Chromalox CES-6 manual Maintenance Immersion Heater Failure Causes

Page 18

Boiler

1" Steam Equalizing Pipe

1-1/2"

Pump and Low

Water Control

 

 

Normal Boiler

 

Water Level

 

Cutoff Level

 

is Arrow Mark

 

Blowdown

 

Valve

 

1" Water Equalizing Pipe

1

2

4

3

2-1/2

 

FIGREF. 3.

 

MAINTENANCE

 

 

8

1

2

 

 

1

 

 

 

 

 

3

2

 

 

6

7

 

 

 

 

3

 

 

 

6

5

4

5

 

 

4

 

5-3/4

 

4-1/2

 

FIG. 1

 

FIG. 2

 

REF.

 

REF.

IMMERSION HEATER FAILURE CAUSES

 

HEATER ELEMENT CONDITION

 

PROBABLE CAUSE

 

 

 

 

 

 

1. Water leakage at heater flange

1.

Heater bolts improperly tightened. Refer to flange tightening instructions.

 

 

 

2.

Debris on heater flange or generator flange surface. Clean prior to installation.

 

 

 

3. Heater bolts not retorqued after initial operation. Refer to flange tightening

 

 

 

 

instructions.

 

 

 

 

 

 

2. Water leakage at heater element

1.

Faulty weld or braze on element to flange connection or corrosion.

 

 

to flange junction.

2. Verify water is not exiting through heater terminal. Normally seen in condition #5.

 

 

 

 

 

 

3. Burned wiring connections

1.

Loose wire connections. Tighten properly after inspection.

 

 

 

2.

High resistance in wire connection due to oxidation. Clean wires before

 

 

 

 

reconnecting to element. Replace if necessary.

 

 

 

 

 

 

4. Heater element has open circuit.

1.

Element has open circuit due to normal wear and tear to end life.

 

 

(Element looks OK but Ohmmeter

2.

If generator is undersized for its application, heaters will be over worked and

 

 

check shows infinite resistance).

 

reach end of life sooner.

 

 

 

3.

Element has been overheated due to excessive scale build up. The scale acts as an

 

 

 

 

insulator retarding heat transfer to the water. Short life will result. If significant

 

 

 

 

scale is observed on element, this would indicate need for more frequent blowdown

 

 

 

 

or descaling.

 

 

 

4.

Wrong voltage supplied to element.

 

 

 

5. Element not totally immersed in water. This causes a localized hot spot which

 

 

 

 

melts the wire inside the element. Cause of problem is fault in water level control

 

 

 

 

system. Elements damaged in this manner may be distorted. Repair and verify oper-

 

 

 

 

ation of the level control prior to restarting the heater.

 

 

 

 

 

 

5. Heater element has developed a

1.

Corrosion of heater element sheath-use of corrosive descaler compounds will etch

 

 

ground fault. When this occurs, a

 

sheath. Use only approved descaler to remove scale.

 

 

hole may be formed in the sheath

2.

Element has overheated due to excessive scale build up. This can cause localized

 

 

material, allowing water to enter the

 

hot spot which sometimes arcs thru insulation and the ground metal sheath. More

 

 

element.

3.

frequent blowdown and/or descaling is needed.

 

 

 

Element not totally immersed in water. This causes a localized hot spot which pro-

 

 

 

 

duces a hole in sheath. Cause of problem is fault in water level control system.

 

 

 

 

Elements damaged in this manner may be distorted.

 

 

 

4.

Excess vibration. Vibration could cause rubbing of elements wearing a hole in the

 

 

 

 

sheath. Vibration could be caused by large machinery nearby.

 

 

 

5.

Wrong voltage supplied to element.

 

18

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Contents Chromalox Dimensions Model CES-6 through CES-18Installation ModelDiagram WiringTypical Wiring Diagrams Boiler 208 240 480Boilers under 40 Amps total not fused Black Diagram Diagram Black Brown Blue White PRE-OPERATION Check Miller LOW Water Cutoff ControlOperation Adjusting Operating Pressure ControlsRecommended START-UP Procedures High Limit Pressure Control OperationAutomatic Blowdown Instructions If FurnishedOptional Equipment for Steam Boilers Boiler Sequence Solid State Solid State Progressive SequencerLOW Pressure Feed Pump Motor DimensionsWater Feed Systems High Pressure FeedPlumbing MaintenanceInstallation Wiring SequenceMaintenance Immersion Heater Failure Causes Renewal Parts Identification Part Description Part NumberLimited Warranty Valves & Gauges

CES-6 specifications

The Chromalox CES-6 is a state-of-the-art electric heating solution designed for industrial and commercial applications. This versatile unit offers a range of features that enhance its efficiency, durability, and ease of use. With a focus on advanced technology, the CES-6 is engineered to meet the demands of various heating requirements, from process heating to temperature maintenance.

One of the standout features of the CES-6 is its robust construction. Built to withstand harsh environments, it is made from high-quality materials that ensure longevity and reliability. The unit's enclosure is resistant to moisture and dust, making it ideal for applications in challenging conditions. This durability ensures that the CES-6 can operate effectively in settings such as manufacturing plants, warehouses, and outdoor installations.

The CES-6 leverages cutting-edge heating technologies, including advanced thermal management systems. This feature allows for precise temperature control, ensuring optimal performance and energy efficiency. By utilizing programmable temperature settings, users can customize their heating profiles to match specific operational needs, reducing energy consumption and operating costs.

Another significant characteristic of the CES-6 is its ease of installation and maintenance. Designed with user convenience in mind, the unit comes equipped with adaptable mounting options and user-friendly interfaces. This makes it straightforward for technicians to install and service, minimizing downtime and enhancing productivity.

Safety is a top priority with the CES-6, which incorporates multiple safety features to protect users and equipment. Over-temperature protection, built-in alarm systems, and fail-safe mechanisms are just a few of the safeguards included. These features not only enhance user safety but also contribute to the overall integrity of the heating process.

In conclusion, the Chromalox CES-6 stands out in the market for its combination of durability, advanced technology, and user-friendly design. Its robust construction makes it suitable for demanding industrial settings, while its energy-efficient heating capabilities and ease of installation ensure it meets the needs of a wide range of applications. Whether you are looking for reliable heating for your manufacturing processes or need a dependable solution for temperature maintenance, the CES-6 is an exceptional choice that delivers performance and efficiency.
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