Accessories and Modifications

Watt-Flex cartridge heaters are built-to-order to meet your electric process heating application. A variety of heater modifications and accessories are available for:

Lead Modifications Heater Mounting Accessories
Lead Wire Protection High Temperature Modifications
Contaminant Protection

Designing a challenging new heating application?

With over 20 years of experience in the manufacture of cartridge heaters, Dalton Electric has the engineering expertise and production capabilities to design and produce modified, special, or custom heaters for your most challenging requirements.

Lead Modifications

Standard Temperature Leads - TGGT insulation (teflon tape primary, glass servings, woven glass braid, teflon coated) over stranded Grade "A" nickel wire.
(< 480o F / 250o C).

Watt-Flex Cartridge Heaters - Standard Leads
Standard Leads

Standard Temperature Teflon Leads - Extruded PFA over stranded Grade "A" nickel wire. (< 480o F / 250o C)

Watt-Flex Cartridge Heaters - Teflon Leads
Teflon Leads

High Temperature Leads - Fiberglass insulation (threaded glass servings primary, treated glass braid) over stranded Grade "A" nickel wire. (< 840o F / 450o C).

Watt-Flex Cartridge Heaters - High Temperature Leads
High Temperature Leads

Fiberglass or Rubber Sleeving - Rubber sleeving provides excellent insulation value for low temperature process heating applications (< 450o F / 230o C). Fiberglass woven glass strands provide good insulation for use in high temperature process heating applications.


Quick Disconnect - a modular plug or terminal junction in the wire for ease of heater disconnection.

Watt-Flex Cartridge Heater-Quick Disconnect
Quick Disconnect

Threaded post terminals - useful when wire must be occasionally disconnected and/or replaced. Often used in conjunction with a bussbar.

Threaded post terminals are useful when wires must be disconnected occasionally.
Threaded Post Terminal

Post Terminal
thread dimensions
Cartridge Heater Post Terminal Thread Dimensions
Watt-Flex O.D.
Terminal Thread
3/8" to 3/4"
(0.1368"diameter with 32 threads/inch)
1/2 to 1"
(0.1894" diameter with 24 threads/ inch)

Integral Ground Wire - attached to the heater, meant for termination to ground on the machine.

Extra Length Leads - available in any length. For wires longer than 10 feet (3 meters), a quick connect or male/female connector plug assembly can be used to reduce heater cost.

Stainless Steel Clip Support - displaces and reinforces the point of wire flexure away from the heater terminal connection. Useful for applications where there is repeated flexing (packaging and sealing).

Dimensions shown  for Watt-Flex cartidge heater clip supports.

Watt-Flex Cartridge Heater - Straight Header with Right Angle Inside Clip Support
Right Angle Clip, Inside


Watt-Flex Cartridge Heater with RIght Outside Clip
Right Angle Clip, Outside


Watt-Flex Cartridge Heater -  Straight Clip
Straight Clip


Watt-Flex Cartridge Heater - Internal Clip Support
Internal Clip Support

Watt-Flex Cartridge Heater - AFX Termination
AFX Termination







Lead Wire Protection

Watt-Flex headers shield lead wires and insulators from abrasion damage caused by machine cycling, severe environment and rough handling.

High-quality stainless steel construction provides long-lasting protection even in the most rugged industrial environments.

Stainless Steel Braid - flexible, with tighter bend radius plus the strength of braided strands of high-quality stainless steel.

Stainless Steel BX - interlocking hose provides greater strength and abrasion protection than braid, and a slight economic advantage.

Straight and Right Angle Headers

Straight and Right Angle Headers

Header O.D.
Hose O.D.
11/32" *

(* 3/8" diameter right angle header with
high-temperature leads has 1/2" hose O.D.)

Watt-Flex cartridge heater abrasion protection header dimensions

Abrasion protection headers for Watt-Flex cartridge heaters include stainless steel straight or right angle headers; stainless steel braid or flexible conduit.
Straight and Right Angle Headers

Watt-Flex Cartridge Heater- Straight Header
Straight Header, Braid


Watt-Flex Cartridge Heater - Straight Header with Braid
Straight Header, Hose(BX)


Watt-Flex Cartridge Heater with Stainless Steel Braid
Small Dia. Straight Header, Braid


Watt-Flex Cartridge Heater - Braid No Header
Braid, No Header

Watt-Flex Cartridge Heater - Right Angle Header
Right Angle Header, Hose(BX)


Watt-Flex Cartridge Heaters - MW Transition FX Wire
MW Transition, FX Wire


Watt-Flex Cartridge Heater - Header, no hose
Header, No Hose


Watt-Flex Cartridge Heater - Individually braided leads - No header
Individually braided leads - No header

Contaminant Protection

A protective contaminant barrier inserted into the terminal cavity can protect the cartridge heating element from moisture, dirt and other contaminants that can damage the heating element.

RTV Potting - RTV (Room Temperature Vulcanized) rubber provides an excellent moisture barrier for low temperature process heating applications (< 450o F / 230o C).

Ceramic Potting - provides good contaminant protection, but is not a complete moisture barrier. Ceramic material supports very high temperature process heating and is rated to 2000+oF / 1090oC.

Glass Potting – superior contamination and moisture protection (hermetic seal) for temperatures to 900o F / 480o C.

Cartridge Heater with RTV potting provides excellent moisture protection for low temperature process heat applications
RTV Potting for contaminant protection


Watt-Flex Cartridge Heaters - Ceramic Potting
Ceramic Potting

Mounting Modifications

Dalton Electric heating engineers can develop mounting apparatus for any heating application. A sampling of standard accessories are listed below.

  • Stainless Steel Flange
  • Puller End Plug
  • Mounting Bracket
  • NPT Fitting
  • In Line Diodes
  • Threaded Extraction Collars
  • Solid Pin Connectors
  • Ground Wire

watt-flex cartridge heater  with stainless steel mounting flange.
At Top: Stainless Steel Flanged Heater
At Bottom: Puller End Plug

Stainless Steel Flange - available in sizes shown at left, the stainless steel flange acts as a mechanical stop at the edge of the heater well.

Flanged cartridge heater dimensions

Stainless Steel Flange Dimensions
Watt-Flex O.D.
.080"R on 1" BC
.080"R on 1" BC
.080"R on 1" BC
.080"R on 1" BC
1 1/2"
.160"D on 1 1/4" BC
.201"D on 1 1/2" BC

Mounting Bracket - an "L" shaped bracket welded to the sheath to act as an insertion stop or for mechanically securing the heater at the edge of the heat sink.

Puller End Plug - used for heater extraction in applications where the terminal end of the heater is not accessible. Interior thread attaches the puller plug to the heater tip.

NPT Fitting - used with Watt-Flex replaceable immersion heaters for heating liquids in vats or tanks.

Watt Flex Cartridge Heater - Puller End Plug
Puller End Plug


Watt-Flex Cartridge Heater - Straight Header with Braid
NPT Fitting


Watt-Flex Catridge Heater with Mounting Flange


Watt-Flex Cartridge Heater with mounting bracket.
Mounting Bracket

High Temperature Modifications

  • Extra Cold Section at End
  • Ceramic Beads

Extra Cold Section at End - when the heater extends out of the bore (through insulation, for example) an extra cold section added to the cartridge heater ensures that the heated section is fully enclosed by the heat sink. The cold terminal end is usually produced by adding a longer terminal pin so no heat is produced. Longer cold sections are created by stretching the continuous coil resistance wire to limited heat production.

Ceramic Bead Insulation - Placed over insulated lead wire to protect beyond temperature rating of insulation. Withstands temperatures to 2000° F / 1090 °C.

Watt-Flex Cartridge Heater - Ceramic Beads
Ceramic Beads

Watt-Flex Heater Applications

Igniter Contact
Igniter Contact


Igniter Hot Air
Igniter Hot Air

Bore Seizure

Uneven Heat

Cost of Heating