Kiln controllers are essential tools for achieving precise and consistent firing results, but like any technology, they can occasionally encounter errors. Understanding these errors and knowing how to troubleshoot them can save you time, frustration, and ensure your kiln operates smoothly. In this guide, we’ll cover some of the most common kiln controller errors, their causes, and actionable solutions.
1. Err1: Slow Temperature Rise
The Err1 error is one of the most common issues kiln users encounter. It occurs when the kiln’s temperature rises too slowly—less than 12°F per hour over a 22.5-minute period during a ramping phase. This error is typically caused by heating problems within the kiln, not the controller itself. To diagnose and resolve this issue, Bartlett Instrument Company recommends performing a Full Power Test.
How to Troubleshoot Err1
- Run a full power test on your kiln. If the Full Power Test doesn't yield a solution, try the other solutions below.
- Examine your elements for black spots, broken wires, and broken elements.
- If all the elements heat, check the resistance of the elements according to the kiln manufacture's guide lines.
- Check the voltage to the kiln to ensure it matches the voltage listed on the kiln's specification plate.
- If the elements have the correct resistance a relay may be at fault.
- If it occurs at random temperatures, electrical noise from the relays is likely the problem. A chattering relay or faulty varistors can both cause excessive noise. Boards damaged by electro static discharge (ESD or static charges) are more susceptible to electrical noise and a new board may correct the situation.
2. FAIL or TC FAIL: Thermocouple Issues
A FAIL error occurs when one or more thermocouples fail or the controller malfunctions. This error is common and can disrupt your firing process.
How to Troubleshoot FAIL Errors
- Thermocouple Bypass Test: Disconnect the power and remove the controller. Place a jumper (e.g., a paperclip) between the screws where the thermocouple connects. Power the kiln and clear the FAIL message. If the error persists, the controller may need repair. If the error disappears, replace the thermocouple.
- Keep Spare Thermocouples: Thermocouples are one of the most frequently replaced parts in a kiln. Keeping spares ensures you can quickly replace a faulty thermocouple and resume firing.
3. E-bd: Overheating Circuit Board
The E-bd error indicates that the controller’s circuit board temperature has exceeded the safe range (0°F–160°F). This can lead to permanent damage if not addressed promptly.
How to Troubleshoot E-bd Errors
- Ensure Proper Ventilation: Make sure the kiln room has adequate airflow to prevent overheating.
- Use a Fan: If overheating persists, place a fan near the controller to improve cooling.
- Check Board Temperature: Scroll through the controller menu until "bd T" appears to check the board temperature. If the reading is inaccurate, the board may need repair.
4. STUC: Stuck Button
A STUC error occurs when a button on the controller is held down for too long or becomes physically stuck.
How to Troubleshoot STUC Errors
- Release the Button: If the error occurs while pressing a button, simply release it.
- Fix a Stuck Key: If the error persists, use a hair dryer on low heat to warm the keypad and smooth out any air bubbles under the overlay. If this doesn’t work, the controller may need repair.
5. Using Diagnostic Tools
Bartlett controllers offer built-in diagnostic features to help identify issues with kiln outputs and relays. For example:
- Hot Key #8: Press the #8 key during firing your V6CF or RTC1000 controller to check which section of the kiln is heating. Decimal points will light up to indicate the active sections. See our full guide for me.
- Controller Diagnostics: Run a diagnostics test to check each output individually. This can help pinpoint issues with specific kiln components.
- Genesis: Go to Menu, then Diagnostics. Here you can view the board temperature, run a manual diagnostics check, run new element diagnostics, or check your relay health.
- V6CF or RTC1000: See our full diagnostics guide for these controllers.
6. Preventative Maintenance Tips
To minimize errors and ensure your kiln operates efficiently:
- Inspect Thermocouples: Replace thermocouples regularly, especially if they are bent, cracked, or discolored.
- Check Kiln Elements: Look for dark spots, broken wires, or worn elements.
- Ensure Proper Ventilation: Prevent overheating by maintaining good airflow in the kiln room.
Need More Help?
While this guide covers some of the most common kiln controller errors, there are many other error codes that you may encounter. For a complete list of error codes and detailed troubleshooting steps, visit our Troubleshooting Page.
