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WHY THE HEATERS FAIL ?
For over 3 decades, EXCEL has been solving complex and unique application problems of heaters. We are continuously improving our design and application knowledge through our engineering expertise and our experience with end - user applications, resulting in the best heat solutions.
  The following are some helpful hints to keep the heaters running smoothly
   WHY THE HEATERS FAIL ?
  REASONS   SOLUTIONS
Loose fitting on the cylinder (barrel) Refer “right mounting of band heaters - Installation procedure”
The selection of the wrong watt densities Match the heater wattage as closely as possible to the actual
load requirements to limit ON / OFF cycling
The watt densities shouldn’t exceed recommended limit
Defective temperatures sense by the thermocouple The "below" (tip) of thermocouple should be inserted deeply in the cylinder
The "below" (tip) should not vibrate
Check the polarity of thermocouple with temperature controllers
Leakage of polymer melt or oil Rectify the leakage immediately
Voltage fluctuation Check the voltage regularly
Heater that is forced to operate beyond its maximum capacity to operate the temperatures To prevent premature failure, the heater shouldn’t operate beyond its maximum recommended temperatures
The wrong reading of the temperature controllers Check ON / OFF cycles of temperature controller

It is important that All heaters should be used with appropriate, approved and precise temperature control/sensor device(s)
The smallest amount of contamination can cause electrical shorts creating heater failure Before installation & during operation, the outer surface of the barrel and inside surface of band heater must be cleaned & should be free of all contamination
Serrated edges may begin to collapse and thrust outwards Tighten the Allen bolt until the serrated edges become firmly in direct contact with the barrel
Incorrect wiring and loose contacts leads to sparks resulting in fire or heaters failure Keep all electrical connections properly protected to avoid electrical hazards to machine operators
Terminals not well insulated and protected from moisture Ensure that the terminals are well insulated and protected since the heater terminals are prone to attracting moisture
Use of substandard raw material & manufacturing defects Standard raw material should be used & without any manufacturing default
Combustible gases or vapours Avoid using heaters in an atmosphere containing combustible gases or vapours
Incorrect wiring Electrical wiring on any type of heaters should be done by a qualified person complying with local electrical codes