A chain is only as strong as the weakest link. In the temperature world, it's clear that sensors are potentially the weakest link. These devices are placed on the "front lines" of any application and are exposed to the harsh environments they are asked to measure. For these temperature sensors, that not only means extreme temperatures and temperature changes, but also extreme electrical environment conditions. Failures can be expected in a relatively short amount of time.
Fast Heat's experience spans to the actual manufacturing of these sensors, and as a group, we recognized early on that some of those failures can be reduced, if not avoided completely, through the use of specialized technology.
How does sensor protection circuitry work?
All heating elements have a certain amount of electricity that "leaks" from the internal construction of the heater to the surrounding metal sheath. This leakage is typically not a problem in some cases where two conditions exist — a good ground connection is present between the application and the temperature controller.
In most cases, over time and due to multiple reasons, including degradation of connections, a ground connection loses its potential to perform its function or is completely disconnected.
The result is that electricity will find the next best path between the application and the controller. Typically the ground connection will be connected through the sensor.
A sensor like a thermocouple is especially vulnerable. In its construction, there are very small wire gauge connections internally required for this type of sensor. Never were they meant to handle the extreme current seen by a ground connection. Almost instantaneously, those small wire gauges fall open.
The solution is simple. Fast Heat's sensor protection circuitry is more sensitive to electrical currents than the sensor's weakest point.
What are the benefits?
Premature sensor failure is reduced significantly, which saves the cost of sensor replacement and the costly downtime of application equipment.