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Contamination is the most frequent cause of heater failure.
Any organic or conductive material that can be drawn into the heater by expansion and contraction during cycling can cause an arcing failure in the heater windings. If allowed to collect at the lead end of the heater, contaminants can cause an electrical short between the power pins. Do not allow lubricants, oils, low-temperature tapes or processing materials to remain in contact with the lead end of the heater. Specify a moisture seal if necessary. Protect leads from damage by high temperatures.