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The following procedures may expose personnel to hazardous voltage and hot or potentially poisonous chemicals. Turn off all tank power, steam, and hot water supplies. Wear recommended protective clothing for the tank contents prior to removing and inspecting the suspect heater. Proper tools, protective insulating gloves and procedures are required. Only a qualified electrician should perform all tests.


The following are links to the different sections of our troubleshooting guide, with an outline of what each guide contains.

The following information is covered in this guide:


1) No power/electrical fusing.
2) Open/overheated thermal protectors on heater.
3) Missing thermal protector.
4) Thermostat not turning heater on (new installations).
5) Thermal protector(s) keep opening (Protector 1 style).
6) Protector 2 bimetallic thermostats opening at a low temperature.
7) Heater blowing electrical protectors.
8) Reduced output of heater.
9) Voltage measured in tank.

1) Holes in heater sheath (metal heaters).
2) Swelled or split heater sheath (metal heaters).
3) Heaters tripping GFP/ELCB circuits.
4) Melted or overheated ground wires.
5) Metal plate-out on heater sheath.
6) Physical damage to heaters.
7) Sand or magnesium oxide found in junction box.
8) Installation problems.
9) Discoloration/blackening of heater sheath; heater is distorted or misshapen.

1) Carbonized buildup inside heater sheath.
2) Buildup on the outside sheath of the element.
3) Tube cracked off at solution interface.
4) Tube cracked or broken off near bottom.
5) Tube cracked or section broken out near center.
6) Tube etched or has porous appearance on outside surface.
7) All three legs of element open, failure after a short period of operation (less than one day).
8) All three legs of element open, failure after an extended period of time.
9) One leg/element open.
10) Bluish spots or discoloration in cold zone transition area.
11) Holes/melting of metal element sheath.
12) Guard melted or distorted.
13) Guard material cracking at weld seams or solution interface.
14) Heaters tripping GFP/ELCB circuits.
15) Quartz heater floating up in guard.
16) Element will not fit in quartz tube.
17) Wrong phase element ordered.
18) Thermowell tubes full of solution.

1) Fluoropolymer sheath melted, split or distorted.
2) Swelled or split heater sheath (any location).
3) Swelled or split heater sheath at the hot zone transition.
4) Section of element that's completely missing.
5) Melting or distortion of junction box at the element insert point.
6) Cracks in internal epoxy encapsulation.
7) Holes in the Thermowell tube.
8) Guard material cracking at weld seams or solution interface.
9) Heaters tripping GFP/ELCB circuits.
10) Fluoropolymer sheath on single element or phase of the heater melted.

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