Heater Leadwire Failure & How To Reduce Its Occurence

Heating elements are a critical component in various industrial applications, and their reliable performance is essential for smooth operations. However, one common issue that can lead to premature failure of heating elements is leadwire failure. Understanding the causes of leadwire failure and implementing preventive measures can significantly extend the lifespan of heaters and improve overall system efficiency.

Pulling on Leadwire: One of the primary reasons for leadwire failure is the repetitive pulling on the leadwires. To avoid this, it is crucial not to carry heaters by their leads. Additionally, in applications where repeated pulling is likely to occur, it is essential to find alternative solutions to minimize stress on the leads.

Excessive Flexing: Excessive flexing of the leadwires can also lead to premature failure. To reduce this occurrence, consider changing the flex point by using a few inches of shrink sleeving over the leads or incorporating a clip support. Creating loops of wire as long as possible, which will drape away from the heater and flex point, allows for movement with minimal stress on the leads.

External Connected Leads: For users who possess the necessary equipment and skills to repair leadwire connections themselves, it is recommended to purchase heaters with external connected leads.

These leadwires connect to 1”-2” long pins, offering better flexibility and reducing the risk of leadwire failure.

Internally Connected Leadwires: In applications where flexing occurs at the point where the leads exit the heater, it is beneficial to use internally connected leadwires. This design allows for greater flexibility, minimizing the strain on the leadwire connection.

Right Angle Leadwire Exit: If space permits, utilizing a right angle leadwire exit can help optimize the leadwire arrangement and reduce the likelihood of damage during flexing.

Protection Against Abrasion: In applications where even a small amount of abrasion is present on the leadwires, accumulated damage over time and cycles can lead to failure. To mitigate this, consider using stainless steel braid or armor for leadwire protection against abrasion.

For situations involving moisture, Convoluted Armor offers water-tight protection, albeit at a slightly higher cost and reduced flexibility compared to square-lock armor.

Flexible Armor Options: Both Square-Lock Armor, Convoluted Armor, and Stainless Steel Braid can be effectively used with both straight leadwire exits and right angle leadwire exits, providing flexibility in designing leadwire arrangements to suit specific application requirements.

By implementing these measures and being proactive in leadwire protection, industrial operators can significantly reduce the occurrence of heater leadwire failure. This not only improves the reliability of heating elements but also enhances the overall efficiency and longevity of the systems in which they are deployed. Choosing the right heater and incorporating proper leadwire protection are essential steps in ensuring smooth and trouble-free operations in various industrial processes.