Furnace Web Site FAQs Pro Press 100 / Pro 100 / Pro 100 plus Lift Belt Noise • • • A Worn belt – Over time the belt may become dry or worn due to heat and travel. – Replace the belt Tight – If the belt was recently replaced or adjusted, the tension may be to high (to tight). – Adjust the belt Alignment – If the belt is rubbing against the chassis while traveling, it may make a squeaking or rubbing sound. – Adjust the belt Motor Noise • • Over tightening – If the motor was recently replaced then the screws holding the motor to the chassis may have been over tightened. If this is the case then the casing may be pulling away from the housing. This will be visible when the chassis top (keyboard) is opened. – Replace the motor. Dirty Motor brushes – If the motor brushes are dirty the motor will not function properly and sometimes make an audible grinding sound. – Remove the motor brushes and clean. Lift will not go up in steps • • Check the program parameters. Call Whip Mix to have the lift calibrated Lift will not go up or down • • If the motor will not go up, then the motor is bad or the main board is bad – Call Whip mix for support. If the motor will not go down then there may be vacuum in the muffle, if not then the motor or main board may be bad. Power The first things to check are the power cord (plugged in?), the circuit breaker and the fuses. Fuses • • Melted Fuse Holder – Power loss accompanied by the smell of burning plastic is a possible indicator that the fuse holders have melted due to overheating, power surge, increased resistance on the power board terminals. – This can be repaired at whip Mix or replaced. Stuck fuse holder socket – If a fuse has gone out and cannot be removed completely. It was probably over tightened or turned in the wrong direction. – Unplug the unit and remove the remaining fuse segments, replace with a new fuse and install power cord. Make sure the unit has power, if not then check the power section of the FAQs. Temperature Runaway Temperature • This is usually caused by a failed relay stuck in the closed position. This can be brought on be excessive heat. If the unit is placed to close to other devises that generate heat or is in a room with poor circulation. – Replace the relay, check the surrounding area, and check airflow. No Heat • The muffle wire (element) has opened (broken) or the solid-state relay has failed in the open state. If the wire failed there are sometimes scorch marks in the section of the muffle that the wire failed. If the relay failed the unit will not heat even with a new muffle. Vacuum Vacuum Leak: A vacuum leak can come from anywhere there is an opening in the vacuum system. Vacuum valve plungers that have worn over time usually cause them, sometimes the vacuum pump can be weak causing the same effect to the porcelain. 1. Run a vacuum test (User Manual) a. If the numbers on the left and middle drop after a short time then there is a leak. 2. Clean the table 3. To find a vacuum leak a. Remove the back cover b. Locate a pair of hemostats or vice grips c. Run a vacuum test and leave it in the hold mode d. Clamp the clear vacuum hose (near the lift) e. If the numbers stop dropping then the vacuum leak is in or near the muffle. f. If the numbers continue to drop then the leak is at or near the vacuum valves. If this happens then the numbers will decrease very quickly. 4. If the vacuum leak is near the muffle: a. The thermocouple potting may have come away from the bolt it sits in. b. If the thermocouple was replaced recently then check for sufficient Teflon tape on the thermocouple and brass plug on the top of the muffle next to the thermocouple. 5. If the Vacuum leak is in the lower half of the furnace then the vacuum valve plungers are usually the culprits. Replace the plungers. Vacuum will not release: 1. Limit switch malfunction 2. Vacuum valve plunger failure 3. Vacuum sensor failure If the vacuum will not release and work is in the muffle, unplug the unit, remove the top cover, and unscrew the brass plug on the top of the muffle next to the thermocouple. This will release the vacuum. Lower the table using a large flat head screwdriver. Using the brass bolt at the back and bottom of the unit. Once the work has been removed, replace the brass plug (using Teflon tape) and the top cover. Run a vacuum test (Special Functions Menu – Test Furnace) • • When the vacuum test is initiated and the table is down (all the way) the number on the right will read “99”. If the table is between top and bottom it will read “0”. If the table is all the way up it will read “99” and the pump will begin to run. The table has to be up and the display reading “99” in order for the vacuum test to begin. If the vacuum test runs and the vacuum will still not be released then the vacuum valve plungers probably need to be replaced, specifically the on toward the front of the furnace. The vacuum valve plungers are inside the furnace where the vacuum hose is plugged. Vacuum will not rise: • Check the vacuum hose connection and vacuum pump. • Run a vacuum program, when the vacuum pump starts, listen to see if the sound of rushing air can be heard near where the vacuum hose plugs in. If so then one of the vacuum valves has failed. General Malfunction If the furnace displays a series of blocks on the top line of the display, then the logic board has lost all memory and will need to be reprogrammed at Whip Mix. Error Messages 1. “Start =Load code”. Furnace software has not been loaded. Generated by the kernel. 2. “No code box”. Kernel tried to load software from the blue box but failed to find the blue box. Check if the blue box is attached. If it is, it may be damaged. Generated by the kernel. 3. “COMPUTER FAILURE”. Error generated by the kernel indicating that CPU has encountered an internal error. This message is sometimes accompanied by another message explaining the nature of the error. 4. “CPU clock fail”. CPU has detected an incorrect oscillator/clock signal. Could mean a bad oscillator, bad CPU (HC11), unstable power line, etc. Generated by the kernel. 5. “COP watchdog”. A bad CPU, bad oscillator, unstable power line, bad fan switch, bad SSR, or software error could cause this error, which is generated by the kernel. 6. “Illegal opcode”. A bad CPU, bad RAM, or error in software can cause this error, which is generated by the kernel. 7. “Software irq”. This error is caused by an illegal interrupt request, usually generated by a software error, but could also mean a bad CPU, bad RAM, etc. Generated by the kernel. 8. “Unknown error”. Unknown error. motherboard, or software error. Can be caused by bad CPU, bad 9. “Connect meter!” This error is generated only on the version of software supporting automatic temperature calibration. If this error occurs, check if the appropriate Omega thermometer is connected to the printer port through the RS232 (Calibration) adapter. 10. “*ABORTED*”. Program was aborted manually. 11. “Check meter!” This error is generated only on the version of software supporting automatic temperature calibration. This error indicates problems with the external temperature meter. Check if the meter set to the proper thermocouple type (R), and that it displays reasonable temperature. Restart the process. 12. “Press Failed!!!” Press did not move up and down properly during the press test that is run before each pressing program. Check all press and press sensor board wiring. Check the pressure supply line. 13. “No Connection!!” This error is generated only on the versions of software that support silver wire calibration. This error indicates that the silver wire is disconnected even before the calibration temperature was reached. Check how tightly silver wire is wrapped around the posts. 14. “Thermo cpl error”. This error is generated if furnace reads temperature above 1200°C, it thermocouple is disconnected, or if open thermocouple is detected. • • The thermocouple circuit is open. This is usually an indication that the thermocouple has failed or gone out. – Replace the thermocouple. The unit has overheated above 1200C for more than 1 minute. – Check solid-state relay and thermocouple. If the previous are ok, then the main board may need to be checked 15. “No vacuum”. Furnace cannot pull vacuum. Check if vacuum pump is connected (both the power and the air tube). Check vacuum valves. Sometimes this error indicates bad top limit switch. 16. “Not enough vac”. Furnace cannot maintain vacuum or pull vacuum fast enough. Check for obvious leaks. Sometimes this error indicates bad top limit switch. 17. “Receive Error”. Furnace cannot read programs from the red box. Check if the red box is connected. If it is, this error may indicate bad red box 18. “Duplicate name”. You have tried to enter a program with the name that already exists. 19. “Program running”. program is running. Certain operations cannot be performed while a 20. “Printer problem”. Problem has been encountered while trying to print. Check printer connection, printer status (on/off, paper, jam, etc.) 21. “Vacuum not zero”. Furnace has detected vacuum in the chamber. Certain operations cannot be performed with the vacuum in the chamber. 22. “Cal temp error”. Error has been encountered while trying to calibrate temperature. Check parameters and try again. 23. “Transmit Error”. Cannot write programs to the red box. Check the presence of the red box. On older versions of software it is possible to receive this error even with a good red box. Try writing to it multiple times. 24. “Check Programs”. Program memory area is corrupted. 25. “Calibrate Temp”. Temperature calibration memory area is corrupted. Recalibrate temperature. 26. “Calibrate Vacuum”. Recalibrate vacuum. Vacuum calibration memory area is corrupted. 27. “Calibrate Lift”. Error was found in lift operation. Recalibrate lift. Sometimes this error indicates bad limit switch or corrupted memory. 28. “Check Memory”. General memory is corrupted. Check furnace settings (idle temperature, night mode temperature, etc.) 29. “Low Voltage” When a Low Voltage warning occurs on the display there are two possibilities, internal malfunction or low external supply: If the low voltage warning appears erratically then the most probable possibility is an external cause. If the low voltage warning happens consistently than an internal malfunction is possible. Intermittent low voltage: 1. Has the voltage supplied from the outlet on the wall been low? 2. Is the furnace power cord on an extension cord or an outlet multiplier? The furnace should be on it’s own outlet or dedicated outlet. 3. Is there any large devise (such as an air conditioner or other large equipment) in the building that turns on and off in conjunction with the low voltage warning? If yes was answered to any of the questions above, the following may be the solution to the problem: 1. Ensure the proper voltage on the outlet line. 2. Place the furnace on it’s own dedicated outlet. 3. Check for other devises in the building or buildings in close proximity for large devises that may be causing the low voltage. Then suggest the use of a power conditioner if this is the case. Maintenance Download the user’s manual.