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| Question: |
| What is the best way to install a band heater? |
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| Answer: |
These suggestions are for conductive heaters only. Ceramics, or ?knuckle bands? have different considerations when installing.
After removing the defective band heater from the barrel or nozzle, inspect the area to be covered by the new heater and make sure it is clean and free from obstructions. Assure that there are no hydraulic fluids or materials that will become trapped between the heater and the barrel. If need be, use a wire brush and solvent to prepare the barrel, then wipe it down and make sure it is totally dry and free of debris before installing your new heater.
REMEMBER: If there are any holes, nicks or air spaces between the heater and the area to be heated, the life of the heater will be significantly shortened. These imperfections should be addressed before installing the heater or when ordering a new heater, assure that there will be no heater coverage over the area in question. The better and more complete the contact between the heater and the area being heated, the better the heat transfer. The better the heat transfer, the longer the heater will live under normal operating conditions.
If using post terminals, make sure you are using high temperature connectors. Typical industrial connectors will fail rapidly and nickel ring terminals should be used. If the environment is exposed to material dust to the point of heaters failing due to carbonization of particulate dust, try ceramic post terminal covers and fiberglass tape (with silicone or non-organic adhesive) to insulate exposed lead wire and ring terminal from the atmosphere. Be sparing with the tape and make sure you give as much space as you can between the connector and the heater. When installing, make sure the strap(s) or clamping mechanism are tight.
After you are satisfied that the heater is installed and wired correctly, check to make sure your temperature sensors are seated firmly and power it up. Give a quick check to assure it is drawing the right current and bring it up to 75% of operating temperature, and cut the power to it. Make sure there is no power going to the heater and retighten all appropriate clamping mechanisms before the heater contracts.
You are now ready to power your heater back up and the job is done. For maximum heater life, check the tightness of the clamping mechanisms at least once a week.
Remember, most heaters that fail prematurely in the field, fail due to contamination or improper installation. Both these reasons are avoidable and with a little extra care and common sense, you can extend the life of your heaters and save your machines from that dreaded unscheduled downtime.
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