fastened 
 
                                                                      Provides maximum protection for abrasive environment
                                                                      10" cable over 12" leads are standard
                                                                      Minimum 1/4" cold section is required


 
 
 Small Diameter Miniature Cartridge Heaters

Small Diameter Pencil/Cartridge HeatersDescription 

Split-Sheath Design
Uniform Heating
Lengths From Inch to 6 Inches
1/8" and 4mm Diameters
Unique Hot Tip
 

Patented high-temperature design provides these advantages:


  •  When energized, the patented split-sheath expands into contact with surrounding bore for maximum heat transfer, fast response.
  • When de-energized, the split-sheath contracts for easy, slide-out removal. Sunrods are guaranteed never to sieze in the bore.
  • Uninterruped hot zone and fully heated tip provides unmatched heat distribution without cold spots. (See upper photo).
  • Slender continuous leads simplify wire management. High flexibility allows free motion when heating "floating" components.
  • The result is a miniature cartridge heater offering longer life, uniform temperatures, and easy installation in the smallest devices.
 
 
 NPH's 1/8" Cartridge Heater with Swaged-In Leads-Simplifies Wiring
 

Extending Miniature Heater Life:

Designing cartridge heaters with reduced watt-density multiplies service life.

The industry-standard warrantee for electric cartridge heaters is 2000 hours, or one year on single shift. This is a reasonable life expectancy for many applications. But some applications demand much more. Life expectancies of five, seven or even ten years are not unreasonable for some mission-critical applications:
 
  • Blood warmers used in medical theaters must never fail
  • Battery conditioners for EVA spacesuits on the International Space Station must last ten years before replacement, due to payload costs
  • Here on earth, high throughput semiconductor chip testers must operate without significant downtime for the 5 year life of the equipment. For these applications, a service life of 50,000 to 90,000 hours is a requirement that is both reasonable and attainable.

How can it be done? 

For every heater power loading (See "Calculating Watt-Density", at bottom) there is a maximum operating temperature that will guarantee 2000 hours life. This is the "Critical Temperature" for that power loading. (See chart below).
 

Power Chart System Temperature versus Maximum Watt-Density 

Critical Temperature (F): 200 300 400 500 600 700 800 900 1000
Maximum Watt-Density : 365 345 310 275 245 225 170 150 130
 
Go above the Critical Temperature by 100 degrees and life will be cut to a third, to 666 hours. But go below it by 100 degrees and heater life will be tripled, to 6000 hours! We can use this relationship to determine the watt-density at a given system temperature that will yield thousands of hours of extra life.
 
For Example
Let's suppose that your system requires a processing temperature of 500 degrees F with an input power of 80 watts. A 1/8" by 1" cartridge heater could provide the necessary wattage, and would have a power density of 270 watts-per-square-inch. As can be seen from the power chart, a heater with a power loading up to 275 watts per square inch would be acceptable. Heater life would be a respectable 2000 Fhours.
Processing Temperature 500*F
Critical Temperature (F) 200 300 400 500 600 700 800 900 1000
Maximum Watt-Density 365 345 310 275 245 225 170 150 130
Maximum Watt-Density 275 W/sq. in.
 
But what happens if we use a utilize a 1 " heater, just a " longer? The heater's power loading is lowered to 210 watts-per-square-inch. The Critical Temperature is raised by 200 degrees. The heater is now operating 200 degrees below the new Critical Temperature and heater life is increased to 18000 hours (2000 hours x 3 to the 2nd)!

Maximum Watt-Density Lowered Watt-Density 

How Do You Reduce Watt-Density?

Your heater watt density may not have to be reduced. Many miniature heating applications inherently require relatively little wattage, due to their small mass. This often results in a minimal power loading on a 1/8" miniature heater. In these cases, miniature cartridge heaters are often under-loaded by 200 to 400 degrees, relative to the Critical Temperature. Their 2000 hour life expectancy* may be multiplied up to 81 times!
 
Increasing Surface Area to Reduce Watt-Density
1. Maximize your heater length. Increasing the length of a 1" heater to 1 " (just a ") can increase the active area* by 33%, reducing power loading by 25%.
2. Consider using more heaters. Two heaters dividing the load will reduce watt-density by 50%.
3. Take advantage of any available space to install a supplemental heater. Adding a " long heater to an existing 1" heater can reduce power loading by 25%.
 
Calculating Watt-Density
Watt-density is the power loading of the heater, expressed in watts-per-square-inch of active heater surface.

The formula for active heater surface is: (Heater Length Cold End Length) x Diameter x Pi. For a 1/8" diameter by 1" long heater it is: (1.00 - 0.25) x .38, or .285 square inches.

The formula for watt-density is: Wattage / Active Heater Surface For 1/8" diameter by 1" heater at 80 watts, this is: 80 watts / .285 in sq or 270 watts/sq inch.
 
Small Diameter, Miniature Cartridge Heaters Selection Guide
The key questions which need to be answered before selecting a cartridge heater for your application are:
  • How much wattage is required?
  • What voltage will be used?
  • What is the heated length? What is the overall length?
  • How long are the heater leads or what is the lead length required?
  • What is the dimentions of the cartridge heater?
  • What is the ambient temperature the cartridge heater will see?
  • What is the maximum temperature required from the heater?
  • How quickly do you want to reach your operating temperature or set point in hour/minutes?
  • What is the type and weight (in lbs.) of the material you want to heat?
  • Special Modifications

How To Order Cartridge Heaters

Quotation Request Form

Select Type of Cartridge Heater
Select Cartridge Heaters Configuration Model Below:
(click on cartridge heaters images below to enlarge)

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Outside Diameter
Inserted Length
Overall Length
Watts
Volts
Lead Length
Lead Exit straight 90 copper elbow
Cartridge Heater Lead Options
Cartridge Heaters Lead Protection Options
Lead Connection Construction swaged in leads crimped on leads
Cartridge Heaters Potting Options
Special Features & Construction
Lead Termination Style
Ground Wire Yes no
Thermocouple None J K T
Thermocouple Junction Grounded Ungrounded
Thermocouple Location Disc End Center Offset
Heater Watt Density medium watt density high watt density
Lead Protection Options fiberglass-high temp sleeve-1200F s.steel overbraid armor cable gas proof armor cable F/G leads with ceramic beads
Potting Options Ceramic potting -temp rating 1000F/538C Epoxy 600F/315C Teflon plug 450/232C High temp silicone 650F/343C
Number of Pcs. Required
Requested Delivery Date
Any additional Application Comments & Details
First Name Last Name
Company Name Position
Address City/State/Province
Zip/Postal Code Country
Phone Number Fax Number
Toll Free Number Email
Web Site OEM Distributor Process User
Quotation Request Required Delivery Date
have a salesperson contact me
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Inquiries & Technical Support

Telephone: 905-859-8225 Facsimile: 905-859-4691

sales@nphheaters.com

Toll Free: 1-877-674-9744

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