| Author: IMS Company |
 Heater
Bands |
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| How to Estimate the Maximum Wattage of a Heater Band and Maximize
its Life |
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 When selecting a
heater, try to match the wattage as closely to what heating is required. One
way to estimate the maximum wattage for a mica material heater bands can be
found by the following formula:
3.14 x Band ID x Band Width x 35
For instance:
3.14 x 1-1/2" ID x 1-1/2” W x 35 = 247.275 Watts
Choosing a quality heater band is critical to your shop’s ability to run
efficiently and effectively. However, the proper usage and application of those
heaters is equally important. From contamination to over cycling, the way a
heater is used is as much a factor in the life time of the heater.
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| Keeping your heaters dry can prevent the most common
contamination of heaters – moisture. Mica and Ceramic material can absorb
moisture when left cool for an extended period of time in a moist or humid
environment. The contamination can build up to the point that immediate failure
can occur when powering up. Also, if the lead wires get wet, that moisture can
seep into the heater or fail on their own when electrical current is applied. |
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| Other contaminants that do not conduct electricity
will cause the heater to under perform instead of a catastrophic failure like
moisture. The heat delivery will be sluggish when the contaminant (oil or other
organic material) carbonizes. |
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 Heaters
should always fit tightly to the nozzle or barrel that is being heated. A loose
fit will shorten a heaters life time. In addition, a loose fit will create a
pocket of air that inhibits the transfer of heat. Direct contact is most
effective method for heat transfer. The loose fit caused the heater to have to
run hotter – eventually leading to a premature burn out. To prevent this
problem, tighten your heaters from the first heating and re-check them often
because the heating cycle can cause the heaters to become "loose" over time. |
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 Constant
cycling on and off will shorten the heater life time. In addition, running a
heater at peak or beyond will cause premature burn out. An additional issue
with cycling is the development of oxidation on the element wire. The oxidized
wire material eventually will break off, exposing more clean wire to be
oxidized. The diameter of the wire shrinks during this process and eventually
will not handle the resistance required to produce the heat – causing an open
circuit or a short to the heater sheath. At this point the heater will fail.
So, reducing the amount of cycles will promote longer heater life by reducing
the oxidization build-up.
A. Top and Bottom Sheet Mica Insulating Covers.
B. Center Mica Core or Strip with Resistance Wire Winding.
C. Inner Sheath: Rust Resistant Dull Finish Steel for maximum
conductivity.
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