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Vulcanic TEE

The Specialists in Custom Heating

Product Troubleshooting

  • Jul 14 / 2014
  • 0

Product Troubleshooting

 

Drum Heaters

FAQ

Do you make heaters that can go directly into my solution?

Thermal has a range of heaters that can be immersed directly into your solution. There are a few factors that will determine the correct element for your application. Contact TEE to confirm the requirements.

Do you make heaters that heat from the outside of the drum?

Thermal has a range of heaters used to heat from the outside of the drum for cases where heating the solution directly is impractical. These heaters can be designed to suit your specific needs and include heater jackets, wrap-around band heaters, base drum heaters and even heated trolleys.

Can I heat multiple drums at once?

Yes and this can be achieved in a variety of ways. Depending on your specifications, our designers can determine the most efficient method for heating your drums, whether it be a number of individual drum heaters, or an industrial oven suited to the specific number of drums you require.

Help

The drum isn’t heating up quickly enough

The temperature probe may be too close to the element which would mean that it is measuring the temperature of the element rather than the solution and switching the element off before the solution has reached the correct temperature.
Ensure you allow adequate heat up time for the drum. Consult with the Design team for an indication of how long it should take to heat up to your desired temperature.

I am having trouble controlling the temperature of the solution

Check the controller. Perhaps a digital controller is required if very accurate sensing is needed.
Check the proximity of the probe to the product.

The element keeps shorting out

Speak with TEE to see what can be done. The current element may not be suitable for that application or environment.

The element has burnt out

This can happen if the solution is not completely covering the heatzone of the element, for instance, if the element is made to be submersed in a certain amount of the solution and the actual level of the solution is much lower this can cause the element to burn out. Please contact us to discuss possible solutions for this issue.

The element is glowing red

If this happens it may be because the heatzone of the element is not covered by your solution. Please ensure the correct level of solution is maintained to ensure the element does not burn out. If you are unsure as to how much of the element should be covered, please contact us.

The heater is burning the product

This may mean that the surface temperature (or watt density) of the heater is too high for your specific application. Please contact us to discuss possible solutions.

The element is not as efficient as it used to be

Check that the element is clean and free of build-up from your solution. Sometimes the solution may become caked on the element causing the heat to become trapped in the element which will not allow it to dissipate the heat that it is generating. This may cause the element to fail.

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Drysafe Drying Cabinet

The unit will not work

Try the following suggestions:

  • Check that the timer is on
  • Press the red button on the manual reset. This is located at the front of the cabinet, underneath the door on the right hand side.
  • Check that the circuit board on the premises hasn’t tripped a circuit breaker.
  • Check that there is nothing restricting the airflow such as boots on the bottom of the cabinet.
  • Note: This step must be done by a licensed electrician. Isolate the power and test the individual components within the enclosure. Please note that any modifications to the unit without the written approval of TEE will void your warranty. Individual components can be purchased through TEE as spare parts.

The unit keeps tripping

Try the following suggestions:

  • Check all of the suggestions above and if still tripping, move on to the following.
  • The high temperature overload may be set too low for the application. This can be adjusted below the red push button using a screw driver. Please contact TEE prior to adjusting to confirm the correct setting.
  • Check that the fan in the roof is operational. This may cause the heat to remain in the cabinet and cause tripping of the overload.
  • The unit may be getting too hot as it may not be positioned correctly, please contact TEE for advice.

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Electric Duct Heaters

Are air pressure switches standard on duct heater units?

No, air pressure switches are an optional extra on our standard duct heater units. We do supply 5mm Millboard internal insulation and a manual reset high temperature thermostat with our standard duct heater units.

Why are TEE’s duct heaters sometimes more expensive than others?

TEE uses the highest quality materials in all of its units as well as maintaining strict quality standards in order to ensure you receive a safe, efficient, high quality product. When you buy from TEE you are buying a higher standard of quality, a higher level of service and technical knowledge.

Why does TEE quote for larger or more elements than others?

TEE manufactures all duct heater units with a minimum duct coverage of 75%, ensuring an even and efficient heating of the air. Using smaller or less elements means that there is more open air within the duct and the heater will have to work harder, costing more money, in order to heat at the same level.

What materials are the duct sections made of?

TEE uses high quality galvanised steel and Isoplan insulation to construct duct sections.

What materials are the elements made of?

Thermal’s finned air heater elements are made of high quality Incoloy 800 with Stainless Steel finning in order to minimise air pollution within the ducts caused by painted or baked elements, and to ensure a long product life.

What is the insulation material used?

TEE uses Isoplan 750 insulation material based on the projects requirements.

Are these units rated for hazardous areas?

Thermal’s standard electric duct heaters are not certified for hazardous areas. We can, however, supply IECEx certified hazardous area electric duct heaters if your project requires it.

What options can TEE provide?

TEE can provide a number of options for your units, including:

  • Various thicknesses of insulation depending on your requirements
  • Either just the heater insert, replacement parts, or a complete unit with duct section
  • Various types of duct section fittings including TDF flanges, slides, raw edges or spiggots
  • Isolators and contactors per wired stage for ease of installation
  • Both manual and/or automatic reset overloads
  • Air pressure switches
  • Wired or unwired units

Do I need a neutral for a 3 phase duct heater?

No it is not a necessity. As our 3 phase units are connected in Star, it can be left as a floating neutral.

Do you supply supports?

TEE can supply supports for duct heater units with long elements in order to minimise movement.

Is there a difference between an indoor and outdoor duct heater?

While both units are made from high quality materials, the outdoor duct heater units will be supplied with weatherproof terminal boxes to ensure the controls and wiring are protected from the weather.
Ensure you specify if you require a weatherproof unit.

My air pressure switch has tripped.

Ensure there is adequate air flow upstream. The adjustment is on the body of the unit. Try using a pipe directed into the air stream.

The overload has tripped.

Check the fans and filters. Check the airflow at the unit. Also check the elements bank for any physical deformation or a blow out.

The overload won’t trip.

Shut off the airflow. Contact TEE for technical support.

What information does TEE need to replace an existing duct heater?

  • Size of duct and entry side for heater bank
  • Size of duct and entry side for heater bank
  • Size of duct and entry side for heater bank
  • Total kilowatts required
  • Number of control steps needed and whether wiring is single or 3 phase
  • Details of controls required to be fitted to the units
  • If you have a specific element required or standard to be met

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Evapodry Condensate Tray

The tray is filling with water and not evaporating

The heater may not be coming on as it may have tripped the circuit. Switch the power off to reset it and then turn the power back on. Check that the power light is on (green light flashes). If the heater is working but not evaporating quickly enough, contact TEE. The unit is designed to evaporate 1 Litre per hour, however, if you are in a high humidity area or have a large split system, you may need a larger Evapodry to allow for this.

The red light has come on

The heater may have tripped the circuit. Switch the power off to reset it and then turn it back on.

Smoke is coming out of the tray where the heater is

Turn off the unit, allow it to cool, then clean the tray thoroughly with a clean damp cloth and water.
Ensure that the tray is not sitting on any combustible material. Eg. A wooden deck.

The unit is staying on all the time

  • Switch the unit off and then back on after approximately 10 seconds. This may reset the circuit board and prevent future problems.
  • Check the tray for debris and remove.
  • Check the stainless steel sensor and ensure it is not touching the tray or the stainless steel perforated cover.

If the problem persists, contact TEE.

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Hot Boxes

Things to try if your Hot Box unit doesn’t work.

  • Check that the thermostat is set above ambient temperature (if applicable).
  • Press the red button on the manual reset. This is located at the side of the terminal enclosure on the top of the unit.
  • Check that the circuit board on the premises hasn’t tripped the circuit breaker.
  • Check that there is nothing restricting the airflow.
  • Check that the main selector switch has been turned on (21kW Hot Box only).
  • Isolate the power and test the individual components within the enclosure. Note: This step must be done by a licensed electrician. Any modifications to the unit without the written approval from TEE will void your warranty. Individual components can be purchased through TEE as spare parts.
  • The fan should run constantly, if it is not going please check your power supply.

Things to try if your Hot Box unit keeps on tripping.

  • Check all of the steps outlined above.
  • The thermostat may be set too close to the overload temperature. Adjust accordingly.
  • The high temperature overload may be set too low for the application. This can be adjusted below the red push button using a screw driver. Please contact TEE prior to adjusting to confirm the correct setting.
  • Check that the fan in the unit is operational. This may cause the heat to remain in the cabinet and cause tripping of the overload.
  • The unit may be getting too hot as it may not be positioned correctly, please contact TEE. Ensure there is adequate distance between the back of the fan and any objects (such as walls).

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Hot Sticks & Immersion Heaters

Hot Sticks

The sheath has corroded

  • This may be due to either:
  • The solution may be more corrosive than indicated, please contact us.
  • The sheath may not be suitable for the solution. You can check the suitability using our Hot Sticks brochure, or by contacting us.

The terminal box controls/components have corroded

  • The solution may be too high and splashing onto the controls, please contact us.
  • The o-ring which stops fluid ingress may be damaged or missing. Please note: There should be 2 o-rings in total. One on the lead and one on the box. Contact TEE if they need to be replaced.

There is fluid leaking through the fittings

The fitting may not be screwed in tightly enough, the gasket could be damaged. After tightening, please contact us if you continue to have problems.

The heater is in the oil and not heating as well as it used to
There could be a build up of oil in the heater. Turn off the heater then remove and clean the excess oil from the elements. Insufficient flow of liquid around the element could also be causing a problem.

The element keeps burning out

The heatzone of the element should be below the minimum liquid level. The heatzone is marked on the hot stick sheath. A liquid level sensor may be required to stop this from occurring in the future. TEE can supply these, please contact us.
You may require a specialised solution, please contact us to discuss.

Immersion Heaters

The element has burnt out

The heatzone of the element could be out of the liquid causing it to overheat. Raise the liquid level higher or immerse the element further.
Try using a liquid level switch in your tank in future to avoid this problem.

The element is corroding

The solution may have some properties that were not catered for in the original design, it might be more acidic/caustic than first indicated, please contact us.

The element is not getting hot enough

The sensor may be in the incorrect position. There could be a restriction to the flow of solution causing the sensor to read incorrectly. Check the thermostat set point.

The solution is not getting up to temperature

There could be a restriction to the flow of solution causing the sensor to read incorrectly.
Ensure you allow adequate heat up time. Contact TEE to get a heat up time estimation.

The overload keeps tripping

  • This might be caused by a few things:
  • The fluid level may have dropped or there may be a restriction to the flow rate of the liquid around the heater.
  • The overload sensor may be too close to the element. Please contact us before moving it.
  • The overload (if adjustable) may be set too low for the application. Contact us to confirm the appropriate temperature before changing.

There is no temperature control on the element

In some cases the temperature control will be fitted into the control box, this stops people adjusting the controls too often and also helps to keep the contents of the enclosure waterproof. Isolate the power before removing the lid to check. Note: This is to be completed by a licensed electrician.

If you have questions about any of TEE’s general services, please visit our FAQ guide.
Learn more about our range of products.

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Industrial Ovens

FAQ

What temperature can the oven go up to?

Thermal’s standard ovens can offer temperature ranges from 40° to 250° Celsius. If you require a temperature outside of this range, please specify your desired temperature when requesting a quote or contact us to discuss further.

What is the biggest size oven you can make?

Thermal’s standard ovens are available in sizes that hold up to sixteen 205L drums. We can, however, design an oven to suit your particular size requirements and have in the past manufactured ovens to hold as many as 64 drums.

Can I get shelves in it?

As we manufacture our ovens to order, we are happy to make them as simple or complex as you require. Shelves are just one option available.

How do I work the controls?

Please consult the operation manual supplied with your unit for assistance on using the controls. If you do not have this operations manual, please contact us for a replacement.

How do I move the unit?

Most units can either be forklifted or picked up using lifting lugs situated on the roof. This is size dependent.

Can your ovens only be made for heating drums?

Thermal’s industrial ovens can be modified and designed to suit your application. If you provide us with details of the product you are heating, the temperature you require and the sort of time frame you are looking at heating it in, we can design the most efficient product for your needs.

How thick is the insulation?

A standard oven has a 75mm wall thickness.

What sort of plug does it come with?

This will be dependent on the kW rating of the particular oven. It will be a 5 pin plug though as a neutral is normally required for the controls.

How much does it cost to run?

This is dependent on the kW rating.

Can the oven be placed outdoors?

Our industrial ovens are suitable for use outdoors. Their robust construction and design ensures protection from the elements. They can also be designed for use in hazardous areas.

What colours are available?

Our standard colour is hammertone green. We can adjust this if requested. Charges may apply.

Can I run the oven without the fans operating?

Yes, however you will get a more even heat distribution with the fans operating.

Can I use the oven to heat flammable products?

Please contact us to discuss your needs.

Can I get the oven with staged temperature controlling?

Yes, please let us know when requesting a quote.

Help

The oven won’t get hot

Check the temperature setting and the indicator lights that show if the oven is on or off.

The lights on the controls don’t come on

Check the switch is turned on and check the main load break switch.

The fan isn’t running

Check the switch is turned on and check the main load break switch. Also check the fan speed control hasn’t been turned right down.

The oven is getting too hot in one spot

Increase the fan speed.

The oven is not getting up to the temperature I need

Check the controller and overload temperatures.

The plug is a different size to my outlet

Check the amp rating of both plugs. Consult a licensed electrician and get them to make the required adjustments.

The circuit breaker keeps tripping when we turn the oven on

Check the unit on a different circuit.
If the problem persists, isolate the power and ask a licensed electrician to test the elements and also the oven electrical. Contact TEE if spare parts are required.
If the problem persists, isolate the power and ask a licensed electrician to test the elements and also the oven electrical. Contact TEE if spare parts are required.

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Refrigeration

My element is not working or has low insulation resistance

The lead or vulcanising rubber could be cracked, allowing moisture to get in. If so, the element would need to be returned to us (or some Heatshrink material may be used), contact us for information.

The earth tab or bracket has snapped off

This would need to be repaired by us, contact us to arrange return of the unit.

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Warmzones

The globe is not working

It may have blown and need replacing, check the power supply, check by using the Warmzone in another power outlet and check that a circuit breaker has not tripped.

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Special Elements

I asked for a thermostat, but I can not see it on the element

Please check your quotation, as you may have been quoted for an internal thermostat.

My element isn’t the shape or size that I thought it would be

Please contact us, we may have redesigned the unit to work better for your particular application.

Can I use my element for a different application? (eg. It was ordered for oil but I want to use it in acidic water)

Each element is specially designed for the details you have provided, in most cases we have used the material that is best suited to the conditions you have outlined. Please contact us to check on the materials suitability to the different application before proceeding.

How do I calculate the Amp draw?

Please refer to the technical section of our catalogue. The formula is Wattage divided by Voltage.

I forgot to order a thermostat, can I get one now and fit it?

Please contact us to determine if this is possible or if the heater will need to be returned to us.
If fitting the thermostat by yourself, please ensure a licensed electrician completes the work.

I have found that the element is too large for my application, can I bend it to fit the area?

In some cases, the element can be bent slightly, please contact us first to check on your particular product and we will advise you.

The element is not working

Check your power supply first and check the circuit breakers before contacting us.
Check the thermostat (it may be set too low) and/or the manual reset overload (it may need to be reset).

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