9 Signs Your Kiln Elements Need to Be Replaced
As experienced kiln technicians, we’ve encountered countless scenarios where kiln elements have reached their breaking point, quite literally. Understanding how to recognize the signs indicating when these crucial components require replacement can save both time and resources for anyone who maintains an electric kiln. We’ve compiled a list of our top 9 telltale signs that it's time to replace your kiln elements, ensuring smooth firing sessions and successful results.
1. Uneven Heating
If you notice that your kiln isn't heating evenly, with some areas consistently hotter or colder than others, it could be a sign that your elements are failing. This can result in inconsistent firing results and can affect the outcome of the bisque or glaze ware in the kiln.
2. Visible Damage
Take a close look at your kiln elements. If you have any visible signs of damage such as cracks, breaks, or areas where the coil appears to be burnt out, these are clear indicators that replacement is needed. A very small glaze drip will burn out and break an element; it can be tough to see without knowing what you're looking for.
3. Reduced Performance
If you noticed that your kiln is taking longer than usual to reach temperature or isn't reaching the set temperature at all - this could be a sign of aging elements that are no longer able to efficiently generate heat.
4. Frequent Firing Issues
If you're experiencing more frequent firing issues such as glaze defects, warping, or under-fired pieces, it may be due to failing elements.
5. Electrical Smells or Sparks
Strange smells or sparks during firing are a bad sign. This could indicate that the elements are overheating or short-circuiting, both of which are serious safety hazards and require immediate attention. If you see smoke, sense electrical smell, or see sparks turn off the kiln at the circuit breaker immediately. Do not turn on the breaker again until the problem has been found and fixed.
6. Visible Sagging or Drooping
Over time, kiln elements can sag or droop, especially if they've been subjected to repeated heating and cooling cycles. This can lead to uneven heating and should be addressed.. Elements should have even coil spacing and their coils should stand up straight.
7. Increased Energy Consumption
If you've noticed a significant increase in your kiln's energy consumption without a corresponding increase in workload, it could be a sign that your elements are no longer operating efficiently and are drawing more power than necessary.
8. Age of Kiln
It is universally understood that kiln elements typically need to be replaced every few years depending on usage and maintenance. If your kiln is approaching this timeframe or has exceeded it, it's worth inspecting the elements for signs of wear and tear.
9. Resistance Tests
Conducting resistance tests on your kiln elements can help determine their health. If the resistance is significantly higher or lower than the manufacturer's specifications, it's a clear indication that replacement is needed. However, resistance tests aren’t useful on all kilns; it depends on how the kiln is wired. Often, worn and heavily oxidized elements will not give reliable ohm readings.
We hope this guide has helped you to identify ways that you can determine if your elements need replaced. If you need assistance in selecting the right elements for your kiln, we can help you order them. Click the button below to fill out our form and we’ll get back to you right away. We understand that time is of the essence when it comes to getting your kiln back up and running!
