GENERAL L&L KILN TROUBLESHOOTING GUIDE TABLE OF CONTENTS Thermocouple Offsets . .8 Vent System . .8 TROUBLESHOOTING GUIDE . .3 LAG & AUTOLAG SETTINGS . .9 RELATED L&L GUIDES . .3 CONTROL ERROR CODES (Auto) . .9 CAUTION INSTRUCTIONS . .3 THE KILN FIRES UNEVENLY (MANUAL) . .9 REGULAR KILN MAINTENANCE . .3 BASIC ELECTRICITY FOR TROUBLESHOOTING . .3 KILN FIRES TOO HOT OR COLD . .9 TROUBLESHOOTING BRICK PROBLEMS . .3 Firing with Cones . .9 TROUBLESHOOTING ELEMENT PROBLEMS . .3 Easy-Fire vs Vary-Fire (Auto) . .9 TROUBLESHOOTING FIRING PROBLEMS WITH CONE Hold Times . .10 PACKS . .3 Control Settings . .10 THE CERAMIC PROCESS . .3 Thermocouple Drift . .10 REPLACEMENT PARTS . .3 KILN STALLS . .10 SERVICE . .3 KILN FIRES SLOWLY . .10 GENERAL TROUBLESHOOTING TOOLS AND Bad or Wrong Voltage . .10 METHODS . .3 Element Aging . .11 BASIC TOOLS REQUIRED . .3 Power Relays . .11 KEYS TO GOOD TROUBLESHOOTING . .4 Bad Wiring . .11 SAFETY FIRST . .4 Wiring in the Kiln . .11 DEFINE THE VARIABLES . .4 Element Connections . .12 ELIMINATE VARIABLES ONE AT A TIME . .4 Heat Leakage & Vents . .12 Single vs Three Zone Control . .12 TROUBLESHOOTING CHECKLISTS . .4 LAG Setting . .13 TROUBLESHOOTING CHECKLIST . .4 Autolag Setting . .13 CONTROL DISPLAY DOESN’T SHOW ANYTHING ShtO (Shut-Off) Setting . .13 (AUTO KILN) . .4 PId Setting . .14 On/Off Switch . .4 Adding More Insulation . .14 Control Fuse . .4 KILN HEATS TOO FAST . .15 Branch Fusing . .4 Voltage . .15 Plug & Cord (if you have one) . .4 Elements . .15 Circuit Breaker / Power Source . .4 Internal Wiring . .5 THE KILN FIRES SLOWLY (MANUAL) . .15 Short Circuits . .5 TROUBLESHOOTING VARIABLES . .15 Control Transformer . .5 Control Board . .6 THE KILN BODY . .16 Layout and Configurations . .16 THE KILN DOESN’T HEAT AT ALL (MANUAL Firebrick . .16 KILNS) . .6 Firebrick Problems and Repair . .16 DISPLAY READS FAIL (AUTO) . .6 Lids and Floors . .16 Stainless Steel Bands . .17 DISPLAY READS 2400 or CPLt WHEN IT STARTS Kiln Stand . .17 UP (AUTO) . .6 Jupiter Stands with Vent Collection Box . .18 Hardware . .18 DISPLAY IS NORMAL BUT KILN WON’T HEAT Econo/Jupiter Standard Lid Hinge . .18 UP (AUTO) . .7 Jupiter “Easy-Lift, Easy-Load” Spring Loaded Hinges . .19 Programming . .7 DaVinci Lid Hinge and Counterbalance . .19 Wiring . .7 Element Holders . .20 Control Board Outputs . .7 Element Holder Replacement . .20 Bad Power Relays . .7 Bad Elements . .7 HEATING ELEMENTS . .20 CIRCUIT . .20 KILN FIRES UNEVENLY . .7 POWER SUPPLY . .20 Peepholes . .7 INSULATION . .21 Lid Seal . .7 ELEMENTS . .21 Elements . .8 ELEMENT TROUBLESHOOTING . .21 Loading . .8 Firing with Cones . .8 KILN ATMOSPHERE & VENTING . .21 troubleshoot-general.pdf 3/1/2004 Rev 4.0 Page 1 2004 L&L Kiln Mfg, Inc. P.O.B 1898, Boothwyn, PA 19061 P:610.485.1789 F:610.485.4665 E:[email protected] www.hotkilns.com GENERAL L&L KILN TROUBLESHOOTING GUIDE INSTALLATION CODES . .21 Wire size too small . .42 GENERAL ROOM VENTILATION . .21 Corrosion . .42 MANUAL VENTING . .21 Dedicated circuit . .42 POWER VENTING . .21 Melting power cord . .42 THE CONTROL . .22 CONCLUSION AND REMINDERS . .42 MANUAL CONTROL . .22 FEEDBACK . .42 AUTOMATIC CONTROL . .22 SERVICEABILITY . .23 SAFETY WARNING . .23 CAUTION - ELECTRICITY CAN KILL GENERAL INFORMATION . .23 Many of the tests described in here are performed REPLACING WIRE TERMINALS . .23 under power. They should be done ONLY by someone MANUAL KILN SWITCHBOX . .23 who is familiar with electrical safety such as an electrician or trained maintenance person. We identify DIAGNOSE A SLOW-FIRING MANUALLY any test that is live with a CAUTION statement. We CONTROLLED KILN & GENERAL TACTICS 24 describe these tests in detail so that an electrically trained MANUAL DAWSON KILN SITTER . .28 person who doesn’t specifically understand kilns can do the troubleshooting - the level of simplicity described is not BASICS . .28 meant as an invitation to harm the untrained. AS LONG The kiln-sitters are used either as a safety backup or as the AS THE KILN IS UNPLUGGED YOU ARE SAFE. primary turn-off control. .29 How the Kiln-Sitter/Timer works . .29 A) The timer . .29 GET A DIGITAL MULTIMETER! B) The shut-off mechanism . .29 If you want to do much of the troubleshooting described Potential Problems with the Dawson . ..