How to optimize the useful life of electric immersion heaters

For the maintenance of Electric Immersion Heaters, it is essential to follow a series of steps to guarantee their proper operation and extend their useful life. This type of equipment is used in various industrial applications and its proper maintenance can avoid costly repairs and service interruptions.

Regular visual inspection

One of the first steps in maintaining an electric immersion heater is to perform regular, annual or semi-annual visual inspections. During these inspections, the condition of the resistor, the wiring, and the electrical connections must be checked. Any signs of wear, corrosion or debris build-up should be looked for as these can affect heater performance.

Cleaning the resistor and the heating element

The heating element of immersion heaters is in constant contact with liquids, which can lead to the accumulation of sediment, scale or other substances. This not only reduces efficiency, but also prevents heat dissipation and can damage the heater in the long run. Regular cleaning with specialized products or pressurized water can prevent this build-up. If used in applications with liquids that tend to leave sediments, this step becomes especially important.

Checking the thermostat and other electrical components

Thermostats and temperature probes such as Thermocouple or Pt100 are fundamental components to limit the surface temperature of the heating elements, preventing overheating that could cause premature degradation of the materials. If the thermostat, thermocouple or probe is not working properly, the heating elements can overheat, reducing their useful life. It is also crucial to check other electrical components such as fuses, magneto-thermals, wiring and electrical connections for any signs of deterioration or overheating, ensuring that the heater operates safely and efficiently.

Verification of insulation and resistance levels

It is important to periodically check the insulation value and resistance of the heater to ensure that the device is working properly. In relation to resistance, once the resistive wire has been annealed 2 or 3 times, its ohmic value does not change, as long as the operation is adequate. If a change in the ohmic value is detected, this could indicate that the resistor has broken or is about to. In terms of insulation, this value can only go down over time, never up. If the insulation value drops significantly, this can be a sign of impending problems, and should be addressed immediately to avoid serious breakdowns or dangerous situations.

Maintenance after periods of inactivity

If an electric immersion heater has been inactive for a long period, it is especially important to have it fully serviced before returning it to service. This includes following all the maintenance steps mentioned above and also checking the probes and thermostats as well as the general condition of the heater to ensure there are no hidden faults that may have occurred during the inactivity. All maintenance work must be carried out when the electric heater is completely switched off. Likewise, ensure that the heater remains de-energized.

Specific maintenance of electric flange immersion heaters

Flanged Immersion Heaters, like the ones we offer at IES SOLER are relatively low maintenance compared to other types of devices. In many cases, reviews are minimal and focus on specific aspects:

• Readjustment of electrical and mechanical connections: Connections can loosen over time, especially if the heater has been subjected to vibrations or sudden changes in temperature. It is essential to ensure that both the electrical and mechanical connections are tight to avoid breakdowns or accidents.
• Filter cleaning: If the heater includes filters, these must be cleaned periodically to avoid the accumulation of residues that could affect the flow of air.
• Checking the heater fans: In heaters that incorporate fans, it is crucial to verify that they are working properly.
• General cleaning: Keeping the heater free of dust and other polluting elements contributes to improving its efficiency and extending its useful life.
• Additional checks after prolonged inactivity: As mentioned above, after long periods without using the heater, it is advisable to check the good condition of the probes and thermostats, as well as measure the resistance and insulation to ensure that everything is working properly before resuming use.

Therefore, regular maintenance of electric immersion heaters is essential to guarantee its durability and efficiency. Although flanged heaters require less maintenance, it’s important not to forget to do basic checks to ensure proper operation and prevent any long-term problems. In addition, we advise you to always have spare parts available. Since these products are usually made to order, the production time can be considerable. Having spare parts in stock guarantees immediate availability in case of need, thus improving operational efficiency and avoiding long stoppages in industrial processes.

At IES SOLER, we not only offer electric heat solutions tailored to your industry, but we also provide expert advice and safety solutions to ensure that all our installations work optimally and safely. With our commitment to quality and innovation, we work alongside you to optimize the performance of your equipment and extend its useful life, ensuring efficiency and reliability in each project.