Content |
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Introduction |
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Cartridge heaters are cheap, robust and easy to install. Highly compacted they reach a surface watt density of up to 50 W/cm² and
withstand highest stress. Apart from our broad standard range we also develop and manufacture cartridge heaters according to your special demands.
Other product description: spiral cartridge heaters |
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| CONSTRUCTIVE SPECIFICATIONS AND TOLERANCES |
| Wattage: |
+5% |
-10% |
| Resistance: |
-5% |
+10% |
| Dielectric stregth (voltage applied): |
1500 |
V |
| Insulation (cold 1000 V DC): |
>10 |
MOhm |
| Leakage current (cold): |
< 0,5 |
mA |
| Max. working temperature allowed on sheath: |
750 |
°C |
| Length tolerance: |
±2 |
% |
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(min. ±1 mm) |
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| Diametre |
4 |
6,5 |
8 |
10 |
12,5 |
16 |
20 |
mm |
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1/4'' |
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3/8'' |
1/2'' |
5/8'' |
3/4'' |
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| Max. Volts |
240 |
240 |
240 |
240 |
240 |
400 |
400 |
V |
| Max. Amps |
1 |
4 |
5 |
7 |
14 |
18 |
22 |
A |
Also available special diametres (on request):
Ø 5,9 / 6 / 12 / 14 / 15 / 18 / 25 / 25,4 / 31,8 mm
square: 4,5 x 4,5 / 6 x 6 / 8 x 8 / 10 x 10 mm (see chapter 1.5) |
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1.1 High-density cartridge heaters |
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High density cartridge heaters
distinguish themselves by their high compression and therefore especially
efficient heat emission. That’s why we produce
them with a grinded surface for a h7/H7 fit.
The resistance wire is spooled
on a ceramic core as shown on the photograph. Afterwards the space between
wire and cartridge sheath is filled with MgO. Finally the cartridge is
swaged and thus compressed.
Advantage of this construction is the resistance
wire’s short distance to the sheath, the resulting very good heat
emission and the excellent control response.
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» Standard connection(s) >> see type I, type N, type F
» Standard diametres, length and power >> see following tables
» Options » see chapter 1.2
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Type I
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Electric contact is made "Inside“ the cartridge heater.
Advantage: flexible termination area |
Type N
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The Normal electric contact is made outside the cartridge heater and is protected
by a silicone impregnated fibre glass sleeve.
Advantage: cheap production, length of the lead freely selectable |
Type F
| Ø |
3/8''
10 mm |
1/2''
12,5 mm |
5/8''
16 mm |
3/4''
20 mm |
| T [mm] |
4 |
5 |
6 |
7,5 |
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Flexible version of the outside contacted “normal” connection type N
Advantage: Connection is protected from bending in a ceramic cap,
can be manufactured of stock cartridge heaters, length of the lead freely selectable
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Standard leads:
250 mm fibre glass insulated nickel leads; Ø 4,0 mm PTFE leads (temperature resistant up to 260°C)
(With thermocouple: 1000 mm)
Thermo leads see chapter 1.2) |
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| Ø |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
Legend
S = Standard
O = Option |
| I |
S |
S |
S |
O |
O |
O |
O |
| N |
- |
- |
- |
S |
S |
S |
S |
| F |
- |
- |
- |
O |
O |
O |
O |
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Also available special diametres (on request):
Ø 5,9 / 6 / 12 / 14 / 15 / 18 / 25 / 25,4 / 31,8 mm
square: 4,5 x 4,5 / 6 x 6 / 8 x 8 / 10 x 10 mm (see chapter 1.5) |
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1.2 Options |
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Following options, if required, are to be specified in inquiry and order:
» Thermosensors
» Connection (leads, moisture protection, earth lead)
» Termination (right angle exit, hexagon head,
flange long, flange round, stop ring, extraction nib)
» Protection sleeve
» Differential power
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| Thermosensors |
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Type TC1 (Standard)
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Hot junction grounded to the bottom disc
Advantage: quick response |
Type TC2
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Hot junction ungrounded near bottom disc
Advantage: little prone to interferences |
Type TC3
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Hot junction grounded to the sheath in the middle of the heated zone
Advantage: quick response |
Type TC4
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Hot junction is ungrounded near of the sheath in the middle of the heated zone
Advantage: little prone to interferences |
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| DIN 43714 |
Recommended
temperature |
TC1
Standard |
TC2 |
TC3 |
TC4 |
| Type |
+ |
- |
| J |
red
(Fe) |
blue
(CuNi) |
< 400°C |
x |
x |
x |
x |
| K |
red
(NiCr) |
green
(Ni) |
< 750°C |
x |
x |
x |
x |
| PT 100 |
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< 150°C |
- |
> 10 / 3/8'' |
- |
> 10 / 3/8'' |
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| Standard thermo leads: 1000 mm, PTFE insulated |
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| Connection |
| leads |
| Apart from our standard "fibre glass insulated nickel
leads“ (< 260°C) other leads can also be fixed. Available are: |
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PTFE insulated nickel leads
Temperature resistant up to 260°C
Advantage: moisture tight |
Silicone insulated nickel plated copper leads
(available only with standard connection type N >> see chapter 1.1)
Temperature resistant up to 180°C
Advantage: flexible, moisture tight |
High temperature leads
Temperature resistant up to 650°C
Advantage: highly temperature resistant |
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| moisture protection |
| Instead of sealing the termination with ceramic cement or installing a ceramic cap (>> see
standard connections in chapter 1.1) we can alternatively
produce other kinds of terminations which provide a special moisture protection.) |
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PTFE
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Cartridge heaters with a PTFE disc are temperature resistant up to 260°C
and should be used in connection with PTFE insulated leads.
Advantage: moisture protected |
Silicone
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Cartridge heaters sealed with silicone are temperature resistant up to 180°C
and should be used in connection with silicone insulated leads.
Advantage: moisture protected |
Epoxy
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Cartridge heaters sealed with epoxy resin are temperature resistant up to 200°C
and can be used in connection with silicone insulated as well as PTFE insulated leads.
Advantage: moisture tight |
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| earth lead |
| Earth leads are available and mountable in all common lead materials (on request) |
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| Termination |
| right angle exit |
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Type A
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Leads directed through sheath of cartridge heater, sealed with ceramic
Advantage: small, cheap |
Type B
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Angle block
Advantage: robust, sleeve installation possible (see protection sleeve), gas tight possible |
Type C
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Angle tube piece
Advantage: small, sleeve installation possible (see protection sleeve) |
| Type D |
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Bent termination
Advantage: gas tight, sleeve installation possible (see protection sleeve) |
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| dimension table |
| Ø |
4,0 mm
only type C |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| A [mm] |
- |
5 |
6 |
6 |
8 |
10 |
12 |
| B [mm] |
- |
8 |
10 |
12 |
14 |
18 |
22 |
| C [mm] |
- |
6 |
7 |
7 |
8 |
10 |
10 |
| D [mm] |
- |
8 |
10 |
10 |
12,5 |
16 |
16 |
| E [mm] |
2,5 |
4,2 |
5,2 |
6,5 |
8 |
10,5 |
13 |
| F [mm] |
12 |
16 |
18 |
22 |
26 |
30 |
36 |
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| hexagon head |
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Ø
thread |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| M (thread) |
- |
M10 x 1
1/8" |
M12 x 1,5 |
M14 x 1,5
1/4" |
M16 x 1,5
3/8" |
M20 x 1,5
1/2" |
M27 x 1,5
3/4" |
| G [mm] |
- |
7 |
9 |
9 |
10,5 |
13 |
13,5 |
| H [mm] |
- |
3,5 |
4 |
4 |
4,5 |
5 |
6,5 |
| I [mm] |
- |
12 |
14 |
17 |
19 |
24 |
30 |
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| flange long |
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| Ø |
4.0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| A [mm] |
- |
3,2 |
3,5 |
3,5 |
4,5 |
5,5 |
6,5 |
| B [mm] |
- |
6 |
7 |
9 |
10 |
13 |
15 |
| C [mm] |
- |
8,5 |
9,5 |
10,5 |
13,5 |
16,5 |
19,5 |
| D [mm] |
- |
13 |
14,5 |
16,5 |
20,5 |
25,5 |
29,5 |
| E [mm] |
- |
3 |
3 |
3 |
4 |
5 |
6 |
| S [mm] |
- |
1,2 |
1,5 |
1,8 |
2 |
2,5 |
3 |
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| flange round |
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| Ø |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
- |
20 |
20 |
25 |
25 |
33 |
33 |
| E [mm] |
- |
14 |
14 |
19 |
19 |
27 |
27 |
| F [mm] |
- |
3,2 |
3,2 |
3,2 |
3,2 |
3,2 |
3,2 |
| S [mm] |
- |
1,2 |
1,2 |
1,8 |
1,8 |
2,5 |
2,5 |
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| stop ring |
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| Ø |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
- |
10 |
12 |
15 |
17,5 |
22 |
26 |
| S [mm] |
- |
1,5 |
1,5 |
2 |
2 |
2,5 |
2,5 |
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| extraction nib |
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| Ø |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
- |
- |
- |
7,5 |
9 |
12 |
16 |
| S [mm] |
- |
- |
- |
4 |
5 |
6 |
8 |
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| Protection sleeve |
| Silicone impregnated fibre glass sleeve |
Temperature resistant up to 260°C (over 260°C the sleeve loses its flexibility)
up to 8 mm cast with ceramic cement in the head
from Ø 10 mm / 3/8'' on with connection tube
Advantage: flexible up to 260°C |
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Ø
connection tube |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
without connection tube |
11 |
10,5 |
14 |
18 (20 mm)
17 (3/4'') |
| E [mm] |
35 |
30 |
40 |
40 |
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| Silicone cable |
Temperature resistant up to 180°C
Advantage: flexible, robust, moisture protected |
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Ø
connection tube |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
- |
7,5 |
9,2 |
11 |
10,5 |
14 |
18 (20 mm)
17 (3/4'') |
| E [mm] |
- |
30 |
30 |
35 |
30 |
40 |
40 |
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| Braided metal sleeve |
Fixed with connection tube
Advantage: flexible, robust |
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Ø
connection tube |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| D [mm] |
- |
7,5 |
9,2 |
11 |
10,5 |
14 |
18 (20 mm)
17 (3/4'') |
| E [mm] |
- |
30 |
30 |
35 |
30 |
40 |
40 |
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| Flexible metal conduit |
Stainless steel sleeve |
| Advantage: robust |
Advantage: robust, gas tight |
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Ø
connection tube |
4,0 mm |
6,5 mm
1/4'' |
8 mm |
10 mm
3/8'' |
12,5 mm
1/2'' |
16 mm
5/8'' |
20 mm
3/4'' |
| C [mm] |
- |
10 |
10 |
10 |
13 |
16 |
20 |
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| Differential power |
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The cartride heater can usually not emit heat homogenously over its
length. For applications in which this is to be avoided
cartridge heaters with heat distribution can be used. For that
purpose the heating wire is coiled denser on a specific length
(L1 and L2) at both ends. This leads to a relative power increase
in these areas (power shares E1 and E2 in %, E1+E2+E3 = 100%). |
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1.3 Medium-density cartridge heaters (spiral cartridge heaters) |
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Medium-density cartridge heaters produce their energy with a heating coil which is lead through
hole ceramics. They are specially suitable for applications where no high surface watt density is needed (max. 15 W/cm² >> see
formula) or very long cartridge heaters are required.
Standard leads: 250 mm fibre glass insulated nickel lead, externally connected (type N)
If required we can produce the cartridges with an h7 surface which is standard only for high-density cartridge heaters. |
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| Ø |
6,5 mm
1/4''
-0,02
-0,08 |
8 mm
-0,03
-0,10 |
10 mm
3/8''
-0,03
-0,12 |
12,5 mm
1/2''
-0,04
-0,14 |
16 mm
5/8''
-0,05
-0,16 |
20 mm
3/4''
-0,06
-0,20 |
| min.L [mm] |
160 |
160 |
200 |
300 |
400 |
500 |
| max. L [mm] |
1000 |
1000 |
1400 |
1800 |
2000 |
2000 |
| max. Ampère |
4 |
500 |
7 |
14 |
18 |
22 |
| max. W/cm² |
15 |
15 |
15 |
14 |
14 |
13 |
| max. Volt |
240 |
240 |
240 |
240 |
380 |
380 |
| max. Watt (240V) |
960 |
1200 |
1700 |
3400 |
4300 |
5300 |
| max. Watt (380V) |
- |
- |
- |
- |
3600 |
8400 |
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1.4 Low voltage cartridge heaters |
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Low voltage cartridge heaters are unipolar elements in which the heating coil (NiCr 80/20)
lies embedded in high compacted MgO co-axial to the sheath. On one side it is connected with the lead, on the other side with the bottom
disc (earthing).
Standard leads: 500 mm fibre glass insulated nickel leads |
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Ø
mm |
L
mm |
W
24 V |
W/cm² |
4,5
-0,02
-0,04 |
40 |
60 |
15 |
| 100 |
25 |
| 50 |
60 |
11 |
| 100 |
18 |
| 60 |
80 |
11 |
| 125 |
17 |
| 70 |
80 |
10 |
| 125 |
15 |
| 80 |
100 |
11 |
| 160 |
17 |
| 100 |
100 |
8 |
| 160 |
13 |
| 130 |
125 |
7 |
| 200 |
12 |
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1.5 Square cartridge heaters |
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Square cartridge heaters are used where much power has to be installed near the surface of a tool,
e.g. in cutting knives,
sealing stations or hot plates. The cartridge heaters can easily be pressed into a rectangular groove.
Apart from the advantageous heat transfer over 3/4 of the sheath, it is not necessary to cement or cast in the heater which
is imperative for round cartridge heaters. Unlike tubular heaters which are also available in square sections
(see chapter 4.1 Flexible Heating Pipes), the square cartridge heaters have the termination on one side and can be loaded with 16W/cm² (2.5W/in²)
due to their special inside construction.
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| Cross sections |
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4,5 x 4,5 mm |
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6 x 6 mm |
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8 x 8 mm |
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10 x 10 mm |
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| Connection |
| Just like round cartridge heaters (see chapter 1.2 Options) |
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| Sheath |
| stainless steel 1.4541 (nickel 2.4068) |
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| Bendable executions |
| adjustable to 2D & 3D contours |
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with terminal head
4,5 x 4,5 mm » Ø 6,5 x 30 mm
6,0 x 6,0 mm » Ø 8,0 x 30 mm
8,0 x 8,0 mm » Ø 9,2 x 30 mm
10 x 10 mm » on request |
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with nickel pins |
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1.6 Service |
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Assembly instructions
» Because of the hygroscopic characteristic of the used ceramic insulation materials
they absorb mois-ture. Therefore we send our cartridge heaters usually in air-tightly closed plastic bags. When stored unprotected
in environmental air it is absolutely important to check the insulation resistance before use and – if necessary – to dry the elements
(controlled start-up or drying oven).
» Bending the outside connection points (exit type N) could break the termination and must be avoided.
» The temperature stress of max. 750°C at the sheath is not valid for the connection area. The tempera-tures arising in the connection
area determine decisively the suitability of the available exits.
» The stated nominal voltage must not be exceeded, otherwise overheat is risked.
» Generally it can be said: the better heat is carried off, or flows into the work piece respectively, the higher the surface watt density
on the sheath can be.
» Watt densities on the cartridge sheath of up to 50 W/cm² are acceptable only controlled and in ideal thermal installation conditions.
Materials with a good thermal conductivity and a narrow tolerated car-tridge heater fit are therefore recommended strongly.
» For our h7-grinded high density cartridge heaters we recommend H7-holes with a surface roughness as small as possible .
» Form errors of the hole, crossing holes or shrinkage cavities obstruct the heat conduction and lead to heat accumulation which could partly
overheat the cartridge critically.
· The connection area of cartridge heaters must be protected from lubricants, detergents and solvents, because these could diffuse into the ceramic
and lead to short-cuts.
» In every practice application there are working and environmental parameters which can not be calcu-lated exactly in theory. That is why we recommend
generally to test cartridge heaters in the application under real working conditions in advance. |
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