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Why Cartridge Heaters Fail

One of the key ways to lower equipment costs for any business it to make sure that each piece of equipment last as long as possible. And when it comes to heating equipment this can be quite a challenge. Logic would suggest that equipment such as cartridge heaters would naturally have a short life due to their very nature. However, cartridge failure is not always due to age. There are other factors that can lead to their failure. Here we outline some of the most common reasons why this happens and offer our top tips on how to prevent cartridge heater failure in the future.

  • Improper fit: Perhaps the most common cause for cartridge heater failure of all is improper fit. If a heater cannot dissipate the heat to the outside of its sheath properly the temperature will rise until it ultimately fails. Eventually, this will cause a breakdown of wires and heater itself.
  • The watt density is too high: All cartridge heaters have a voltage at which they are designed to work. Outside of this voltage rating they may be ineffective or may fail eventually. So, if the applied voltage is too high then this will increase the watt density of the heating element. This will result in heat not being dissipated in the way that it should. The result can be that the unit fails to operate.
  • Frequent temperature cycling: Excessive temperature cycling places undue stress on cartridge heaters. This can cause them to expand and contract at a fast rate (i.e. every 30-60 seconds). Eventually, this will reduce the lifespan of your heating element.
  • Moisture and impurities: These elements can be drawn into your heating cartridge from the surrounding environment. These two elements can often cause a short circuit to occur which can lead to the heater failing.
  • High temperatures and excess movement: Cartridge heaters can also be damaged by two other external factors – high temperatures and excess movement. To give your heater an added level of protection, make sure that you supply it with a suitable level of insulation when it is mounted onto moving machinery. In other words, the heating element should be as stable as possible or at the very least protected from excess movement which can lead to an eventual breakdown.jobco

The takeaway from all this is that just because your cartridge heater has a difficult job to perform does not mean that it has to burn out quickly. When certain precautions are taken your Watlow cartridge heater can have a life that is as long as any other vital equipment you own. Moreover, our customer cartridge heaters are made to fit the needs of all kinds of businesses. Check out our models and the specs and you will see how they can be an asset to your company.

4 Machine Safety Tips To Prevent Workplace Injuries or Worse

The Watlow cartridge heater, hot air heater, ceramic heater and other machine components that we sell help with the smooth operation of a number of machines across a wide variety of industries. But when equipment is mishandled, accidents and even deaths can occur. Listed below are 4 general workplace safety tips to always keep in mind for ensuring machine safety in the workplace and for ensuring that our heaters help you meet your industrial goals.

  • Never have your people operate machinery for which they have not been trained: Be sure that anyone who handles the machinery in question has received some sort of training or tutorial. This will help ensure that the machine is more productive and that the person operating it is safe from serious injury or even death. Some of the machines that hold our heaters can cause great damage including burns to operators and even people who happen to be nearby.
  • Never distract persons who are operating industrial machinery: Operating certain kinds of machines for which our heaters are integrated requires great focus. If that focus is broken the result can result in injury or a fatality. Moreover, you will want to be sure as the operator to stay away from certain moving parts that may capture clothing or limbs or that may cause burns to occur.
  • Constantly have faulty or failing equipment serviced: A machine that is not performing up to specs can not only cause your company to be less productive, it can also pose danger to employees resulting in regulatory penalties, lawsuits and time off.safety
  • Have your employees wear the proper equipment: If goggles are required make sure that employees wear them. If other equipment is needed to safely operate certain machinery make sure that all operators know to wear this equipment at all times while operating machines.

Finally, no one wants an industrial accident to occur. Our heaters are designed to create intense heat. It is therefore important that you take extraordinary caution with operating the machines and servicing the heaters that are installed in those machines.

Tips for Handling Cold Weather Equipment Failure

In all the industries that we serve it is critical that owners be able to keep their equipment at a specific temperature. Unfortunately, that responsibility becomes difficult to fulfill when cold weather sets in. Our coil heaters, band heaters, ring heater, hot air heater etc are products that can help businesses stay productive and avoid the loss of time and money. If you use cartridge heaters, for example, in any of the following applications you can relate to this problem in particular:

  • Immersion tank heating
  • HVAC compressors
  • Fuel cells
  • Semiconductors
  • Medical devices
  • Sensor measurement devices
  • Extrusion
  • Die casting
  • Hot melt adhesives

But what do you do for equipment that has failed because your current heating product has stopped working due to cold weather, etc? Here are our suggestions for business owners.
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Troubleshoot the equipment: The first step is to properly diagnose the problem. This is should be done with the goal of getting the machine up and running as soon as possible so as not to slow down productivity. Often, if a particular malfunction has occurred often and has been diagnosed in the past, then the whole troubleshooting process can be shortened considerably. Trouble shooting should involve:

  • Verifying that a problem exist
  • Narrowing down the cause(s)
  • Correcting the problem
  • Work to prevent future issues

On the last point, we can help you by supplying you with products that will help your equipment run smoothly.

Implement a contingency plan: It is wise at some point to have a contingency plan in place if a major piece of equipment does break down. This way, your business will be able to save product, by switching to the temporary solution. Hopefully, your business will have planned for a contingency such as equipment breakdown.

Finally, many problems that involve heat product related breakdown are caused by owners failing to purchase and maintain the proper equipment. On our site, we will help you choose the right equipment for your industry and for the machine (s) you need to keep up and running.