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Cartridge Heater With Convoluted Condiut
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Cartridge Heater with Swaged In Leads
Cartridge Heater With Swaged In Leads
Cartridge Heater With Convoluted Condiut
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Cartridge Heater with Swaged In Leads
Cartridge Heater With Swaged In Leads

Swaged Cartridge Heaters (HotRods)

The engineers at Backer Marathon have developed a swaged cartridge heater that exceeds the performance and durability of others in the industry.

Through refinements in the swaging process, specially designed cores, careful selection of magnesium oxide fill, nickel chromium resistance wire, stainless steel tubing, and carefully controlled production processes, HotRods routinely outperform other cartridge heaters in difficult applications.

HotRods are available in a wide variety of diameters and configurations. Choose from our 14,000+ stock heaters for immediate delivery or let the engineers at Backer Marathon design a unique heater for your special application. Standard manufacturing times are normally less than 2 weeks.

Construction

  1. High Temperature Lead Wires for temperatures up to 550° C.
  2. High Impact Ceramic Cap retards contamination and is suitable for high vibration applications. Deep holes in cap prevent fraying of leads when bent.
  3. Nickel-Chromium Resistance Wire for maximum heater life, evenly wound for even heat distribution.
  4. High Purity Magnesium Oxide fill selected for maximum dielectric strength and thermal conductivity, highly compacted for maximum heat transfer.
  5. 304 Stainless Steel Sheath for oxidation resistance in a wide variety of environments. 316 Stainless Steel and Incoloy® are also available. Please consult the Sheath Suitability Chart to determine which material is best for your application.
  6. TIG Welded End Disc to prevent contamination and moisture absorption.

HotRods are UL recognized, File #E202904, CSA certified, CSA file no. LR 109455-1 and RoHS Compliant.

Standard HotRod Specifications

Nominal Diameter Minimum Diameter Maximum Diameter Std. Lead Wire Gage Max Amps w/ Std. Gage Max Lead Wire Gage Max Amps Max Volts
1/8" .119 .124 24 3.6 24 3.6 240
1/4" .244 .249 24 6 22 9 300
6.5 mm .250 .255 24 6 22 9 300
5/16" .306 .311 24 6 22 9 300
8 mm .309 .314 24 6 22 9 300
3/8" .369 .374 22 9 18 15 480
10 mm .388 .393 22 9 18 15 480
12 mm .466 .471 22 9 18 15 480
12.5 mm .486 .491 22 9 18 15 480
1/2" .494 .499 22 9 18 15 480
13 mm .506 .511 22 9 18 15 480
17/32" .525 .530 22 9 18 15 480
14 mm .545 .550 22 9 18 15 480
5/8" .619 .624 18 15 14 26 480
16 mm .624 .629 18 15 14 26 480
17 mm .663 .668 18 15 14 26 480
11/16" .682 .687 18 15 14 26 480
19 mm .742 .747 18 15 14 26 480

3/4"

.744 .749 18 15 14 26 480
20 mm .782 .787 18 15 14 26 480
25mm .978 .983 18 15 14 26 480
1" .994 .99 18 15 14 26 480
  • Length tolerance is +/- 3% or +/- 3/32, whichever is greater.
  • Camber tolerance is .025" per foot of length. Slight camber is normally not a problem since the heater will flex enough to enter a clean hole.
  • Wattage tolerance is +5%, -10%

Options

There are literally hundreds of options that can be added to your HotRod cartridge heater. Here are a few of our most popular modifications. If you don't see what your looking for, contact us at sales@backermarathon.com for assistance.

  • Terminations - swaged in leads, crimped on leads, post terminals
  • Configurations - right angle leads, copper elbow, copper coupler, bent heater
  • Lead Protection - braid, stainless steel conduit, convoluted hose, sleeving
  • Fittings - flanges, brass NPT, stainless NPT, tab stops, locating rings
  • End Seals - ceramic, Teflon seal, lava seal, RTV, cement, epoxy potting, epoxylite potting
  • Sheath Materials - 304 Stainless Steel (standard, up to 1400°F), Incoloy (up to 1600°F), 316 Stainless Steel (for corrosive environments), See Sheath Suitability Chart for more information
  • Lead Wire - 550ºC Duraflex wire is standard, other lead materials are available.
  • Other Options - distributed wattage, internal thermocouple, dual voltage, multi-zone, three phase, double ended construction

Watt Density

  • The tighter the hole fit, the better. Loose fit equals poor heat transfer and shorter heater life.
  • Clearance is determined by taking the hole diameter and subtracting the heater diameter. 
  • Cycling reduces heater life and high cycling applications should use lower numbers. 
  • Please consult the following table for the maximum allowable watt density for heating metals. 

Formula 

Watt density is calculated with the following formula:

Watt Density = Wattage / Heated Length x Diameter x 3.14


Maximum Watt Density for Heating Metals

Hole Clearance 1200°F 1000°F 800°F 600°F 400°F 200°F
0.002 140 270 300 300 300 300
0.003 120 205 295 300 300 300
0.004 100 175 240 300 300 300
0.005 90 145 200 285 300 300
0.007 70 100 150 200 250 300
0.010 60 90 110 150 200 225
0.015 50 75 95 110 140 165
0.030 40 60 80 90 100 110
0.060 30 40 50 55 65 65
0.100 25 35 45 50 50 50

Maximum HotRod Watt Density In 200°F Moving Air

  Air Velocity, Feet per Minute                  
Air Direction 0 500 1000 1500 2000 2500 3000 3500 4000  
Parallel to Heater 44 52 56 60 64 67 72 75 78  
Perpendicular to Heater 44 68 76 82 86 93 97 103 108  

Maximum HotRod Watt Density In Still Air

  100°F 250°F 500°F 750°F 1000°F 1100°F 1200°F 1300°F 1400°F
Max Watts/in2 53 52 50 46 40 35 28 20

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HotRod Sheath Temperature In 70°F Still Air

  Watt Density (watts/in2)              
  5 10 15 20 25 30 35 40
Oxidized Sheath 450 800 1050 1100 1200 1300 1350 1400
Non-Oxidized Sheath 750 1000 1150 1300 1400 1500 1600 1650

Stock Parts

1 - 20 of 13864 Filter Results

Part No. Diameter Watts Volts Length Available Qty Price
HR10035A 1.000 inches 600 watts 240 volts 3.50 inches 56 Sign In for Pricing
HR10035D 1.000 inches 600 watts 240 volts 3.50 inches 21 Sign In for Pricing
HR10035E 1.000 inches 600 watts 240 volts 3.50 inches 122 Sign In for Pricing
HR25010H 0.250 inches 55 watts 120 volts 1.00 inches 7 Sign In for Pricing
HR25010J 0.250 inches 100 watts 120 volts 1.00 inches 20 Sign In for Pricing
HR25010K 0.250 inches 100 watts 240 volts 1.00 inches 10 Sign In for Pricing
HR25010L 0.250 inches 150 watts 120 volts 1.00 inches 9 Sign In for Pricing
HR25012F 0.250 inches 100 watts 120 volts 1.25 inches 14 Sign In for Pricing
HR25012G 0.250 inches 150 watts 120 volts 1.25 inches 14 Sign In for Pricing
HR25012H 0.250 inches 150 watts 240 volts 1.25 inches 36 Sign In for Pricing
HR25012T 0.250 inches 75 watts 120 volts 1.25 inches 14 Sign In for Pricing
HR25015AU 0.250 inches 150 watts 240 volts 1.50 inches 45 Sign In for Pricing
HR25015K 0.250 inches 100 watts 120 volts 1.50 inches 8 Sign In for Pricing
HR25015L 0.250 inches 150 watts 120 volts 1.50 inches 42 Sign In for Pricing
HR25015M 0.250 inches 200 watts 120 volts 1.50 inches 33 Sign In for Pricing
HR25015N 0.250 inches 200 watts 240 volts 1.50 inches 8 Sign In for Pricing
HR25015Y 0.250 inches 200 watts 240 volts 1.50 inches 14 Sign In for Pricing
HR25017B 0.250 inches 200 watts 240 volts 1.75 inches 7 Sign In for Pricing
HR25020AC 0.250 inches 200 watts 240 volts 2.00 inches 28 Sign In for Pricing
HR25020AX 0.250 inches 40 watts 120 volts 2.00 inches 14 Sign In for Pricing
1 - 20 of 13864 Filter Results