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Make sure you wait until the release agent is completely dry before putting the custom carridge heater into the hole when using one to make the process of removing the heater from its hole easier. A portion of the liquid will often be forced toward the lead end if the heater is installed before the agent is completely dry.

It will then seep into the heater through the lead insulation or the lava or ceramic plug at that end. In that case, it is reasonable to anticipate that the heater will malfunction as soon as electricity connects. You can prevent water from entering the heater by selecting the plug and wire insulation option.

Tips and Tricks to Follow

The heater may fail early if there is moisture, oil, or other substances on the lead wires. At high temperatures, oil or other organic material on the heater’s lead end cap will carbonize, creating a short from the leads to the sheath. Let’s discover some more easy tips to follow:

Preventing Overheating

Because the heat generated is not transferred efficiently to the item or substance being heated, a loose fit of the cartridge heater in its hole will shorten its lifespan by requiring the heater to run at a higher temperature to transfer its energy. The lifespan decreases with increasing operation temperature. The hole diameter should be no more than.005 inches larger than the heater’s diameter as a general fit guideline.

Choose Low Wattage

Select the lowest wattage heater that will sufficiently decrease the start-up time. Also, while maintaining the component being heated at the required operating temperature. To maintain the proper temperature and a higher working temperature on on-time, the controller will switch on and off the heater if the heater is with a greater wattage than is necessary.
The heater’s lifespan will be decrease by these factors. The kind of fluid and its speed as it passes over the heater are crucial considerations when using an immersion heater. Speak with an Applications Engineer for assistance.

What Reduces Resistance Heater Lifespan?

In addition to manufacture flaws and mechanical misuse, the following factors are common reasons for premature high temperature cartidge heater failure:

• Contamination: More cartridge heaters have experienced life-shortening due to hydraulic fluids, materials, and moisture than any other factor. When contamination is unavoidable, lead configurations can help delay its entry into the heater.
• Lead Failure Owing To Heat: Under ideal circumstances, our standard leads can rate to only to 842 degrees Fahrenheit. Higher amperages cause this rating to drop, therefore frequently lowering the wattage or raising the voltage will fix the issue. Alternatively, you may use the cartridge heater design, which insulates the pin wires by covering them with ceramic beads.

Lead Failure Owing To Excessive Movement: Swashed leads, as opposed to crimped leads, are the initial, simplest, and least costly solution for this problem. The crimped lead arrangement includes a solid nickel pin wire entering the cartridge heater to which the stranded lead wire is crimped and subsequently covered.