HDC00001-Series

Supported Applications

The Omega HDC Series Hi-Density Cartridge Heaters are engineered for high-temperature applications requiring precise thermal control. The series is designed with a Grade 'A' Nickel-Chrome resistance wire wound on a high-purity magnesium oxide core, enclosed in a 321 Stainless Steel sheath. Documented application areas include plastic extruders, hot runner molds, medical equipment, and food processing.

Operating Conditions & Performance

The series supports maximum operating temperatures up to 760°C (1400°F). For standard heaters utilizing a 321 Stainless Steel sheath, the maximum recommended sheath temperature is 648°C (1200°F); this limit must be considered alongside the ambient temperature rating of the selected termination. Maximum watt density ranges from 15.5 to 46.5 watt/cm² (100 to 300 Watt/in²), depending on heater size and operating conditions.

Performance specifications vary by diameter:

• Diameter Tolerance: ±0.051 mm (±0.002") for diameters from ⅛" to ½", increasing to ±0.076 mm (±0.003") for ¾" and 1".
• Camber Tolerance: 0.254 mm (0.010") per foot of length for heaters up to 305 mm (12"); 0.508 mm (0.020") per foot for lengths over 305 mm (12").
• Length Tolerance: ±2% of sheath length for heaters over 127 mm (5"), with specific tolerances such as 2.4 mm (±3/32") or 3.2 mm (±1/8") applied to shorter units depending on diameter.

Electrical ratings are defined by nominal diameter, with maximum voltage limits of 240 V for diameters up to ½" and 480 V* available for larger sizes. Wattage tolerances range from +10%, -15% (⅛") to Plus 5%, minus 10% (¼" through 1"). Resistance tolerance is specified as +15, -10% or Plus 10%, minus 5% depending on the diameter.

Configuration Options

The HDC Series offers extensive configurability across dimensions, materials, and electrical features to accommodate specific installation requirements.

• Diameters: Nominal sizes include ⅛" (3.10 mm), ¼" (6.25 mm), 5/16" (7.82 mm), 3/8" (9.42 mm), ½" (12.60 mm), 5/8" (15.77 mm), ¾" (18.95 mm), and 1" (23.30 mm).
• Lengths: Available from 25.4 mm (1") to 914.4 mm (36").
• Sheath Materials: Standard construction uses 321 Stainless Steel. Incoloy® 800 is available for higher temperatures up to 760°C (1400°F) or corrosive immersion heating applications.
• Terminations: The standard termination is Type N, featuring 254 mm (10") long nickel conductor lead wires with fiberglass insulation connected to 32 mm (1¼") solid conductor terminal pins. These leads are UL approved for temperatures up to 250°C (482°F). Over 40 standard termination styles are available.
• Electrical Features: Options include Dual Volts, 3-Phase power, Dual Circuits, and Multiple Heat Zones (maximum 3 zones), with availability dependent on diameter. For example, ⅛" through 5/16" diameters do not support these features, while ½" and larger offer full capability.
• Accessories: BNS Anti-Seize Cartridge Heater Coating is available in aerosol spray (Part Number: CML00010) or paste with brush applicator (Part Number: CML00020).

Key Product Differences

Variations within the series are primarily defined by physical dimensions and electrical configuration capabilities. Smaller diameters (⅛" to 5/16") are limited in maximum voltage, amperage, and advanced electrical features compared to larger sizes. For instance, Dual Volts, 3-Phase, and Multiple Heat Zones are not available for heaters smaller than ½", though some features may be offered with asterisked conditions on 3/8" units.

Material variations distinguish between standard service (321 Stainless Steel) and high-performance or corrosive environments where Incoloy® 800 is specified. The series also differentiates based on termination style, offering over 40 options beyond the standard Type N configuration to suit specific mounting and environmental constraints.