Replace Impulse Wire

The impulse wire heating element used in the Belt Cutter is a round Nickel Chromium wire.  It is held on both ends with a wire clamp fastener that is attached to the Cutter Assembly Press Bar.  The following instructions can be used to make suitable heating elements for the Belt Cutter.

Components:

• Propane torch
• Brazing Alloy suitable to bond tin-plated copper ring terminal to NiCr wire.
• 23.5-inch length of NiCr wire.  Different diameters produce different results.  We used 0.04” diameter.
• 2 Ring Terminals.  Use noninsulated heavy duty ring terminal for standard wire size 22-18 AWG, stud size 1/4”.
• Bench Vise
• Needle Nose Plier
• Crimping Tool
• Vise-Grip Locking Plier
• Disposable Respirator Mask
• Safety Goggles

Instructions:

1. Insert one end of NiCr wire through crimping barrel of Ring Terminal. 
2. Use Needle Nose Plier to form a 1/4-inch fold-back loop at end of NiCr wire.
3. Clamp NiCr wire with Ring Terminal into Bench Vise such that Ring Terminal stays captured by the folded back loop of the NiCr wire.  Use Crimping Tool to securely crimp Ring Terminal Barrel.  Next use the Needle Nose Plier to slightly tighten wire against Ring Terminal crimped barrel.
4. Cut a piece, approximately 2-inches, of brazing alloy and use Vise-Grip Locking Plier to hold one end.
5. In preparation of brazing materials, wear safety goggles and disposable respirator mask.
6. Use torch to heat crimped end of Ring Terminal.  When “red hot” apply brazing compound.
7. Allow a few minutes to naturally cool, then squelch in water to accelerate cooling.
8. Repeat same process for other end of NiCr wire.

Questions?  Contact Novaseal for additional information.