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Applications needing constant, high heat depend heavily on cartridge heaters because of their high watt density and accurate heating characteristics. However, several often modifiable elements can impact their lifetime. We’re going to talk about these aspects today, as well as some adjustments you should make to extend the life of your custom carridge heater.

Temperature of Operation

Impact: A cartridge heater’s lifespan can be considerably shortened by high working temperatures. Rapid deterioration may result from constant exposure to temperatures close to or higher than the heater’s specified capability. 

Consideration: Verify that the temperature rating of the cartridge heater corresponds to the needs of the application. To extend life, run at temperatures lower than the maximum rated temperature whenever feasible. To make sure a heater is the right one for the job, this process must begin at the design stage. Make sure the set points don’t surpass the heater’s temperature rating by regularly checking your controller’s proportional-integral-derivative (PID) settings.

Density of Watts

Impact: Uneven heating and hot patches brought on by high watt density might result in early failure. Overheating and failure may result from using the cartridge heater at power levels above those recommended by its design. It is essential to follow the suggested power ratings.

Consideration: Select a cartridge heater whose watt density is suitable for your use. When the design permits sufficient distance between the resistance wires along the heated region, electrical process heaters generally operate at their peak efficiency. An abrupt increase in current flow and damage to the resistance wires result from short circuits that occur when the spacing is too close.

Method of Installation

Impact: Damage may result from uneven heating and thermal expansion brought on by improper installation, such as an unsatisfactory fit in the bore or an unsuitable heat transfer medium. Additionally, physical harm from improper handling, vibration, or other mechanical causes might compromise the heater’s integrity and shorten its lifespan. It is crucial to follow the right handling and installation protocols. 

Consideration: Make sure that the cartridge heater is securely inserted into the bore. To encourage even heat distribution and lessen thermal stress, use thermal grease or other heat transfer medium. To avoid mechanical stress and damage, make sure the installation is done correctly and in accordance with the pencil heater manufacturer instructions. Therefore, to facilitate installation, heaters will always be somewhat smaller than the nominal process hole diameter.

Conditions of the Environment

Impact: The lifespan of heaters can be impacted by harsh surroundings, such as exposure to dampness, chemicals, or vibrations. For instance, even small levels of moisture might affect how well the cartridge heater works. Small quantities of moisture may accumulate in the heater over time if it is in an area with high humidity. 

Consideration: If cartridge heaters will be exposed to wet or corrosive conditions, choose ones with protective coatings or seals. Use a “soft start/bake out” step in your startup procedure if you detect moisture. This step involves performing a soft start to gradually bake out any moisture that could be present in the heater. Make sure the heater’s design considers any vibration as well.