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Installing a kiln element

This guide will assist you to install a kiln element. It should be noted that this is the way Van Tuyl fits elements on a Front Loading Kiln but this could change from time to time, so always check with your supplier. Fitting elements to other kilns (e.g. top loaders) can also be a DIY job, ask your manufacturer for details.

It is normally fairly easy to change the elements in your kiln.

Steps to follow

• Make sure your kiln is switched off and disconnected from all power sources.
• Before you start to disconnect any wiring, mark all the wiring and take photos that you can use to refer to later.
• Most elements are supplied as a closed coil with 2 tails on either side. Most kilns are built as a standard, however over time some changes might have been made, the tails should compensate for any changes that might have been made.
• Inside your kiln the element normally consists of several rows. Depending on the size of you kiln these rows could run back and forth across the side and back walls as well as the door. Do not make the mistake of thinking that each row is an element.
• Each element (normally) has a ‘Power IN’ and a ‘Power OUT’ where the tails of your coil fits through. You should find these on the back wall of your kiln.
•  Count the number of rows on the wall where you need to fit the element and divide the closed coil into equal lengths or segments.

IMPORTANT: Elements are manufactured to ensure the correct Ampage. Never cut or altered the
element as this could affect the Ampage.

• You should now stretch the element to the same length as the groove in the kiln wall.
• Clamp the tail to (for instance) a workbench and stretch each segment to the required length. (In a standard 5.2 cu ft. Van Tuyl kiln it will be 440mm long.)
• Once you have created the stretched segments, you need to straighten out the segment elbow. This is the section between each segment. Do this by straightening out a coil or two with a pair of pliers. Each segment should now fit nicely into the horizontal grooves in the kiln wall.
• There should be a smaller vertical groove in the brick between each horizontal groove. This is where you need to fit the segment elbow you made between each segment.
• It is not an issue if the segment is not totally exact as long as the fit into the horizontal groove neatly and are not bunched together (you can always stretch the coil out a little bit more if need be).
• Now push the tails through the holes in the back wall where they can then be connected to the power on the back of the kiln.
• Sometimes elements are pinned to the bricks using element pins. If you do have some element pins you can do this, but it is not necessary. You can make small element pins from the old element wire. These pins are U-shaped and easy to make using pieces of wire about 50mm long and then bent into a U shape. Push the pins into the soft brick to secure the element.
• The element tails needs to be connected to the electrical power. You can do this either with a line tap or a bolt connection. If you will be using a Bolt connection create a loop at the end of the element tail for the bolt to go through and connect as shown in the illustration below.

All connections should be as tight as possible to prevent a ‘Hot Joint’ that can impact the performance of
your kiln.

 

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