A good general method of trouble shooting is to cut the problem in half and determine which half is causing the problem. Then, continue cutting the problem in half until you can diagnose the problem. For example, when a controller display shows fail, the problem can be due to the thermocouple (T/C) or the controller. If we disconnect the T/C and short the controller's T/C input connections together and the problem goes away, we know the problem was the T/C and not the controller.
Another second practical approach is to determine what has changed or what is different. Was anything done differently with this problem firing from previously good firings? For example, has the load increased significantly, is there a new program, have the elements been changed, is there a new T/C, are you using different clay or glaze? If the system is similar to another system that is working properly, try to determine what differences there are between the two systems.
Error Condition - Err0
Err0 indicates a software failure caused by hardware or electrical noise. Probable causes are an electrical spike or surge, or arcing across the relay contacts. To correct this error, try resetting the system by disconnecting power for 10 seconds, then reconnecting the power. The controller will display 'ErrP'. Check that your current firing program wasn't cleared from memory by pressing "Review Program". If your program reviews correctly, you can restart the kiln. If the error persists, the controller must be serviced or replaced.
Error Condition - Err1
Err1 indicates temperature is rising slowly (less than 12 deg/hr over a 22.5 min period) during a ramping phase.
Causes include:
If the kiln reached a temperature greater than 1300°F before getting the Err1 message, then the most likely cause of the error is worn elements or low kiln voltage. You should begin by running the "full power test" and if all the elements heat, check the resistance of the elements according to the kiln manufactures' guide lines. Also, check the voltage to the kiln to ensure it matches the voltage listed on the kiln's specification plate.
If you received the Err1 message and the firing reached a temperature less than 1300°F, one bank of elements is probably not firing. Run the "full power test"to determine which bank of elements is not working. Look for broken wires or broken elements. If the elements have the correct resistance, then a relay is most likely faulty.
If Err1 occurs at random temperatures, the cause is most likely electrical noise from the relays. The pilot relays should have MOV's (Metal Oxide Varistors) across the contacts of the relays. These MOV's subdue the noise caused by the relays. If the varistors are faulty or not present the electrical noise generated may cause an Err1 message. A chattering relay can cause excessive noise as well. Boards damaged by electro static discharge (ESD or static charges) are more susceptible to electrical noise and a new board may correct the situation.
If the actual temperature appears to be hotter than the indicated temperature when Err1 occurred, the problem is generally related to a faulty or old T/C.
Error Condition - Err2
During a hold segment the temperature is more than 50°F above the hold temperature which was set. The temperature must stay 50°F above this set temperature for 18 seconds before the error is displayed.
The most probable cause of this is either a relay stuck on or a stuck output on the controller. First, stop the kiln. If all the relays remain on then it is probably a controller problem. If only one section (or relay) remains on then it is a stuck relay.
Error Condition - Err3
During a hold segment the temperature is more than 50°F below the hold temperature which was set. The temperature must stay 50°F below this set point for 18 seconds before the error is displayed.
Opening the door or lid of the kiln can cause this. However, Err3 is generally caused by a burned-out element or a defective relay. Run the "full power test" to isolate the problem section. If no sections are heating then the controller outputs may be bad. If only one section is not heating, follow the kiln manufactures' procedure to test the element. If the elements are all good, then the problem is most likely a defective relay.
Error Condition - Err4
The firing is in a ramp segment where the temperature is programmed to decrease and temperature is more than 50°F above the previous hold temperature. The temperature must remain 50°F above the hold temperature for 18 seconds before the error is displayed. Err4 is the same as Err2 except that Err4 occurs during a ramp phase rather than a HOLD.
The most probable causes of Err4 are either a stuck relay or stuck output on the controller. If all the relays remain on while Err4 is displayed, then probably the controller output is stuck on. If only one section (or relay) remains turned on then the problem is a stuck relay.
It is also possible to get an Err4 message if you use the skip step feature. If you get Err4 after skipping to the next ramp phase, press a key to clear the error, allow the kiln to cool to within 50°F of the next hold temperature, restart the kiln and skip steps until you get to the segment you want.
Error Condition - Err5
The temperature is more than 50°F below the local set point during a ramp segment where the temperature is programmed to decrease. The temperature must stay 50°F below this set point for 18 seconds before the error is displayed.
This can be caused by opening the door or lid. However, it is generally caused by bad elements or relays. Run the "full power test" to isolate the problem section. If no sections are heating then the controller outputs may be bad. If only one section is bad, follow the kiln manufacturer's procedure to test the non-heating element. If the element tests good, the relay is most likely the cause of the problem.
Error Condition - Err6
A negative temperature is displayed. This can be caused by using the kiln in temperatures below 0°F (or 0°C). If this is the case, warm the T/C manually before starting the kiln.
Other reasons for Err6 are the T/C connected backwards (red and yellow leads reversed), the board has been damaged by static electricity or ESD (electro static discharge), or electrical noise. If the T/C was not just changed and previous firings have been OK, then the problem is either a defective circuit board or electrical noise. Do the "T/C by-pass test". If the temperature reading is negative the board has been damaged and needs service. If room temperature is displayed with the T/C screws shorted together then the thermocouple (T/C) is the problem.
Error 7 is not implemented at this time.
Error Condition - Err8
When using the Cone Fire Method, the temperature is decreasing during the last ramp segment, usually indicating the kiln sitter has turned the kiln off.
If this error occurs without a kiln sitter attached, a faulty relay, broken element, or electrical noise could be the cause of the problem. Do the "full power test". If all the elements glow at a low temp, let the test proceed and make sure they continue to glow at high temperatures.
To troubleshoot zone control kilns, first set the display to read Idle, tc 1, and temperature. Apply heat to the top T/C. If the temperature increases then T/C 1 is connected correctly to the top section of the kiln. If the temperature does not rise, apply heat to the other two T/Cs to see which is connected to T/C 1. Check all of the therocouples and move them to the correct positions if needed.
If a thermocouple is in the correct location but it does not register a temperature increase then the T/C is faulty or its lead wires are shorted together.
If all of the T/Cs are in the correct positions and register temperature increases, proceed to testing the outputs.
To test the outputs on controllers without the diagnostics routine in software, you will first have to disconnect power from the kiln. Remove the V6-CF controller and run the "full power test". Only the top section should heat up. If another section is heating up instead, then remove the wire from Output 1 and put it on the output that corresponds to the section that is heating.
Repeat this procedure for Outputs 2 and 3 as well. If the problem persists, look for electrical noise sources or defective T/Cs.
To test the outputs on the controller using the diagnostics routine in software, press the "OTHER" button until 'rSEt' is displayed. Press "4", "4", "3" and "notC" will be displayed. Press the "OTHER" key until 'diAG' is displayed. Press "ENTER". 'OUt1' will be displayed and Output 1 will come on; the top section of the kiln should start to heat. If the display and section heating do not match then remove the wire from Output 1 and place it on the correct output for the section that is actually heating. After about 1 minute, 'OUt2' will be displayed and the middle section of the kiln should heat. Similarly, Output 3 will come on after another minute and the bottom section of the kiln should heat. Make sure that the correct kiln section is heating compared to the output that is displayed.
Error Condition - Err-
The Err with a dash indicates there was a power loss to the controller while writing a program to the non-volatile memory chip. Check the selected program, and reprogram if necessary. If you get this error on a regular basis, the board may need to be serviced.
Error Condition - Errd
This error is triggered when the temperature is more than 100°F above the traveling set point. On a single or zone board this can be caused by a stuck relay or electrical noise. On zone control kilns, Errd is generally caused by crossed wiring of the T/C's or the outputs.
To troubleshoot zone control kilns, first set the display to read Idle, tc 1, and temperature. Apply heat to the top T/C. If the temperature increases then T/C 1 is connected correctly to the top section of the kiln. If the temperature does not rise, apply heat to the other two T/C's to see which is connected to T/C 1. Check all of the thermocouples and move them to the correct positions if needed.
If a thermocouple is in the correct location but it does not register a temperature increase then the T/C is faulty or its lead wires are shorted together.
If all of the T/C's are in the correct positions and register temperature increases, proceed to testing the outputs.
To test the outputs on controllers without the diagnostics routine in software, you will first have to disconnect power from the kiln. Remove the V6-CF controller from the control box and disconnect outputs 2 and 3 (see connection diagram). Reinstall the controller and run the "full power test". Only the top section should heat up. If another section is heating up instead, then remove the wire from Output 1 and put it on the output that corresponds to the section that is heating.
Repeat this procedure for Outputs 2 and 3 as well. If the problem persists, look for electrical noise sources or defective T/C's.
To test the outputs on the controller using the diagnostics routine in software, press the "OTHER" button until 'rSEt' is displayed. Press "4", "4", "3" and "notC" will be displayed. Press the "OTHER" key until 'diAG' is displayed. Press "ENTER". 'OUt1' will be displayed and Output 1 will come on; the top section of the kiln should start to heat. If the display and section heating do not match then remove the wire from Output 1 and place it on the correct output for the section that is actually heating. After about 1 minute, 'OUt2' will be displayed and the middle section of the kiln should heat. Similarly, Output 3 will come on after another minute and the bottom section of the kiln should heat. Make sure that the correct kiln section is heating compared to the output that is displayed.
Error Condition - ErrE
A hardware error has been detected by the controller's software. The controller must be returned for service.
Error Condition - ErrA
ErrA indicates that the controller failed the self-check of the non-volatile memory chip where all the programs are stored. You need to reprogram all 6 user programs. Turn the controller off then back on. If you do not get the error again, continue as normal. However, if you continue to get ErrA then the board needs to be serviced.
Error Condition - ErrH
ErrH indicates that the Analog to Digital Converter did not pass the self-check diagnostic test on reset. If you get this error then the board will need to be serviced.
Error Condition - Errb
Errb indicates that the controller is reading a board temperature above 250°. This means the actual temperature is above 250° or the board needs to be serviced.
Error Condition - Errt
An Errt indicates that a write cycle to the non-volatile memory chip took too long. The board will need to be serviced.
Error Condition - ErrP
A continuous ErrP in the display indicates a long-term power outage. The kiln has been shut down. Press "1" to clear the display.
If ErrP and the current temperature are alternately flashing, this indicates a short-term power outage. To clear the display, press the "1" key. If a firing was in progress, it will continue.
If you are getting an ErrP message during a firing without having a power loss, this indicates the controller is being reset by radio frequency (RF) noise. This electrical noise can be generated by the relays. When a relay drives an inductive load (i.e. mercury displacement contactor) it generates electrical noise; to suppress this noise, varistors (MOV's or Metal Oxide Varistors) must be placed across the contacts of the relay. Locating the controller circuit board away from the relay, contactor, and high voltage wiring will also reduce the effects of the electrical (RF) noise.
Error Condition - StUC
If 'StUC' appears on the display, one of the keys is stuck. The controller needs to be returned for service.
Error Condition - FAiL
Fail indicates that the controller is not getting a thermocouple (T/C) input; therefore, it cannot determine the temperature. The first thing you will need to do is disconnect the thermocouple (or thermocouples if you have more than one) and perform the "T/C By-pass test". If the controller displays room temperature with the T/C bypassed then you will need to replace the thermocouple.
If you are getting Fail during a firing and the "T/C By-pass test" is successful, but a new thermocouple does not fix the problem then you will need to watch the temperatures during a firing to see if they are erratic. You could be having interference due to electrical noise.
Other Controller Related Firing Symptoms
Does Not Heat When Start Is Pressed