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1. Lock out and tag out all power sources supplying power
to the boiler. Double check with voltmeter to verify there
is no voltage present at the boiler.
2. Remove the boiler jacket panel from the element
connection side of the boiler.
3. Make a diagram or sketch of all element jumper wires
and connections. It is not necessary to remove the
jumper wires from the blades that are not being
replaced.
4. Number all leads removed from the element so they
can be correctly connected after completion of the
blade replacement and reinsertion the element in the
boiler.
5. Remove the bolts and nuts attaching the heating
element to the boiler element flange.
6. Remove the heating element bundle from the boiler.
7. Mark the element blades that are to be replaced. This
will avoid damaging element blades that are not to be
removed.
8. Use a hacksaw to sever the desired element blades on
the water side of the flange. Leave approximately 1/4
inch of element blade protruding past the edge of the
flange.
9. After severing the element blade, carefully remove the
cut portion of the blade from the separator plates.
10. If not previously done, remove the nuts, washers,
insulators and silicone bushings from the ends of the
heating element blade.
11. Remove the short stub of element blade from the
element flange. The stub may have to be driven out
from the water side of the flange with a drift punch or
other suitable tool.
HEATING ELEMENT BLADE REPLACEMENT
5
12. Install the new element blade through the separator
plates and element flange. The sheath of the element
blade should protrude about 3/4 to 1 inch past the face
of the flange.
13. Slip the bronze ferrule onto the element blade. Screw
the compression nut into the flange and tighten to
approximately 40 - 50 Ft/Lb. torque.
14. Install the silicone bushing, ceramic insulator, washer,
and nut onto the element connection. Tighten the nut to
only 1 or 2 Ft. Lb. torque.
15. Clean the gasket surfaces to remove all old gasket
material from the element flange and element bundle.
16. Reinstall the new element gasket and element bundle
into the boiler. Install the bolts and nuts and tighten all
bolts evenly to approximately 120 – 130 Ft. Lb. torque.
17. Fill the boiler and hydrostatically test it to insure there
are no leaks at the element flange or element blades.
If there are leaks at the element blades, tighten the
compression nuts only enough to stop the leakage.
18. Reinstall jumpers and wiring according to the
previously made diagram or sketch.
19. Check each circuit to be sure no errors were made
during reattachment of the wiring.
20. On the load side of each contactor, verify that ohms
resistance T1-T2=T2-T3=T1-T3. High resistance
indicates a loose connection.
21. Reinstall the boiler jacket panel which was previously
removed.
22. Close control panel door and turn on all power sources
to the boiler. Follow start-up procedure until normal
operating conditions are achieved.
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