Tempco Custom Heater Manufacturing

Hi-Denisty Cartridge Heater Specifications and Tolerances

Performance Ratings

Maximum Temperature: 1400°F (760°C)

Maximum Watt Density: 100-300 W/in2 (15.5-46.5 W/cm2) depending on heater size & operating temperature.

Note: The maximum operating temperature and the life expectancy of a cartridge heater is dependent on two main factors:
1. The maximum recommended sheath temperature (v1200°F for a standard heater)
2. The maximum ambient temperature for the termination selected.     Consult Tempco if you require a recommendation for your application.

Dimensional Specifications

Nominal Diameter 1/8" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1"
  in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)
Actual Diameter 0.122 -3.1 0.246 -6.25 0.308 -7.82 0.371 -9.42 0.496 -12.6 0.621 -15.77 0.746 -18.95 0.996 -25.3
Diameter Tolerance ±.002 -0.051 ±.002 -0.051 ±.002 -0.051 ±.002 -0.051 ±.002 -0.051 ±.002 -0.051 ±.003 -0.076 ±.003 -0.076
Minimum Length 1.25 -31.8 1 -25.4 1 -25.4 1 -25.4 1 -25.4 1 -25.4 1/1/04 -31.75 1/3/04 -44.45
Maximum Length 12 -305 36 -914 36 -914 48 -1219 60 -1524 72 -1829 72 -1829 72 -1829
Length Tolerance ±3/32 (2.4) ±3/32 (2.4) ±3/32 (2.4) ±3/32 (2.4) ±3/32 (2.4) ±3/32 (2.4) ±1/8 (3.2) ±1/8 (3.2)
Heaters up to 3.5" (89 mm) Heaters up to 5" (127 mm)
±3% of Sheath Length ±2% of Sheath Length
Heaters over 3.5" (89 mm) Heaters over 5" (127 mm)
Camber Tolerance Heaters up to 12" (305 mm) long 0.010"(.254 mm) per foot of length
Camber Tolerance Heaters over 12" (305 mm) long 0.020"(.508 mm) per foot of length

A certain amount of Camber is unavoidable. With a slight force, Hi-Density Cartridge Heaters will flex enough to fit into a straight reamed hole.

Electrical Specifications

Nominal Diameter 1/8" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1"
Maximum Voltage 240 240 240 240 240 480* 480* 480*
Maximum Amperage (see next line for exceptions) 3 4.4 4.5 6.7 10.5 23 23 23
†Maximum Amperage for Types C1C, C1D, C2C, C2D, CS, F, M3, R1B, S1, S2, SA, W & W3 Terminations 3 3 5.5 7.6 9.7 9.7 9.7
Minimum Wattage at 120V on a 1" long Heater 50 45 45 50 50
Minimum Wattage at 120V on a 2" long Heater 5 20 20 20 20 20 20 20
Maximum Wattage at 120V 360 525 540 800 1260 2760 2760 2760
Maximum Wattage at 240V 720 1050 1080 1600 2520 5520 5520 5520
Maximum Wattage at 480V 11,000 11,000 11,000
Wattage Tolerance +10,-15% Plus 5%, Minus 10%
Resistance Tolerance +15,-10% Plus 10%, Minus 5%

†Current carrying capacities are for ambient temperatures up to 482°F (250°C) with mica insulated lead wires.
*480V when applicable. Consult Tempco.

Length TOLERANCE for:
– Lead Wires
– Wire Braid Leads
– Armor Cable Leads

  • Up to 36": -1/2", +1" (-12.7 mm, +25.4 mm)
  • 36" to 72": -1", +2" (25.4 mm, +50.8 mm)
  • Above 72": ±4" (101.6 mm)

Note: Specifications detailed on this page are standard. Consult Tempco if your application requires tighter tolerances or has other special requirements.

Temperature Coefficient of Resistance

The electrical resistance (ohms) of the heater resistance wire increases with temperature rise.
Tempco standard Hi-Density Cartridge Heaters are manufactured with ohms (cold ohms) 3.3% lower than the actual calculated ohms (hot ohms) to compensate for this increase.

Available Electrical Features

Diameter Dual Volts 3-Phase Dual  Circuits Multiple Heat Zones
(maximum 3 zones)
1/8" No No No No
1/4" No No No No
5/16" No No No No
3/8" Yes* No No Yes*
1/2" Yes* Yes Yes Yes*
5/8" Yes Yes Yes Yes
3/4" Yes Yes Yes Yes
1" Yes Yes Yes Yes

Consult factory for maximum wattages and voltages.
* Heaters may require a larger diameter transition area at lead end.

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Wood Dale, IL 60191-1452 USA
Phone: 630.350.2252   Toll Free: 888.268.6396
Fax: 630.350.0232   Email: info@tempco.com

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