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Troubleshooting and repairs should only be attempted
by qualified maintenance personnel.
WARNING
Hazardous voltages are present in this equipment.
Lock out and tag the branch circuit disconnect switch
before working on this heater.
Periodically check all electrical connections, including field
and factory-made connections for tightness, and all wiring for
deterioration at least once a year.
Periodically inspect for leakage and retighten flange bolts
when required.
Inspect the terminal enclosure and conduit connections for
evidence of water leaks or moisture collection. Tighten
connections as required. Do not continue using a heater with
signs of damage.
Heating Element Installation & Removal
Remove electrical terminal connections after noting how they
are connected. Remove insulation blanket in the bottom
section of the terminal box to provide access to the heating
elements.
To remove the heating element from a heater pipe, first
remove the fastening nut at the terminal end. Hold the
ceramic insulator firmly in order to avoid undue pressure on
the ceramic and possible breakage. If obstructions are
encountered, rotate the heater slightly back and forth while
pulling out.
Since heating elements can be of considerable length, it may
not always be possible to remove the element in a straight
line, due to space limitations. Since the element bar is
flexible, the element may be curved on a radius of 4 feet
minimum. It is recommended that at least 2 people be used
for this procedure, in order to avoid breaking the ceramics.
After the element bar has been removed, it should be
carefully stretched out on a clean table for inspection. Broken
ceramics must be replaced and burn spots should be cleaned
with a dry clean paper or cloth towel. Oil or other
contamination on the heater will cause a failure.
When installing the heating element into the heater pipe,
reverse the steps noted above.
Heater pipes must be perfectly clean before installation of
element. Use only a clean dry cloth to clean. Never use a
CAUTION
MAINTENANCE
lubricant. Compressed air with a long wand may be used to
remove ceramic chips, etc.
CAUTION -Hazard of Electric Shock
Heaters must be bolted into position at the terminal
end to prevent movement, which could allow the
heater to short out against the pipe.
See figures attached for mounting configurations.
The heating element is only intended to be installed with the
sheet metal strip on the bottom. Do not rotate the heater in
the pipe.
Thermal insulation must be installed between the first few
ceramics in the "cold" section of the heater where the
resistance wire is not coiled. A loose fill cerafiber (INDEECO
P/N 1008466) or equal, rated for 2000°F, is preferred. The
insulation must be free of moisture or contamination in order
to provide electrical isolation. The insulation is necessary to
allow 90°C rated field wiring.
Caution, INDEECO recommends replacing the entire pipe
insert assembly under most conditions. The condition of the
ceramics must be considered before attempting to replace
coils. Field replaced heating coils must be installed properly
or failure may occur.
If field-replacing one or more heating coils, mechanical
connections at the end ceramics need to be removed.
Remove the burned out coil from both ends by pulling lightly,
and at the same time turning the coil back and forth. Check
the ceramics near the area where the burnout occurred.
Broken ceramics must be replaced, and burn spots should be
cleaned with a dry clean paper or cloth towel. Oil or other
contamination on the heater will cause a failure.
The new coil should be stretched to the correct length (do not
over stretch), and then inserted from the far end by lightly
pushing with a constant back and forth turning motion. After
the coil is in place, the loop at the end of the coil should be
guided over the bolt on the end ceramic and then tightened in
place with the previously removed unit.
Re-install the heating element in the pipe by reversing the
instructions above.
Use care when making connections to the heating element to
avoid breaking the end ceramic.
Where the heater is installed in cold climates, consider safety
precautions to prevent damage due to freezing fluid when the
heater is not in service.
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