Troubleshooting Experimental Electric Furnace: Temperature Fluctuation & Heating Element Damage

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Troubleshooting Experimental Electric Furnace: Temperature Fluctuation & Heating Element Damage

As a core heating equipment in laboratories, the experimental electric furnace is widely used in scenarios such as material sintering and sample annealing. Its operational stability directly affects experimental results. During long-term use, temperature fluctuation and heating element damage are frequent faults, which will interfere with the experimental process and even lead to the scrapping of experimental samples. This article focuses on these two major faults, disassembles the troubleshooting steps and corresponding solutions, and helps to quickly solve problems and ensure the operation of the equipment.

I. Temperature Fluctuation Fault: Troubleshooting and Handling

Temperature fluctuation refers to the actual temperature inside the furnace deviating from the set value with a fluctuation exceeding ±5℃, which is manifested as sudden rise and fall during heating and unstable constant temperature, and will affect the repeatability of experimental data. Its causes involve power supply, temperature control, sealing, environment, etc., and need to be investigated in accordance with the principle of "from easy to difficult".

1. Core Troubleshooting Steps

- Check Power Supply Stability: Use a multimeter with an accuracy of ≥0.5 class to monitor the power supply voltage for 5-10 minutes and check if the voltage fluctuation exceeds ±10V; at the same time, inspect the insulation layer of the line, plug oxidation and terminal looseness. Voltage fluctuation of high-power experimental electric furnaces is likely to cause temperature abnormalities.

- Test Temperature Control System: Investigate the core components one by one: ① Temperature controller: Check for errors, and calibrate PID parameters if there is no abnormality; ② Thermocouple: Inspect the probe status, wiring firmness and installation position, and replace with spare parts for testing if a fault is suspected; ③ Solid-state relay (SSR): Use a multimeter to measure on-off status. Poor conduction or adhesion will cause severe temperature fluctuation.

- Check Furnace Door and Interior: Observe if the sealing strip is aging or damaged, and verify the sealing performance with the "paper strip test method"; check if the thermal insulation layer is peeled off or carbonized. Poor sealing or thermal insulation will lead to heat loss and cause fluctuation.

- Eliminate Environmental Interference: Keep away from strong air flow and temperature-changing environments, and do not share the circuit with high-power equipment; place samples evenly, with the total amount not exceeding 1/3 of the furnace cavity, and pre-treat volatile samples in advance.

2. Corresponding Handling Solutions

- Power supply problems: Install a high-precision voltage stabilizer if the voltage fluctuation exceeds the allowable range; replace aging or oxidized lines and plugs, and fasten the terminals after applying conductive paste.

- Temperature control system faults: For abnormal controller parameters, back up and restore factory settings for calibration; contact for maintenance if ineffective; replace damaged thermocouples with the same model and install them standardly; replace SSR according to original parameters, distinguishing input and output terminals.

- Sealing and thermal insulation problems: Replace damaged sealing strips and clean the sealing groove; contact the manufacturer for professional maintenance if the thermal insulation layer is damaged, and avoid disassembly by yourself.

- Environmental and sample problems: Adjust the placement of the electric furnace, keeping a distance of ≥1m from interference sources; place samples evenly in the middle layer of the furnace cavity, and pre-treat volatile samples in advance.

II. Heating Element Damage Fault: Troubleshooting and Handling

Heating elements are the core of heat generation in electric furnaces, with common types including nickel-chromium resistance wire and silicon carbide rod. Damage manifestations include inability to heat up, slow heating, uneven temperature, and even breakage and deformation in severe cases. The causes include high-temperature aging, overvoltage impact, poor contact, atmospheric corrosion, etc., which need to be accurately investigated.

1. Core Troubleshooting Steps

- Visual Inspection: After cutting off the power and cooling to room temperature, observe if the heating element is broken, deformed, oxidized or peeled off; for hidden elements, the side cover can be removed for auxiliary inspection.

- Multimeter Detection: Check the manual to confirm the nominal resistance, and measure with a multimeter. If the resistance is infinite or the deviation from the nominal value exceeds ±10%, timely replacement is required.

- Investigate Inducing Factors: After confirming the element damage, investigate the inducing factors: ① Whether there is overvoltage in the power supply; ② Whether there are frequent starts and stops; ③ Whether there is corrosive atmosphere in the furnace; ④ Whether the terminals are oxidized or loose; ⑤ Whether there is over-temperature operation.

2. Corresponding Handling Solutions

- Replace elements: Select suitable products according to the electric furnace model and original element specifications, operate after cooling, handle with care, install firmly and keep a safe distance; conduct no-load heating test after replacement, and use only after confirming no abnormality.

- Solve inducing factors: ① Install overvoltage protector and voltage stabilizer; ② Replace with corrosion-resistant elements in corrosive atmosphere, and replace the atmosphere with inert gas before the experiment; ③ Polish the oxide layer of the terminals and fasten them, replace if severely damaged; ④ Set parameters according to the rated temperature, set the over-temperature protection threshold and check regularly.

III. Daily Maintenance Suggestions

Scientific maintenance can extend the service life of the electric furnace and reduce the incidence of faults. The key points are as follows: ① Check the power supply lines, plugs and terminals weekly; ② Clean the debris on the sealing surface and the oxide scale on the elements weekly; ③ Calibrate the temperature controller and thermocouple monthly; ④ Select suitable heating elements according to experimental requirements; ⑤ Standardize the start-stop and heating-cooling operations; ⑥ Clean, cut off the power, and prevent dust and moisture when not in use for a long time.

Zhengzhou Protech Technology Co.,LTD is a professional manufacturer specializing in tube furnaces, muffle furnaces, atmosphere furnaces, and vacuum furnaces. We are committed to providing targeted solutions to meet your diverse heating equipment needs.

For customized heating solutions tailored to your specific requirements, feel free to get in touch with us:
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