PTC heaters can drop into applications that use resistance wire heaters, with one modification: the overtemperature protector circuit will need to be modified because PTC heaters do not require a separate protector device.

PTC heaters are able to be wired into existing temperature control and power circuits based upon the wattage and voltage ratings. Thus, existing resistance heaters can be directly replaced by PTC heaters. (It is always recommended that plant operators carefully inspect heaters regularly to ensure optimum performance.) In many cases, however, the overtemperature protector circuit will need to be modified because PTC heaters do not require a separate protector device.

Reduced Downtime and Cost of Operation. Possible downtime caused by a tripped protection device is eliminated because PTC heaters do not require protectors. When a tripped protector cannot be immediately replaced because a spare is not kept in stock or is not readily available, the resistance heater must not be used until the replacement protector is installed. An unheated tank may result in longer soak times, slower production throughput on the line, or may even cause the process line to be shut down until the heater is once again operational. All of these consequences can impact the cost of operation and profitability of the process line. With PTC heaters, this is not a concern.

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