Thunderbolt & Standard Cartridge Heater Application Basics

This product group is an excellent choice for direct insertion heating of platens, dies, various metal shapes, and products requiring maximum amount of heat within a limited space. With the addition of threaded fittings or other leak tight mounting fittings these heaters are also an excellent choice for direct immersion into liquids.

Heater diameters with tolerances are shown within the Product Catalog Tables. Units without mounting fittings are designed to fit holes with a diameter tolerance of plus .001 inch - minus .000 of nominal heater diameter. Example: A 1/2" diameter heater (actual size .499 +.000" -.004") is designed to fit a hole size of .500" +.001 -.000. Higher rated watt densities on the heater combined with larger hole clearances will reduce heater life.

Holes drilled to accept heaters should be drilled all the way through if possible. Corrosion or scaling may make heater replacement difficult in blind holes.

Do not allow the heated portion of the heater to operate in air or an air pocket. Do not operate any Thunderbolt or Standard Cartridge heater in air.

Straightness or total heater run-out (camber) along the axis can be held to plus or minus .010 per inch for lengths up to 4" and .020 per inch up to 1 foot. Run-out increases for lengths over 1 foot, however, heaters are normally flexible enough to fit into long holes.

Heaters installed into moving blocks or dies should have provisions for preventing the leads from being damaged from motion. Options are available such as secondary strain relief, stainless overbraid, flex conduit, and right angle lead exit.

Cartridge heaters with liquid tight mounting fittings are suitable for use in liquid applications. Heaters mounted in a tank or other vessel should be mounted horizontally and near the bottom, however, above any sludge in the bottom. Heater must be covered with liquid at all times. Product, process, or system should include a device to protect heater from operation if no liquid covering the heater. System should be designed to avoid air entrapment or pockets of overheated liquid around the heater. Heating performance in tanks can be improved by agitation of the liquid in the tank.

In all cases, due to normal high temperature attainable on any metal sheathed heater, avoid contact with combustible surface or materials.

As with any electrically heated product, the proper application of Vulcan Heaters and the temperature control is the most important factor in optimum performance, efficiency, and longevity. No two systems are alike. It is extremely important that attention has been given to the total product or system design as well as operating environment.

Please refer to general application guidelines, recommended watt densities, sheath temperature limitations, corrosion guide, and other engineering data to assist you with product selection.

Please do not hesitate to contact us for application or product assistance.