Industrial Heater Selection, Installation and Maintenance Guide

Select the heater according to the surface or medium that must be heated. Mica Band Heater Suitable for economical barrel and nozzle heating at moderate operating temperatures. Ceramic Band Heater Better for higher temperatures, improved insulation and reduced external heat loss. Cartridge Heater Used inside drilled holes in moulds, dies, hot plates and sealing jaws. Tubular or Immersion Heater Used for air, water, oil, tanks and custom-formed heating arrangements.

Provide the heater type, diameter, width or length, voltage, wattage, quantity, terminal position and machine application. For replacement heaters Send a clear photograph, outer dimensions, inner diameter and connection details. For new applications Also share the operating temperature, material being heated, available control system and expected heat-up time.

Watt density is the heater wattage divided by its effective heating surface area. Excessive watt density can cause overheating, insulation damage and shorter heater life. Correct practice Use the lowest practical watt density that still achieves the required heat-up and process temperature. Important The correct limit depends on heater construction, fit, operating temperature, material and airflow.

Clean the barrel surface and remove plastic, oil, rust and dirt before installation. Fit and clamping The heater must fit tightly and evenly around the barrel. Retighten the clamp after the first heat cycle where applicable. Lead protection Keep wires away from hot surfaces, sharp edges, moving parts and leaking material. Control Use a suitable temperature controller and correctly positioned sensor.

Common causes include loose fitting, incorrect voltage, excessive watt density, moisture, poor temperature control, damaged leads and contamination. Band heaters A loose band creates an air gap, causing the heater to run hotter than the barrel. Cartridge heaters An oversized hole reduces heat transfer and increases internal heater temperature. Immersion heaters Never energise the heater unless the heated section is fully immersed.

Choose the sensor according to temperature range, controller input, response speed and mounting arrangement. Thermocouple Commonly used for wide industrial temperature ranges and fast response. PT100 RTD Suitable where better accuracy and stability are required in a moderate temperature range. Installation The sensor tip must make proper contact with the measured surface or medium.