Reasons For Cartridge Heater Failure and How To Extend Their Lifespan?

One of the most crucial heating components in many industrial applications including plastic molding, food packaging, and electronics manufacturing, is the cartridge heater. Cartridge heaters, like any other heating element, can malfunction at any point while being used. To guarantee efficient operation and long service life, it is crucial to recognize and comprehend the causes of Cartridge Heater failure, which can occur for several reasons. This is what we are going to discuss in this blog along with the preventive ways to extend heaters life. So, keep on reading!

Reason for the Failure of Cartridge Heater

Some of the typical causes of heater cartridge damage include the following:

Improper Fit 

Improper fit is probably the most prevalent reason for heater failure. If a heater is unable to adequately dissipate heat to the outside of its sheath, the temperature rises until it fails. This will eventually cause a breakdown of the cables and heater itself.

High Watt Density

These heaters are all designed to run at a specific voltage. Outside of this voltage range, they may be useless or fail ultimately. If the applied voltage is too high, the heating element’s watt density will increase. As a result, heat will not be dissipated properly. As a result, the unit may not function properly.

Constant Temperature Cycling 

The nonstop temperature cycling puts undue strain on heaters. This can cause them to expand and collapse rapidly (once every 30-60 seconds). This will eventually diminish your heating element’s lifespan.

Contamination and Moisture 

These factors can enter your heating cartridge from the surrounding environment. These heaters can experience life-shortening due to hydraulic fluids, materials, and moisture than any other factor. If contamination is inevitable, lead configurations can help delay its entry into the heater. Additionally, you can usually run the heater at a lower voltage for a few minutes if there is a moisture issue to lessen the likelihood that the element will short to the sheath when the power is applied fully.

High temperatures and excessive movement 

Two more external factors that can damage heaters are high temperatures and excessive movement. When mounting your heater to moving machinery, make sure you provide it with adequate insulation. In other words, the heating element should be as stable as possible, or at least protected from excessive movement, which might lead to a failure.

Here Are The Tips To Prevent Your Cartridge Heater From Damage

• Use the heater cartridge according to its specifications and temperature range.
• Avoid being exposed to moisture, dust, or chemicals.
• Shield the heater cartridge from impact, vibration, and physical stress.
• Install the heating cartridge according to the instructions.
• Perform frequent inspections and maintenance on the heater cartridge.
• If the heating cartridge exhibits any symptoms of damage replace it immediately.

In addition to minimizing damage, the advice provided above can increase the heater cartridge’s effectiveness and safety. Remember that the heater cartridge is a significant investment in the manufacturing process, and with correct maintenance, the benefits are maximized.

Closing Thought

Just because your cartridge heater has a difficult job to do does not indicate it will burn out rapidly. When certain precautions as mentioned above are taken, your heater can last as long as any other critical piece of equipment you own. Furthermore, our range of heaters is designed to meet the needs of various types of enterprises. Check out our models and specs offered by Patel Heaters & Control Pvt Ltd to see how they can benefit your organization.