TUTCO CONDUCTIVE

Standard Cartridge Heaters

TUTCO Standard Cartridge Heaters are designed as an economical quality heater for lower temperature use (typically 45 Watts/in²), depending on the application. They are made to temperatures up to 1000ºF (538ºC) and feature a stainless steel sheath for resistance to oxidation. High purity magnesium oxide (MgO) fills any space surrounding the resistance wire in order to optimize heat transfer and increase the life of the heater. Like Hi-Temp Cartridge heaters, many options are available to customize your heater.

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FEATURES AND BENEFITS

High watt density rugged construction
Efficient dissipation of heat
Many voltage variations and power options
Wide-range of diameters
Many termination styles – see below
CSA and UL recognized (where applicable)
High quality Nickel-Chromium connections provide consistent junctions and terminations
Use in distributed wattage systems

Specifications
Maximum Watt Density	45 Watts/sq. in
Maximum Sheath Temperature	1000°F (538°C)
Sheath	Stainless Steel
Wattage Tolerance	+5%/– 10%, based on NEMA standards
Resistance Tolerance	+10% – 5% 8.5% lower at room temperature
Standard Voltages	120V, 240V. Others available upon request

APPLICATIONS

PLASTICS

Compression Molding
Blown Film Processes
Blow Molding Machines
Plastic Pellet Drying

PACKAGING

Platen Heaters
Packaging and Sealing Bars
Form Fill Packaging Machines

PROCESSES

Textile Processing
Chemical Processing
Laboratory Warmers
Bolt Heaters
Laminating Applications
Scientific Testing Equipment
3D Printers
Plastic Pipe Cutting / Joining
Glass Processing

FOOD SERVICE

Food Grade Sealing/Wrapping
Food Service Warming
Refrigeration

TRANSPORTATION

Automotive Applications
Space Heaters for Public Transport
Agriculture Transportation

MORE APPLICATIONS

Holding Tanks
Drum & Barrel Heating
Battery Warmers
Deicing Applications
Defrost Heaters
Cryogenic Applications
RV Water Heaters
Control Panel/Enclosure Heater

Standard Cartridge Heaters Application image

RESOURCES

MANUALS

Fit and Installation

BROCHURES

Cartridge Heaters

CUSTOM OPTIONS

Cartridges can be modified to meet the demands of special applications. Our engineers can utilize a variety of alternative features and options to customize the heater to your specific needs. Common customizations include:

Internal Thermocouples
Flanges
Threaded Bushings
Epoxy Seals
Leadwire Termination Options
Mica Tape Leads
Stainless-Steel Braid or Armor
Lead Area Sealing
Distributed Wattage
No-Heat Sections
Three Phase Construction
Dual Voltage
Zoned Heaters
Square Cartridge Heaters

Learn more about customizing cartridge heaters in Ian Renwick’s white paper.

LEAD OPTIONS

FLEXIBLE LEADS
Internally connected leads. For applications requiring maximum flexibility at lead exit. 10” (25.4 cm) leads standard, other lengths are available.

EXTERNALLY CONNECTED LEADS
Hi-Temp Cartridges are provided with approx. 1” (25.4 mm) sleeving over lead junction as standard. 10” (25.4 cm) leads standard, other lengths are available.

STRAIGHT LEADS WITH CLIP SUPPORT
Clip support helps to minimize lead breakage where leads exit heater. 10” (25.4 cm) leads standard, other lengths are available.

90° LEADS
Leads exit at 90° angle for applications where space is limited. 10” (25.4 cm) leads standard, other lengths are available. Order heater by overall length.

90° LEADS WITH CLIP
Clip support helps to minimize lead breakage where leads exit heater. 10” (25.4 cm) leads standard, other lengths are available.

LEAD PROTECTION

STRAIGHT STRAIN RELIEF SPRING
Straight strain relief spring minimizes bending strain on lead wires. Spring extends approximately 3â€³ (76.2 mm) beyond end of sheath.

STAINLESS STEEL BRAID
Stainless steel braid over lead wires. For applications requiring small radius bending and lead wire abrasion protection. 10â€ (25.4 cm) braid standard, other lengths are available.

STAINLESS STEEL ARMOR
Straight stainless steel armor cable protects leads from abrasion. Sizes include: 1/4â€³, 5/16â€³, 1/2â€³, and 5/8â€³. 10â€³ (25.4 cm) standard, other lengths are available.

CONVOLUTED ARMOR
Used in situations that require moisture resistant armor. Available in most instances in which armor is utilized. Sizes: 3/8â€³, and 5/8â€³ only. 10â€³ (25.4 cm) standard, other lengths are available.

RIGHT ANGLE ELBOW
Right Angle Elbow Right angle copper elbow for applications requiring right angle lead exit. Moisture-resistant seal is optional. 10â€³ (25.4 cm) leads standard, other lengths are available.

FITTINGS

NPT BUSHING
Hex head N.P.T. bushing attached. Must specify insert length and bushing material. Sheath material types: stainless steel, cold rolled or galvanized. Bushing material types: brass, stainless steel or steel. 10″ (25.4 cm) leads standard, other lengths are available. Octagonal box available.

HEX CENTER BUSHING
Hex head N.P.T. bushing attached. Must specify insert length and bushing material. Sheath material types: stainless steel, steel or brass. Bushing material types: brass, stainless steel or steel. 10″ (25.4 cm) leads standard, other lengths are available. Octagonal or explosion-proof boxes can be adapted to both Standard and Hi-Temp Cartridge heaters.

ADAPTER
Must specify insert length and bushing material. Sheath material types: stainless steel, cold rolled or galvanized. Bushing material types: brass, stainless steel or steel. 10″ (25.4 cm) leads standard, other lengths are available.

ADAPTER WITH HEX HEAD
Must specify insert length. Bushing material is copper. 10″ (25.4 cm) leads standard, other lengths are available.

THERMOCOUPLE

BOTTOM GROUNDED
For fast response, heater is positioned in a blind hole or where material flows past or encompasses the heater. The end disk is always welded in place. Machined flat up to 1/2″ (12.7 mm) dia.

BOTTOM UNGROUNDED
Where circumstances are such that an ungrounded thermocouple is required.

CENTER GROUNDED
Selected when a fast response is required. The thermocouple can be located in any position along the length of the heater. Standard location is midway along the length with approximately 1/4″ (6.4 mm) cold section on either side of the junction. Not available on 1/4” diameter heaters.

CENTER UNGROUNDED
The thermocouple is positioned internally and ungrounded to monitor the heater temperature. Generally used in research and development applications.

Removable Thermocouple
The thermocouple is inserted down a hypotube for easy removal.

Thermocouple Availability

All heaters shown are Hi-Temp with type “J” thermocouple standard. Type “K” thermocouples are available. For standard Cartridge heaters thermocouples are available located at the bottom or center, ungrounded only.

OTHER OPTIONS

ARMOR WITH PLUG
Armor cable with power plug attached. Must specify armor length and HubbellÂ® power plug number. Moisture-resistant armor available. Other Plugs are available. Also available with Hex Head NPT bushing and armor.

BOLT HEATER
Bolt heaters are designed to heat drilled metal surfaces quickly while minimizing heat loss to surrounding areas. Each is designed to expand drilled bolts or studs while maintaining a uniform heat throughout its heated length. Typically, after a bolt is heated (expanded) the holding nut is tightened. The shrink tightness is obtained when the heater is removed and the bolt cools. This process is frequently used in the assembly and/or servicing of heavy duty equipment such as compressors, steam turbines, pressure vessels, etc.

DIAMETER SIZES

Frequently Asked Questions

How do I pick the right wattage for my cartridge heater?

Choosing the right wattage is all about balance. Too little wattage, and your heater won’t reach the desired temperature efficiently; too much, and you risk overheating or shortening the heater’s lifespan. Consider the mass of the material you’re heating, the desired temperature rise, and how fast you need it to heat up. TUTCO can help match a heater’s wattage to your specific application for optimal performance.

How long will a cartridge heater typically last?

The lifespan of a cartridge heater depends on how it’s used. Frequent on/off cycling, high watt density, poor fit, or exposure to moisture can shorten life. When installed correctly, in a compatible environment, and with proper thermal control, these heaters can last thousands of hours, making them a reliable solution for demanding applications.

Can I install cartridge heaters myself, or do I need a professional?

Many cartridge heaters are straightforward to install if you have the right bore and mounting. However, proper fit is critical: too loose, and you lose efficiency; too tight, and you risk damaging the heater or your equipment. If you’re unsure, it’s a good idea to consult TUTCO or an experienced technician to ensure correct installation and long life.