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How do I replace the wire heating elements in my furnace or oven?

Step-by-step instructions for safely installing a wire heating element in an industrial furnace or oven. Includes handling tips and diagrams to ensure efficient installation or replacement of your heating elements.

Preface: 

The high temperature alloy wire used in the heating elements loses ductility and becomes very brittle after being heated. When a heating element is removed, the wire itself will probably break at some point between the terminal bolt and the end of the coil. Therefore, if one intends to save an element as a spare after removal from the furnace, there is a high probability that the heating element will be permanently damaged during the replacement. Lucifer Furnaces strongly recommends that the heating elements be replaced only when necessary. For service and repair, Lucifer Furnaces recommends wearing a NIOSH approved N95 respirator or higher. 

Installation Instructions:

  1. Disconnect power to the furnace at the disconnect switch. Never work on the furnace elements with the power connected. 
  2. Remove the cover on the back of the furnace.
  3. Remove items required to access the heating elements such as chamber liners or hearth plates.

  4. Disconnect heating element lead wire at terminal bolt mounted on the back of the furnace wall.

    (Make note of all jumpers and interconnecting wires for reconnection after replacement).

  5. Straighten the element lead wire and remove the entire heating element (ceramic holder and wire) by pulling the holder from inside the furnace out through the door opening.
  6. Straighten the lead wire on the new heating element and carefully feed the wire through the existing holes in the refractory. Lengths of ¼” copper tubing can be used to help guide the lead wires through the back wall insulation. Make sure the wire coils remain fully supported inside the groove of the holder. The end of the coil should remain supported at the end of the groove after installation.
  7. When the heating element is correctly positioned in the furnace, install the ceramic protection tubes over the lead wires and into the brick work from the rear of the furnace. The ceramic protection tubes help insulate the lead wire and prevent a premature burning out of the heating element.
  8. Once the ceramic protection tubes are installed, wrap the lead wire at least two (2) or three (3) times around the terminal bolt in a clockwise direction. Cut the additional wire off at an appropriate length after the lead wire has been wrapped around the terminal bolt. Do not pull on the wire when wrapping it or the coil might pull out of the holder groove and become unsupported.
  9. Replace the jumper and interconnect wires.
  10. Replace the cover on the back of the furnace. The furnace is ready for the required dry out procedure. New refractory or cast material installed with the elements will require a dry out procedure of increasing the chamber temperature 1000F every half hour until 3/4 of the maximum furnace temperature has been reached.

The furnace is ready for normal operation.

Note: The installation of the side, floor, roof, door, or back heating element, when applicable, is the same. In certain furnace models the roof may require removal for easier access to the heating elements.

Illustrations:

Wire Element Install with picture older 8AM Series_Page_2

Parts Assembly Disassembly Drawing - Upper Chamber

Wire Element Install with picture older 8AM Series_Page_3Parts Assembly Disassembly Drawing - Lower Chamber

Wire Element Install with picture older 8AM Series_Page_4

If you need help purchasing heating elements for your furnace, submit a part order form request.