Warning and Cautionary Statements:

Read and understand all warning statements before proceeding:

Warning: The following may involve exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  

Warning: Some sections of this manual may require the Load Unit and Hydraulic Pump be de-energized and locked out and tagged out according to all local and facility regulations. Failure to do so could lead to serious injury or death

Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.    

Warning: Hot surfaces may be present which could result in severe burns.  Wear suitable Personal Protective Equipment to avoid injury from accidental contact with hot surfaces.  

Warning: The Gleeble is capable of generating strong electromagnetic fields. Individuals with pacemakers or other medical equipment should not use or work on the Gleeble. Failure to obey can result in serious injury or death.

Caution: Improper measurements or mishandling of measurement equipment could result in damage to equipment. This work must be performed by experienced, qualified personnel.

Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump 

Caution:  Observing test samples at elevated temperature could lead to vision damage. Proper vision protection must be used when observing samples at high temperature.

Caution: The reader should fully understand all instructions listed in this article. If any points are unclear or the reader is uncomfortable performing any listed steps they should contact DSI before proceeding with any of the listed actions. 

                                                                                                                      

Troubleshooting Steps:

All steps mentioned here assume that the Gleeble system is in proper operating condition (not an emergency stopped condition) and that the main vacuum pump power is connected.

Turn on Main Air Supply:

The vacuum pump will need to have a supply of compressed air going to it in order for the pump to function properly.

1. Go to your facilities main air supply for the Gleeble system, verify that there is pressure and ensure all valves are open allowing air flow. The Gleeble system will operate correctly on 60psi up to 120psi of compressed air of quality class 2 (as defined by ANSI/ISA-7.0.01-1996). 
   
2. Go to the console and try to turn on the rough pump. If it works, then no further action is required. If it does not, then continue checking the air supply in the next steps.
   
3. After confirming that the main air supply to the Gleeble is ON, verify that the vacuum pump's air hose is connected to the Gleeble's air/water distribution block:
   

                                                                                                                         

1. Next, verify that the vacuum unit's air pressure gauge reads at least 50psi: 
   

Note: The side panel to the right side of the vacuum unit. when standing at the front of the vacuum tank, must be removed to access the air pressure regulator.     

                                       

                                                                                                                          

1. Once it is found that there is at least 50psi of incoming air pressure, verify that the air pressure switch is closed. Disconnect the molex connection and with a multimeter set to measure resistance, measure the wires connected to the switch. If the switch is operating correctly, a low resistance will be measured, otherwise it will measure OL (or Open Loop).
   

If the switch measures Open Loop and there is pressure shown on the gauge, please contact DSI for further assistance.

If the switch was found to be closed, but the vacuum pump still does not turn on proceed to  Turn on Main Water Supply

Turn on Main Water Supply:

1. Verify that the chiller unit is on and the main water handles at the chiller's bulkhead are open.
   
2. Confirm water pressure between 35 and 70 psi as measured on the chiller's supply gauge.
   
3. At the Gleeble's air/water distribution block, ensure that the on/off switch is in the ON position and the two black knobs that straddle the switch are in the horizontal position. 
   
4. Ensure the vacuum pump water hoses are plugged into the manifold.
   

                                                                                                                                    

1. The floats inside the Gleeble water flow meters should be elevated, indicating there is water flow. The vacuum flow meter should indicate close to 1 GPM (gallons per minute) of water flow.
   
2. If each of the above conditions are true, using the multimeter set to ohms, check for continuity on the vacuum pump water flow switch. The water flow switch is located adjacent to the diffusion pump and has been outlined in the image below. When the switch is in proper operating condition, the multimeter will measure a low resistance, otherwise it will measure Open Loop as found in the procedure for the pressure switch. If the switch is determined to be faulty, please contact DSI for further assistance. 
   

                                                                                                                                   

If turning on the main water supply has succeeded then no further action is needed.

If it has failed please proceed to  Check Rough Pump Temperature Switch.

Check Rough Pump Temperature Switch

Warning: The following involves exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  

                                                                                                                                 

1. Remove wire 409 from position DIO5-6 on the upper green combicon connector. Reference wiring drawing 3000VAC04 to confirm the wire location on your machines wiring revision.
   
2. Check the wires electrical continuity to a ground reference terminal block (green/yellow terminal bock).
   
3. If a high electrical resistance or open circuit is measured:
   
1. An over temperature event has most likely occurred with the rough pump causing the rough pump temperature sensor to trip.
   
2. Degraded vacuum oil is the most common cause of a rough pump overheating. Try replacing the rough pump oil as is described in the (Series 3/GTC) 38045/38046 Vacuum General Maintenance- Maintenance article. 
   
4. If a low electrical resistance is measured:
   
1. Re-attach wire 409
   
2. Remove and check the pump temp brown barrel fuse for electrical continuity. The fuse is located directly to the left of the white relay found in position DIO5-13. Replace the fuse if it is blown (DSI Part Number: FS072). 
   
3. If the fuse seems to be intact, try replacing the white relay located in position DIO5-13 (DSI Part Number: SC0042).
   

If investigating the rough pump temperature switch has been successful, contact DSI for any required replacement parts

If the issue still exists, proceed to  Check Red Relays.

Check Red Relays

Warning: The following involves exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  

1. Turn the rough pump on via the console button. 
   
2. Verify that the Pump Relay LED is toggling ON 
   
3. Using a multimeter set to measure DC Voltage, check for 24Vdc on the lower green combicon connector at location DIO5-25 (wire 321) while referencing ground. Reference electrical drawing 3000VAC03 to confirm the measurement location on your machines wiring revision. 
   
4. If 24Vdc is not measured at this location:
   
1.  Remove and check the Pump Relay brown barrel fuse for electrical continuity. The fuse is located directly to the left of the red relay found in position DIO5-10. Replace the fuse if it is blown   (DSI  Part Number: FS072). 
   
2.  If the fuse seems to be intact, try replacing the red relay located in position DIO5-10 (DSI Part Number: SC0041).
   
5. Verify that the Rough Valve LED is toggling ON
   
6. Using a multimeter set to measure DC Voltage, check for 24Vdc on the lower green combicon connector at location DIO5-21 (wire 317) while referencing ground. Reference electrical drawing 3000VAC03 to confirm the measurement location on your machines wiring revision. 
   
7. If 24Vdc is not measured at this location:
   
1. Remove and check the Pump Relay brown barrel fuse for electrical continuity. The fuse is located directly to the left of the red relay found in position DIO5-8. Replace the fuse if it is blown  (DSI  Part Number: FS072). 
   
2. If the fuse seems to be intact, try replacing the red relay located in position DIO5-8 (DSI Part Number: SC0041).

                                                                                                                                 

If Checking the Red Relays has succeeded, Contact DSI to receive a quote for any required parts.

if this step has failed please contact DSI for further assistance.