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Causes of Lead Wire Burnout in Cartridge Heaters

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Cartridge heaters, also known as cartridge heating elements, are highly regarded for their compact size, rapid heating capabilities, consistent temperature output, and ease of installation and maintenance. They find widespread application across various industries. However, there are instances of lead wire breakage, disrupting their normal operation and potentially posing safety hazards. 

The primary causes of lead wire burnout in cartridge heaters are as follows:

Overloading:
When the voltage or power applied to a cartridge heater exceeds its designed specifications, the heater experiences an increase in current and surface load. This results in an elevated temperature in the lead wire, ultimately leading to burnout.

Poor Wire Connection:
In cases where the lead wires of the cartridge heater are not securely connected, it can result in inadequate contact. This poor connection will lead to overheating and eventual burnout when electrical current flows through the wire.

Harsh Storage or Working Conditions:
Storage or operating a cartridge heater in an environment with excessively high temperatures or humidity levels will cause damage to the insulation material inside the heater (The Mgo insulation). This damage may cause the electrical current to bypass the heating filament and flow through the lead wire, leading to wire burnout due to excessive current.

 

Effective Solutions for Addressing Lead Wire Burnout in Cartridge Heaters:

Reconnect the Lead Wires:
If the lead wire of the heater is due to poor connection, it can be fixed by reconnect the lead wires (when heater lead wires are crimped on type). 

Replace the Heater:
In cases where the lead wire of the heater has completely burned out, lead wires are swaged in type or with other forms of heater damage, our recommendation is to replace the heater with the usage requirements and specifications.

When repairs or replace the heater, safety should be the utmost priority to prevent accidents. Please carry out these actions under the guidance of a qualified person.

 

To prevent lead wire burnout, it is imperative to ensure that the heater operates within the rated voltage and power, conduct regular checks on the device's condition, and promptly address any issues related to poor contact or other potential concerns. Furthermore, maintaining the heater's operating environment within the appropriate temperature and humidity parameters plays a vital role in preventing wire burnout.

When dealing with lead wire burnout issues in cartridge heaters, it is essential to consider both safety and usage requirements. Consulting a professional if there is uncertainty about the appropriate remedial measures.

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