I recently answered a call to fix a steam generator in Mississauga, near Square One. They reported intermittent steam, and fluctuating temperatures. After seeing the images, we also noticed the control had been damaged. Our first thought was that a bather had shorted a circuit while adjusting the control. However, upon our first troubleshooting, we found zero steam generation. The unit was entirely out of commission. We decided to remove the generator to troubleshoot and diagnose the failure.
· The steam room
The steam room itself was a large 14x7 room, with 8’ cathedral ceilings, and the back right quarter closed off with an inside corner. Room volume was over 800 cu/ft. There was a single bench along the left 14’ wall, and a 7’ bench on the right of the door. The steam heads were on the inside corner facing the long bench. We found the temperature probe immediately above the steam heads. The steam generator itself was a Steamcore 36kw 600v unit, and the serial number indicated it was manufactured in 2010.
· Control and Temperature sensor - Troubleshooting
The initial concern of inconsistent temperatures led us to check the temperature probe. We found it had nearly slipped inside the ceiling. Had it fallen behind, we would have no access to fix the probe without removing some drywall. Luckily we fished out the probe with some needle nose pliers and secured it with some high-temperature silicone. Damage was seen on the control, as a couple buttons had lost the protective coating overtop, meaning someone with wet fingers could short out the system. However, we found the control was giving an accurate temperature reading. A second control was brought for troubleshooting. This also recorded the correct temperature, and also failed to generate steam. At this point, we determined the unit must be removed for testing.
· Disconnecting
When we returned to disconnect the heater for servicing, we got lost looking for the electrical disconnect. The attendant initially led us to the basement, but there were no sauna controls there. We went back up to the 5th floor, and an outdoor walkway led to a rooftop pool building that had a second electrical room hidden underneath. This required us to crawl under pipes to access the disconnect and lock out the steam generator. We found the unit to be exceptionally heavy on removing it. We later found out it’s because the tank was full of water. The original control was removed, and a wooden ‘Out of Order’ sign was put up over the electrical box. It was easy enough to use channel locks to remove the 1” copper unions for the 3 steam lines. We disconnected the power cable, so we could hook it up later for the bench test.
· Cleaning
Once we opened up the machine, we found calcium buildup in several locations. The temperature probe had significant buildup, leaching down into a couple elements, and pooling at the bottom. Some of the insulation had calcium residue which was removed. Upon removing the drain valve, we found the interior was fully caked with calcium. The valve was completely blocked. Fortunately, we had a spare valve in stock, and it was a quick fix. The tank itself had a plug of calcium that we uncorked, causing the entire tank to empty into a waiting bucket.
· Bench Test
After cleaning and draining the tank, we wanted to hook it up and test functionality. The steam generator was connected to the panel in my shop, and hooked up to my shop’s water line. Upon starting up the unit, we heard it draw water as normal, and it started boiling after a minute. Shortly we saw steam coming out the nozzles, confirming it was back in operation. We also tested all the elements to ensure the correct voltage was passing over them, as a damaged element would provide electrical resistance. You could hear the contactor engage, and feel the heat from the steam heads. When we returned the generator to Mississauga, we ran the unit for a full cycle to ensure it was generating steam properly. The heat was glorious, and the steam was enough to fog out the room right away. I’m sure the residents were happy to have their steam room operational again!
