Standard Electric Kilns

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Standard Electric Kilns Operating Manual

Division of Haugen Mfg.P. O. Box 1347, 4225 Thurmon Tanner Parkway Flowery Branch, GA 30542

Sales (800) 241-4400 Help Line (770) 967-4009 Fax (770) 967-1196 Email [email protected]

www.greatkilns.com

Building the Finest Kilns for Your Creative Spirit!


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CORRECTIONS of ERRORS and OMISSIONSWe have made every effort to ensure the accuracy of theinformation provided in this manual; however, we reserve theright to correct any errors and/or omissions found in this manual.


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CONTENTS Page Number

Model & Serial Number Identication ...........................................................3

Locating Your Kiln..........................................................................................4

Electrical Requirements .................................................................................4

Assembly & Preparation of Your Kiln .............................................................7Taking Apart a Stackable Electric Kiln ....................................................8Counter Weight Lid System ...................................................................9

Kiln Operation...............................................................................................15Kiln Equipped with Pyrometer...............................................................15Kiln Equipped with Electronic Controller ..............................................16Electro Sitter..........................................................................................24Electronic Wall Unit..............................................................................253 Zone Control .....................................................................................25Dual Media...........................................................................................25Electric Raku .........................................................................................26

Loading Kiln for Pottery and Ceramics ...........................................................28

Kiln Firing......................................................................................................30

Kiln Maintenance ..........................................................................................32Replacing Parts .....................................................................................33

Kiln Troubleshooting......................................................................................39

Warranty .......................................................................................................Back Cover



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Congratulations on your purchase of an Olympic Kiln! You have every reason to be proud and to feel you havethe very best kiln. Your kiln, with the proper care, will provide you many years of dependable rings. Enjoy and

Happy Firings!

Firing your ware is an art, not a science. You may need several tests

and trials to perfect your rings. This book will give you suggestionson how to re your kiln, but ultimately you will have your own

unique ring method.

If you have any additional questions that are not covered in the manual, please contact your distributor or useither by phone (770) 967-4009, e-mail ([email protected]) or fax (770) 967-1196 and provide the kiln modelnumber and serial number located on the silver tag on the kiln.

Building the Finest Kilns for Your Creative Spirit!


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How to determine Kiln Model and Serial Number (SN):The serial tag is silver in color with black writing and is usually located on the back or side of the rst electricalbox on the standard kiln line.

Model DesignationOlympic Kiln models signify their interior dimensions on most kilns and letters are abbreviations of howthe kiln is built and equipped.

2327HE

DM dual media kiln designed for glass and ceramics ringE kiln equipped with an electronic controllerFL front loadingH high-re, 3 brick and kiln res to cone 10, 2350FHB HotBox, small 120 volt high ring kilns; ex: HB84EKS kiln equipped with kiln sitterP kiln equipped with pyrometerS a solid stainless steel jacket kilnT the kiln has a kiln sitter and timerTopHat dual media kiln designed for glass and ceramics ring

ELECTRIC KILN

MODEL XXXXXXXXXXXXSN XXXXXXVOLTS XXX AMPS XXXWATTS XXXXX PHASE X HZ XXMAX. TEMP XXXXF CONE XX

When Operating: FireOnlyonMetalStandProvided

AvoidContactwithOutsideofKilnDuringFiring

Provide10-inchMinimumClearanceBetweenKiln

and Wall or Other Combustibles DisconnectPowerSupplyCordWhenInterior

Reaches Maximum Temperature

HAUGEN MANUFACTURING INC.

4225 THURMON TANNER ROAD

FLOWERY BRANCH, GA 30542

Kilnisequippedwithanelectroniccontroller

Kilnsinteriordepthis27

Kilnsinteriorwidthis233/8

Kilnhas3brickandrestocone10,2350F

Model & Serial Number Identifcation


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1. Adequate space at least 12 inches of space between the kiln and the wall. (However, for operatorcomfort, allow room to walk around the kiln if maintenance is required. Stackable kilns requiretightening of the kiln rings while ring for proper alignment.)

2. All ammable materials such as curtains, plastics, etc. in the area of the kiln should be removed.3. Choose a dry, well-ventilated area with good access to allow easy loading and unloading, yet out of

the way of children and other activities.

4. For kilns equipped with a power cord, place the kiln so that the cord can be plugged in withouttouching the stainless steel jacket.

5. Because all kilns generate heat, the frame should be placed on a concrete or non-combustible oor.6. If the kiln is to be placed outside, make sure it doesnt get wet.7. Remember to use sheet metal or non-ammable material to shim the legs when leveling the kiln.8. Before your rst ring, vacuum the inside of the kiln to remove any dust caused by shipping.

ELECTRICAL HOOK-UPTo provide the performance it was designed to give, your new kiln must have the proper outlet and breaker tosupply adequate voltage and amperage. An incorrect connection may cause disappointing or even hazardousresults. A qualied electrician needs to be consulted to determine whether your wiring is adequate.

Electric kilns running on 120 volts will plug into a standard outlet if the power cord is a NEMA 5-15 butrequire a NEMA 5-20 receptacle if the power cord is 5-20. Any kiln running over 24 amps with a powercord will have a NEMA 6-50 plug. Any kiln over 50 amps will be direct wired. See congurations underelectrical specications chart.

Standard electric kilns will run on 240 volts, single phase. If your kiln was ordered 208 volts, single or three-phase power, it will be noted on the nameplate on the kiln.

Any kiln ordered three-phase will be direct wired. Please review the following chart for proper hook-upinformation.

Note: Olympic Kilns creates new kilns every year and the model number may not be on the chart. TheOlympic Kilns web site www.greatkilns.com will always have the latest and most updated informationavailable. Check the site if you do not nd the model on the chart.

Locating Your Kiln

Electrical Requirements

RECEPTACLE, 2 POLE-3 WIRE GROUNDING NEMA CONFIGURATION


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Electrical Specications Standard Electric 120, 240-208 Volt Kilns

ModelAmps

120 voltsWatts

BreakerRequired

Copper WireSize

Receptacle,2 Pole-3 Wire

NEMAConguration

HB64, HotBox, HB86,HB84, HB89, DOLL/TEST

15 1,800 20#12, #10 if circuit is

longer than 40 ft.5-15R

129FL, 139FL 15 1,800 20 #12, #10 if circuit islonger than 40 ft.

5-15R

129, 1214-120,1214 E Raku

16 1,920 20#12, #10 if circuit is


ModelAmps

240/208volts

WattsBreaker

Required240/208 volts

Copper WireSize


NEMA Conguration240/208

1214FL, 1214-240 13/15 3,120 20#12, #10 if circuit is


149FL, 1414FL, 1414,Freedom 1414HE

15/17 3,600 20/30 #12, #10 if circuit islonger than 40 ft.

6-30R

S1814 20/23 4,800 30#10, #8 if circuit islonger than 40 ft.

6-30R

1818FL, S18, S18H, 1818,1818H

21/24 5,040 30#10, #8 if circuit islonger than 40 ft.

6-30R

TopHat 189 26/28 6,240 40#10, #8 if circuit islonger than 40 ft.

6-50R

1823FL, S1823, S1823HE 26/30 6,240 40#10, #8 if circuit islonger than 40 ft.

6-50R

1823 E Raku, 1823

(formerly 1823W), 1823H,Freedom 1823HE

26.25/30 6,300 40 #10, #8 if circuit islonger than 40 ft. 6-50R

DM 1818HE 29/32 6,960 40#8, #6 if circuit islonger than 40 ft.

6-50R

1827, 1827H 31/36 7,560 40/50#8, #6 if circuit islonger than 40 ft.

6-50R

DM 1823HE 34/38 8,160 40/50#8, #6 if circuit islonger than 40 ft.

6-50R

2318H, 2818 34/40 8,400 50#6, #4 if circuit islonger than 40 ft.

6-50R

2518, 2523 35/40 8,400 50 #6, #4 if circuit islonger than 40 ft. 6-50R

2318, 2323 (formerly2323W), 2018

36/41 8,600 50#6, #4 if circuit islonger than 40 ft.

6-50R

TopHat 239 38/42 9,120 50/60#6, #4 if circuit islonger than 40 ft.

6-50R


6-50R


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ModelAmps

240/208volts

WattsBreakerRequired

240/208 volts

Copper WireSize


NEMA Conguration240/208

2323H, Freedom 2323HE,2818H

40/46 9,600 50/60#6, #4 if circuit islonger than 40 ft.

6-50R

2018H 41/47 9,840 60#6, #4 if circuit islonger than 40 ft.

6-50R

2518H, 3018, DM2318HE 42/48 10,080 60 #6, #4 if circuit islonger than 40 ft.

6-50R


6-50R/Direct Wired

2327, 2327H, Freedom2327HE, 2331

47/4811,280/9984

60#6, #4 if circuit islonger than 40 ft.

6-50R

2827 47/49 11,280 60/70#6, #4 if circuit islonger than 40 ft.

6-50R

2027 47/54 11,280 60/70#6, #4 if circuit islonger than 40 ft.

6-50R/Direct Wired

DM2323HE, DM2818HE,

TopHat 2814 48/54 11,520 60/70

#6, #4 if circuit is

longer than 40 ft. 6-50R/Direct Wired

2823H, Freedom 2823HE,2023H, 2523H, 2527

48/55 11,520 60/70#6, #4 if circuit islonger than 40 ft.

6-50R/Direct Wired

2331H 54/62 13,080 70/80#4, #2 if circuit islonger than 40 ft.

Direct Wired

DM2327HE 55/56 13,200 70#4, #2 if circuit islonger than 40 ft.

Direct Wired


Direct Wired

DM2823HE, DM2023HE,

DM2523HE

56/63 13,440 70/80#4, #2 if circuit is

longer than 40 ft.

Direct Wired

2027H, 2527H, Freedom2527HE, 2827H, Freedom

2827HE, 302756/64 13,440 70/80

#4, #2 if circuit islonger than 40 ft.

Direct Wired

DM2827HE 64/72 15,360 80/100#4, #2 if circuit islonger than 40 ft.

Direct Wired


Direct Wired


Direct Wired

DM3018HE 67/71 16,080 90/100

#4, #2 if circuit is

longer than 40 ft. Direct Wired


Direct Wired

DM3023HE 78/88 18,720 100/120#4, #2 if circuit islonger than 40 ft.

Direct Wired


Direct Wired


Direct Wired


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Olympic 120-volt, Front Loader, Electric Raku, TopHat or Solid Jacket electric kilns are assembledupon arrival. After the kiln is unpacked or removed from the pallet, place the kiln directly on thestand; or in the case of a kiln with attached frame, place the kiln where it is to be located, plug-inand re away.

Kilns built in rings and those with counter weight lid systems must be disassembled from theshipping pallet then reassembled on the stand. The proper method is to remove the top ring andplace the bottom of the top ring at on the oor. Repeat for each section until you reach thebottom of the kiln. Place the bottom on the kiln stand with the hose clamps to the back. Level thekiln stand at this time. If shims are required to make the bottom level, or prevent rocking of thebottom on the stand, use only sheet metal under the legs of the stand. Now reassemble the kilnwith the observation holes to the front and electrical boxes aligned. Grasp the rings by the outsidesurface, and not by the rebrick, to avoid damaging the kiln.

Assembly & Preparation of Your Kiln


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Once the steps have been completed, the kiln will come apart in sections by lifting eachring straight up.

STEP 1.

Use a Phillips screwdriver to unscrewscrews on the ring lock on the topring of kiln. There are two ring locksper ring.

STEP 2.

Undo interbox plugs from receptacleof electrical boxes. Twisting andunlocking the plugs achieve this.

If the lid brace of your kiln wasdisconnected for shipping, it should

be reconnected. Slide arm throughbrace pads and secure with nut. Whenopening the lid, insure the lid brace islocked by hooking it to the body bracepad. Do not release kiln lid until thebrace is locked.Nut to

secure lidbrace arm

LidBraceArm

Body Brace Pad

Taking Apart a Stackable Electric Kiln


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Counter Weight Lid System

Installation Instructions for Taking Apart Kilns with Counter Weight Lid Option toMove through Small Openings and for Retrotting Kilns without Lid Option

Double Bar Single Bar

The counter weight lid system comes complete with stand, kiln feet and frame pieces for easy, simple installation.There are two systems, 1) double bar for oval and GF 2, 3, 6 series kilns; and 2) single bar for all other models.

Double Bar Counter Weight Lid System

Attach feet ontolegs of stand.

Insert horizontal back supportframe to frame pieces on stand.

Insert vertical back support frameuntil pieces lock in place.

For kilns ordered with a vent,the vent cup will need to beplaced on the frame of the

double bar stand before settingthe kiln oor on the stand.

Position kiln oor and rings on stand with hose clamps on the stainless steel jacketfacing the back supports. Plug in twist n lock interbox plugs and receptacles.


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Double Bar Counter Weight Lid System

Position arm lifter holes to match back of vertical back support holes and holes of lidhinge. Insert stiffening strut through holes and lock in place with cotter pin.

Tighten bolts on back of frame of lid opener. Lift kiln lid straight up and attach ringlock to arm lifter. Slowly lower lid to closed position.

When lid lifter is attached in back, insert boltinto front of bar and screw nut to hold.

Attach lid brace with nut and bolt. Screw ring locks in place.


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Single Bar Counter Weight Lid System

Tighten bolts on back of frameof lid opener.

Lift kiln lid straight up and attach ring lock to arm lifter.Slowly lower lid to closed position.

When lid lifter is attached in back, insertbolt into front of bar and screw nut to hold.

Attach lid brace with nut and bolt.

Screw locks in place.


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Your new kiln is constructed of insulating rebrickwhich is hand selected for the highest quality. Thislightweight brick is an efcient insulator, whichforms the ring chamber. In Olympics standardline of electric kilns the bricks are held togetherby compression of the stainless steel jacket. The

wall bricks are not cemented together to facilitatemaintenance of your kiln if necessary.

ElementsYour kiln is equipped with iron-chrome Kanthal A-1 type elements, suitable for high re use. Theelements are pinned in place to prevent contraction and intrusion into the ring chamber.

Kiln elements will become brittle after a few rings, so care should be taken if handling isnecessary. When your kiln is rst turned on, it is normal for the elements to hum for a short timeand the clicking sounds you hear are from the relays turning the elements on/off as they go throughthe ring cycle.

An element is designed to have a very long life and is capable of many rings. The lifespan can beshortened considerably by contact with materials such as bits of bisque, glaze, glass, cones, metal,or kiln wash. Keep your elements clean by vacuuming the inside of your kiln regularly.

Observation Holes/PlugsThe observation holes of the kiln allow viewing of the ring chamber and

pyrometric witness cones used in pottery and ceramics. They also providean escape for water vapor and gases. The tapered shape and mortar coatingof the peep hole insure a good t for an observation hole plug, andeliminate abrasion of the brick by the observation hole plug.

Use dark glasses or a number ve welders lens when looking throughan observation hole to reduce excessive glare from a hot ring chamber.Observation hole plugs are hollow ceramic and should be treated with care.

Pilot LightElectric kilns have a pilot indicator light, which illuminates when the kiln is activated.

Lid PropMany of the Olympic models come with a brick wedge to prop the kilnlid during the early stages of ring. The wedge is soft brick and will notabrade the refractory coating of the lid. DO NOT USE OTHER ITEMSSUCH AS KILN FURNITURE (SHELVES AND POSTS) AS A PROP SINCETHIS WILL DETERIORATE THE LID AND THE KILN BRICK.

Observation Hole Plugs

LID WEDGE

Firing Chamber


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BRICK WEDGES ARE NOT TO BE USED ON OVAL LIDS AND ARE NOT INCLUDED IN KILNACCESSORY BAGS FOR OVAL, HB64, HOTBOX, HB86, ELECTRIC RAKU, OR FRONT LOADINGMODELS.

Kiln StandYour kiln must be red only on the metal stand or frame provided. The space beneath the kilnis necessary for air circulation, and prevention of heat build up. ALWAYS make sure the stand islevel to avoid problems such as glaze ow, kiln sitter activation.

Power CordIf your kiln is equipped with a power cord, do not add extension cords to the kilns power cordplug. Doing so will void the warranty of the product. The power cord on a kiln is heavily insulatedand designed to meet UL requirements. A standard extension cord will not be able to handle thepower and may cause a re hazard.


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Kiln Operation

An innite switch controls the heating rate and power owing through the kiln. The pyrometershows the kiln temperature in the ring chamber. It can be used to help you control the heating orcooling rate of your kiln. It is the kiln operators responsibility to monitor the kiln at all times. Thesekilns do not have a shut-off device and must be turned off by the kiln operator.

If your kiln has the pyrometer installed on the kiln, you will adjust the temperature in the kiln byturning the innite switch either up or down. The kiln operator must turn the kiln off when thering is complete. Do not leave the kiln unattended while ring.

Wall-mounted pyrometer1) Most Olympic kilns have a hole punched through the stainless steel jacket that allows you to

drill a hole through the exposed brick for insertion of the thermocouple. The thermocoupleshould be inserted so it extends into the ring chamber 1 inch.

2) The pyrometer needs to be wall mounted awayfrom the kiln since the heat will damage theinstrument.

The pyrometer should registered around 100 Fat room temperature. If you need to calibrate thepyrometer, adjust the instrument by turning thesetscrew on the face below the meter.

Setscrew

KILN EQUIPPED WITH PYROMETER


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KILN EQUIPPED WITH AN ELECTRONIC CONTROLLERStandard electric kilns are equipped with the Bartlett Instruments 3-Key-Cone-Fire, V6-CF orRTC-1000 electronic controller.

KILN EQUIPPED WITH KILN SITTERRefer to kiln sitter manual for operating instructions.

Ceramic Cone-FireCone-Fire mode is based on pyrometric cones. It is not designed for heat-treating, glass fusing andenameling. Use Ramp-Hold to re ceramic pieces that require a custom ring schedule, such assome types of stoneware sculpture or crystalline glaze. To re faster than Cone-Fire Fast speed, useRamp-Hold.

Pyrometric Witness Cones in Ceramic FiringsAlthough the controller res the kilns electronically, every ceramic ring should include shelf orwitness cones. They measure heat work accurately and give a history of the ring.

If you re the same sized load and type of ware regularly, the shelf cones let you compare onering to the next and alert you when something is wrong. For example, if the shelf cone bendsfarther and farther with each consecutive ring, this may indicate thermocouple temperature drift.

The Orton Ceramic pyrometric cone charts on the following pages show end temperature range forslow and fast cone rings.


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BARTLETT 3 KEY-CONE FIRE CONTROLLERThe 3 Key-Cone Fire controller provides cone-re and ramp/hold

programming.

When power is applied, the display will ash rC-A, Idle, the

room temperature; example 77 for 77F.

The rC indicates the controller is programmed for cone-re andramp/hold.

The letter (A) indicates the software version.

IfErrP (means a loss in power) is displayed, press any key to clear this message.

IfStOP or IdLE is alternating with the current temperature, you are ready to begin programming.

Cone Fire ProgrammingSTEP DESCRIPTION

1. Start with the display reading IdLE, Press enter.

2. Select cone re. If C-Fr (cone-re) is displayed, press enter, if r-Hd (ramp/hold) is

displayed, press an arrow key to display C-Fr and then press enter.

3. dELA will display for Delay Start Set delay start The beginning of the ring can be delayed

from the time you press start. This allows the ring to start later and end when you can

supervise the end. Use the arrow keys to adjust the amount of delay and press enter. If you do

not wish to delay the ring, enter all 0000 and press enter.

4. PrH will display for preheat. Enter the preheat time. The rst segment of a cone re program

ramps to 200 F. The preheat time is the length of time you will hold at 200 F. Thin, dry clay may

not need any preheat time and thick hand-built items may require several hours of preheat. Use

the arrow key to adjust the preheat time and then press enter to store the value. REMEMBER

the time is displayed in the form HH.mm. H= hours, m=minutes, so anything after the decimal

point represents minutes and in front of the decimal point represents hours. If you do not need

to preheat your items, scroll to 0000 and press enter.

5. Enter Cone #. Use the arrow keys to display the desired cone number. The up arrow moves

toward a hotter cone number. Press enter to store the displayed cone number.

6. Slo, nnEd, FAS will be displayed for Slow, Medium and Fast. Select heating rate. Use arrow

keys to display Slow, Medium or Fast.

7. HLd is displayed for Hold Time. Enter hold time. A hold at the top temperature adds heat work

and can help produce a more even ring from top to bottom. Typical hold times are in the

10-15 minute range (00.15). Use the arrow keys to display the desired hold time and then press

enter to store the value. If you do not need hold time scroll to 0000 and press enter.

8. rEdl will display for Ready. Press enter to start the ring.

]]


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3 KEY-CONE FIRE CONTROLLER

Ramp/Hold ProgrammingThe controller has 4 user programs with 8 segments per program. Once you have entered a program for User 1,it remains there until you enter a new program. You can use each User program for different types of ring andthe program will remain in the controllers memory.

STEP DESCRIPTION1. Start with the display reading IdLE, Press enter.2. Select ramp hold. If rH is displayed, press enter, else press an arrow key to display rH and

then press enter.3. dELA will display for Delay Start Set delay start The beginning of the ring can be delayed from the

time you press start. This allows the ring to start later and end when you can supervise the end. Usethe arrow keys to adjust the amount of delay and press enter. Example: If you want to begin ring 5hours and 30 minutes after you key in the program, enter 530 and then press Enter. If you want the kilnto begin ring immediately scroll to 0000and press enter when the dELA message appears.

USr1, 2, 3 or 4 will display for the User program. Select the number you designate for the program and pressEnter.

SEG is displayed asking how many segments you desire to have throughout the ring. A segment is raising ordecreasing the temperature to a certain temperature in a period of time.Example: You have a piece that needs three segments: Use the up and down keys to reach the number 3 andpress enter.

rA 1 will display rate (rise or decline) of temperature per hour as rA1 for the rst segment. Use the up/down keyto enter the desired temperature and then press enter. F 1 will display for the target temperature for the rstsegment. Use the up/down keys to select the target temperature for each segment. Scroll to the temperaturerequired and press enter. HLd1 will display for any hold time needed during the segment. If time required, scroto the number of minutes or hours and press enter.

Example: 1st segment (rA1) raises temperature 150 degrees per hour to reach the (F1) or target temperature of

900 degrees. Scroll to 150, press enter. F1 will ash, scroll to 900, press enter. HLd1 will ash, scroll to 0000,press enter.2nd segment (rA2) raises temperature 200 degrees per hour to reach a target temperature of 1800 degrees (F2).Scroll to 200, press enter. F2 will ash, scroll to 1800, press enter. HLd2 will ash, scroll to 0000, press enter.3rd segment (rA3) decreases temperature 150 degrees per hour to reach 1000 (F3) degrees. Scroll to 150, pressenter. F3 will ash, scroll to 1000, press enter. HLd2 will ash, scroll to 0000, press enter.

rEdl is displayed for Ready after all the segments in a ring have been entered. Press START to begin the ring.If you have entered time for a delayed ring, press START and the controller will begin counting down until thedesired time is reached.

CPLt is displayed for Completion of Firing.Once your kiln has red, the display CPLt will ash to notify you that the kiln has completed the ring process.Allow the kiln to cool down before opening.

]]


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BARTLETT V6-CF CONTROLLER

STEPS FOR CONE FIRING

BARTLETT V6-CF CONTROLLER

Step 1: Turn the kiln on and

the message will displayERRP, press 1, which clearsthe display. Idle will displayalternately with the roomtemperature ashing on thecontroller display.

Step 2: Select one of theoptions for cone ring. Youcan think of the Slow and Fastbisque as ring the kiln at

Slow, Slow-Medium speedsand the Slow and Fast Glazeas ring the kiln at Mediumand Fast speeds. In otherwords, you can use the FastGlaze for bisque ring if youwant the kiln to re as fast asit can.

Once you select the option,press ENTER.

Step 3: Enter the cone numberyou wish to re; example Cone 05, press zero and veand then press ENTER.

Step 4: The controller willdisplay HLD, asking if youneed a hold time. If no, press0000 and ENTER. If yes,press the number of minutesand press ENTER.

Step 5: The controller displaywill read CPL for complete. Youmay now press START and thekiln will being ring.

VARY-FIRE RAMP/HOLD PROGRAMMINGOn the left hand side of the controller you may choose the VARY FIRE METHOD to re. This allows youto create your own programs for customized rings. Press ENTER PROG and then press ENTER.

USER 1 will be displayed. There are six programs in the controller identied as USER 1-6 with eightsegments per program.

Press ENTER after USER 1 is displayed and the controller will request how many segments you willneed. (If you wish to run one of the other User programs, press 2 - 6 to reach the desired program.) Asegment is a rate of rise in temperature per hour, which reaches an end point temperature and a hold time.Depending on the number of segments you need, press that number and then press ENTER.

Slow Rate FiringBisque or Glaze

Slow to Medium Rate FiringBisque or Glaze

Medium Rate FiringBisque or Glaze

Fast Firing RateBisque or Glaze


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The controller will then ask what the rate in rise is needed to run the rst segment. The controller willdisplay rA 1 for segment 1, rA 2 for segment 2 and so forth. Enter the degrees (example 250 F) youwant the kiln temperature to rise per hour and then press ENTER. You can also decrease temperature byfollowing the same steps and entering a lower end temperature at the completion of the segment.

The controller will ask what end temperature you want the kiln to reach in the designated segment(example 1250 F) and press ENTER. The controller will ask if you need to Hold for a certain amount oftime during the current segment. Enter the minutes or hours you need and press ENTER.When you have entered all your segments the controller will display ALAr for alarm. If you do not require

an alarm, press 9999 so that the alarm will not go off and press ENTER. If you require an alarm, enter thetemperature you want the alarm to sound.

The controller will display CPL for complete, press START if you are ready to re.

The USER programs stay in the controllers memory until you enter new information.

Under the Options section the feature DELAY allows you to delay ring until you are ready. After youhave entered your program and the START key, press DELAY, press ENTER, and the number of hours lateryou want the kiln to begin ring. Enter number of hours and press ENTER.

OTHER section allows you to preheat the ware in the kiln if needed.

BARTLETT RTC-1000 CONTROLLER

This controller is used primarily with glass, heat-treating, jewelry, enameling,and dual media kilns. There are six User programs with eight segments perprogram. Segment programming is determined by the rate of rise or decline intemperature required per segment with a target point temperature and hold.

The RTC-1000 controller provides cone-re and ramp/hold programming. Itallows the kiln operator to add time or skip a segment during a ring. If you

nd during a segment that you need to increase your hold time, press ADDTIME (2) and you will be able to increase the HOLD time in that segment. Ifyou nd you need to skip a segment in one of the USER programs, when thesegment comes up during the ring, press 9 and SStP will appear. Press ENTERand the segment will be skipped during the ring.

Press ENTER if the controller displays ERRP for power failure. The display should then read IDLE and youare ready to begin entering your program.

Press ENTER again and _ _ _ _ will be displayed. From _ _ _ _ press Ramp/Hold (4) and USER 1 willappear. There are six programs in the controller identied as USER 1-6 with eight segments per program.

The controller will request how many segments you will need or will already have a number ashing. Asegment is a rate of rise in temperature per hour, which reaches a target point temperature and a holdtime. Depending on the number of segments you need, press that number and then press ENTER.

The controller will then ask what the rate in rise or decline who need to run the rst segment. Thecontroller will display rA 1 for segment 1, rA 2 for segment 2 and so forth. Enter the amount of degrees(example 250 F) you want the kiln temperature to rise per hour and then press ENTER. You can alsodecrease temperature by following the same steps and entering a lower end temperature at the completionof the segment.


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RTC-1000Cone-Fire Programming

As the RTC 1000 prompts for cone, speed, etc., values entered for the last ring will appear. To use thesevalues again, press ENTER.

To re without Delay or Alarm:Follow steps 1-6 below.Then from IdLE press START twice.1. Apply power to the kiln.

2. ErrP will appear. Press ENTER. IdLE will appear.3. Press ENTER then 1. ConE will appear. Enter cone number. (If ---- appears instead of ConE,

your controller uses Ramp-Hold only.)4. Press ENTER. SPd will appear. Enter speed: Fast (1), Medium (2), Slow (3).5. Press ENTER. HLd will appear. Enter hold time, if any, in hours and minutes (i.e. 12 hours and 30

minutes = 12.30).6. Press ENTER. IdLE will appear.

7. To set alarm, press ENTER then 7. ALAr will appear. Enter alarm temperature. (Enter 9999 to turnalarm off.) Then press ENTER.

8. To set delay re, press ENTER then 3. dELA will appear. Enter delay time in hours and minutes

(i.e. 12 hours and 30 minutes = 12.30). Press ENTER. (Delay zeroes out after each ring.)9. To start program, press ENTER twice. -On- will appear, then time remaining until start. To stop the

program during re, press STOP.

The RTC-1000 controller provides the ability to add time or skip a segment during a ring. If yound during a segment that you need to increase your hold time, press ADD TIME (2) and you will

be able to increase the HOLD time in that segment. If you nd you need to skip a segment in oneof the USER programs, when the segment comes up during the ring, press 9 and SStP will appear.Press ENTER and the segment will be skipped during the ring.

The controller will ask what end temperature you want the kiln to reach in the designated segment(example 1250 F) and press ENTER. The controller will ask if you need to Hold for a certain amount oftime during the current segment. Enter the minutes or hours you need and press ENTER.

When you have entered all your segments the controller will display ALAr for alarm. If you do not requirean alarm, press 9999 so that the alarm will no go off and press ENTER. If you require an alarm, enter thenumber of hours you in which you want the alarm to sound.

The controller will display CPL for complete, press ENTER if you are ready to re and then press START forthe kiln to begin ring.

The USER programs stay in the controllers memory until you enter new information.

DELAY allows you to delay ring until you are ready. After you have entered your program and the STARTkey, press DELAY, press ENTER, and the number of hours later you want the kiln to begin ring. Enternumber of hours and press ENTER.

H


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Electro Sitter will replace your obsolete kiln sitter equippedmodel! Its easy, and best of all, parts are available! TheElectro Sitter box is complete with thermocouple attached,and it has the option to re either cone-re or ramp/holdprograms. The box will t where the kiln sitter/timer areattached to the kiln. Simply remove the screws from thekiln sitter on front of the kiln, then detach wires connectingto the kiln sitter. Wires will be attached to the back of theElectro Sitter exactly as they were attached to the kiln sitterterminal block.

Kiln with kiln sitter Detach screws romkiln sitter plate

Remove wires rom back okiln sitter terminal block

ELECTRO SITTER Available with 3 Key-cone Fire, V6-CF or RTC-1000 Controller

Electrical box withoutkiln sitter

Install Electro Sitter in the samelocation as the ormer kiln sitter plate.

Connect wires to back o Electro Sitter just likethe connections to the back o the kiln sitter.

Install electrical box back on kilnwith Electro Sitter installed.

Insert thermocouple throughkiln sitter hole

Thermocouple will show through brick wall ata maximum o 1. Pack kiln sitter hole with

ceramic fber to seal it.


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ELECTRONIC CONTROLLER WALL UNITSKilns wired for kiln sitters are wired differently from those wired for electronic controllers.An electronic wall unit may be added to a kiln sitter equipped kiln so they may run bycontroller; however because of the differences in wiring, the controller is placed on thewall and the thermocouple from the wall unit is placed inside the kiln. Wall units areavailable for 120 volt, 20-30-50-100- amp, and three-phase wired kilns with the choice ofthe 3 Key-Cone Fire, V6-CF or RTC-1000 as the controller. The controller on the wall unitoperates the same as if it was attached to the electrical box on a kiln.

To install the wall unit follow the steps below.1. Attach wall mount control vertically to wall.2. Plug or direct wire Wall Unit to the power source3. Plug or direct wire the kiln into the wall unit4. Drill a hole the size of the wall units thermocouple through the kiln wall and insert

thermocouple from wall unit into the kiln. Insert thermocouple approximately 1inside the kiln.

5. Place a junior cone that is one size hotter than you intend to re into the kiln sitterand activate the kiln sitter.

6. Turn all switches on the kiln to the high setting.7. Read electronic controller instructions thoroughly and follow programming instructions that best suit your

ring requirements.

ZONE CONTROLKilns equipped with electronic controllers have the option of zone control. The standard built electronic controkiln has one zone, one thermocouple senses the kilns temperature and sends the information back to thecontroller.

When a kiln is 2-zone or 3-zone, two or three thermocouples are placed in each section of the kiln to regulatetemperature. 2-zone control has two thermocouples for the top and bottom section of the kiln. 3-zone kiln has three thermocouples, one in the top, middle and bottom section of the kiln.

Each thermocouple senses the temperature in the particular section it sets and can be read through the controlledisplay by pressing the Options key. Innite switches for each zone allow the kiln operator to manually adjust telement output as needed. To select an individual zone, press 1, 2 or 3 and the temperature of the selected zonwill be displayed. Pressing 8 will illuminate indicator lights in the display showing which zone is on.

LidElemenDUAL MEDIA KILNS

Dual Media kilns are designed to re ceramics and glass

240-208 volt Dual Media kilns have a lid element for glass fusing. The kilnoperator manually activates the lid element with the rotary switch. The

switch is turned to the desired intensity (0 - HI) when the lid element is inuse.

Innite Switch for LidElement Activation


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ELECTRIC RAKU KILNS

LOCATING YOUR KILN:Three things should be considered when locating your Olympic Kiln:1. Adequate space2. Proper ventilation3. Convenience of electric outlets

For the area that has been chosen, allow 12 inches of space between the kiln and the walls. All

ammable materials such as curtains, plastics, etc. in the area of the kiln should be removed.

If the kiln is to be placed outside, it must be kept dry. Use a roof over the kiln or some type waterresistant tarp when the kiln is not being red. Because all kilns generate heat, the stand should beplaced on a cement oor. Tiles or linoleum could be damaged without this precaution.

RAKUINGPlanning

Reduction containers - (galvanized garbage cans arebest) that are the correct size and are arranged for easyaccess and clear movement around the kiln. Grass,

leaves, sawdust or shredded paper work well. Combustibles should be at a safe distance from the kiln,yet easy to reach during post ring process

Helpers that know their job Arrange water sources for cooling and emergency

situations Provide safe, clear avenues for unencumbered

movement

Operating the kiln Plug kiln into a receptacle that has an adequate breaker To operate kiln pulley system, unlock lever and turn the

hand winch. Ensure winch is in a locked position beforereleasing the handle.

Use only raku clay pottery and raku glaze whenrakuing. This clay and glaze is designed for thermalshock the ware must go through, other materials may explode and damage the kiln as wellas other pottery ware.

Begin heating the kiln with the re chamber completely closed. The 120-volt electric raku kilnmay take approximately 2 hours to reach raku temperature; however, the 240/208-volt electricraku will reach temperature in about 60 minutes. As the kiln reaches approximately 1900Fahrenheit begin loading your ware. To preheat and avoid thermal shock to your ware, slowlylower the raku-ring chamber. Maintain full power when opening to minimize heat loss betweenpieces.


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Electric Rakus Equipped with an Electronic Controller

3 Key-Cone-Fire Controller Choose User 1 - 4 using the Start, Stop, Enter button for the program Choose one segment when the controller requests how many segments and press ENTER. For rate in rise of temperature per hour press 9999 and ENTER. (9999 tells the controller

to reach the end temperature as quickly as possible.) For end temperature press 1900 - 1950 F and press ENTER. For hold time, enter the number of hours you plan to raku and press ENTER.

The controller will display rEd1 for Ready and you may press START to begin heatingyour kiln.

The program will be saved in the User program number you selected until new information isentered in the select program.

V6-CF Controller Use the Vary Fire Method side of the V6-CF controller to run

the raku ring. Choose User 1 - 6 for the program and press ENTER. Choose one segment when the controller requests how

many segments and press ENTER. For rate in rise of temperature per hour press 9999and ENTER. (9999 tells the controller to reach the endtemperature as quickly as possible.)

For end temperature press 1900 - 1950 F and press ENTER. For hold time, enter the number of hours you plan to raku

and press ENTER. The controller will display CPL for Complete and you may

press START to begin heating your kiln.

The program will be saved in the User program number youselected until new information is entered in the select program.

Around 1900-1950 Fahrenheit the rakuing process will begin totake place. You can tell the ware is ready to remove by its shiny,wet appearance. Raise the ring chamber; remove pieces withtongs and place in reduction containers as quickly as possible.Once ware is inside the container add more reduction material andcover within 15 seconds to ensure efcient smoking. (It is not howmuch reduction material you use, but how fast you can get potteryware into the container and covered that provides exceptional rakupieces.) Keep container covered for 15 minutes - 1 hour. Afterware has cooled, wash each piece to remove soot and carbon.

Olympic Raku kilns are designed to maintain their temperature (even when the ring chamber islifted) so that you can continue the rakuing process without interruption. Once ware is removedfrom the kiln and placed in reduction containers, new items may be loaded in the kiln. Youmay also want to place items on top of the raku-ring chamber (on the outside) that you will berakuing next so that they are preheated before placing in the kiln.


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Loading Kiln for Pottery & Ceramics

Follow these instructions when loading your kiln:1. Load only bone-dry greenware (unred clay shapes) into the kiln. Wet ware may crack on ring

or even explode resulting in damage to the other ware or the kiln. Ceramic greenware should bedried for at least two days with larger or thicker pieces requiring even longer. Glazed (painted)ware should dry for six hours before ring.

2. Plan the load before starting. Arrange the load so that thick and thin walled pieces will be mixedthroughout the kiln to give a uniform mass or density.

3. It is best not to load pieces directly on the kiln bottom.4. The bottom layer should either be stilted or loaded on a shelf supported 1/2 inch from the bottom

to allow adequate air circulation and heat distribution.5. Place small, low pieces on the bottom layer, and taller pieces on the top shelf. This enables

loading with shorter posts.6. Allow at least one element groove between every shelf. If your kiln has a blank ring, let at least

two element grooves contribute to the heating of the blank space.7. Do not jar or shake the kiln after loading has started since ware on a shelf could be knocked

down or broken.8. Keep shelves and ware at least 1 inch from the thermocouple, and 1/2 inch from the wall of the

kiln. At least one element groove must be between the top shelf and the top of the kiln.

9. If large at pieces are being red, the edges should be placed between elements. This mayeliminate possible cracking from uneven heating.10. Place the shelves in the kiln carefully so the walls of the kiln will not be bumped and damaged.11. If a witness cone is being used, the cone should be placed 3 inches behind the observation hole

so it will be completely visible.

Loading Low Fire BisqueBe sure the greenware is dry before loading. Greenware that feels cool is probably still damp. Youcan compare the temperature of the ware to be red to an old piece of greenware that you know isdry.

Greenware can touch other greenware as well as the kiln shelves. Kiln washed shelves are not

necessary when bisque ring.

It is best to re a piece in its natural position, however large at items such as wall plaques or clocksshould be red on a at side to prevent ware from warping.

Thin cups may be red upside down or stacked lip-to-lip if the rims are strong enough. Canisters andother pieces with lids should be red with lids in place for a good t.

Loading Low Fire GlazeDo not place greenware and glazed ware in the same load. The gases emitted by the greenware claybody can cause discoloration of the glaze. If it is necessary to mix glaze and bisque in a load, theglazed pieces should be loaded in the lower part of the kiln with the greenware above it.

Do not load red family glazes, green, yellow, or yellow-green glazes, metallic or luster glazes withgreenware. Allow a minimum of 2 inches of space around red glaze pieces. Again, if it is absolutelynecessary to mix loads, always place the red glazes on a shelf below other items, which maycontaminate.

Glazed pieces must not touch or they will stick together. At least 3/4 inch must be allowed betweenglazed pieces to prevent contamination from the release of bubbles and gases from other glazes.


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The tops of shelves and kiln bottom must be kiln washed to protect against drops of glaze. The kiln lidand the underside of shelves must be clean to prevent dust particles from falling on the glazed ware.

Glazed ware must be stilted and dry footed to prevent sticking to the shelves. (Dry footing is removingall glaze from the portion of the piece that will rest on the shelf. A wet sponge or piece of cloth can beused for this.) For low re (cone 04, 05, 06) glazes, stilting is recommended. If a piece wobbles whenstilted, it may fall during the ring. Be sure all stilted pieces are solid. Note: Be sure your hands areclean when loading glaze.

Loading Overglaze(China paints, lusters, metallics applied over a glazed surface and red.)Overglaze ware is loaded in the kiln in the same manner as ordinary glazed pieces. Ware must beprevented from sticking by the use of stilts, and care should be taken so pieces do not touch eachother.

Plates will re best when supported by a rack or when placed on edge to permit even heating. Platesred on edge may be supported at the bottom with stilts.

Spacing is important when ring lusters, to prevent contamination.

China paints should be applied in light coats, and red between coats until the desired shade isreached. China paints applied too heavily will crack and peel.

Loading Porcelain BisquePorcelain is a high re clay body, which vitries (becomes non-porous) when red. Loading porcelainbisque and glazed ware is similar since both will stick to anything when being red.

Stilts cannot be used to support porcelain bisque as they will adhere to the porcelain when heated tohigh temperatures.

Porcelain bisque and glaze are always red resting at on surfaces coated with high re kiln wash.Two pieces of ware that are to be used together must be red together, such as a piece with a lid.

Powdered silica (int) must be applied at any point where contact is made.

Hollow rolls of porcelain clay shaped to hold up the parts that may sag should support pieces that arelikely to warp during ring. Apply silica at the points of contact to prevent the supports from sticking.To prevent distortion due to uneven heating, never place a piece of porcelain closer than 3/4 of aninch from the sidewalls of the kiln.

Loading Porcelain GlazePorcelain glaze requires loading which allows good spacing between the pieces with at least 3/4 ofan inch between the piece and the kiln wall. All glazed ware should be dry footed since stilts cannotbe used on porcelain. It is important to have a good coating of high re kiln wash on the shelves andbottom of the kiln. Pieces with lids and other items, which have been red together in the bisque,cannot be red together in the glaze ring since they will stick together. Shrinking has alreadyoccurred in the bisque, so the piece will still t after the lower temperature glaze re.

Loading Stoneware(A non-transparent clay body requiring a high temperature to vitrify a glassy non-porous state causedby heat or fusion.)Stoneware greenware items must be bone dry before ring. Stoneware should be handled and loadedin the same manner as porcelain. Stilting of greenware is not required. For glaze ring, the tops of theshelves must be coated with kiln wash, and the ware should be dry footed.


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Kiln Firing

Firing is probably the most important part of your ceramic work. All of your previous work on aceramic piece can be spoiled and your kiln permanently damaged from careless loading or ring.

Firing is usually accomplished by bisque ring followed by a glaze ring. The bisque ring allowsthe dried clay to harden enough so it can be handled, yet remain porous enough to accept glazesor stains.

The bisque piece having been glazed or decorated is red a second time to mature the decorativecovering. Some pieces may require more than two rings.

Maturity of clays and glazes occurs at different times and temperatures. Always check the ringtemperature recommended by the glaze manufacturer or clay supplier to be sure.

If during a ring you suspect something has shifted inside the kiln or something is abnormal, shutthe kiln off immediately. Allow the kiln to cool, check the load, reenter your program and re-reas usual. The same procedure should be followed if the kiln shuts off by itself prematurely.

Standard Firing Schedules for Full KilnsBisque or low re glaze rings (cone 04-06) usually require 5 to 7 hours. Porcelain and stonewarehigh rings take from 6 to 10 hours. The following ring schedule is a recommendation onlyandcan be use for all types of ceramic, porcelain, and stoneware rings. You should experiment withring times and adapt your ring schedule to t your type of ring. Some types of ceramics can bered much faster than the recommended standard ring schedule, while other types of ware mayrequire slower schedules. Keep a record of your rings, so any deviations resulting in good ringsmay be repeated.

If kiln has a vent, skip numbers 1& 4.1. If the kiln has a lid wedge, prop the lid after loading the kiln.2. Plug all observation holes except the top, which should remain unplugged throughout the

ring to allow a vent for fumes and vapors.3. Key in the cone re method you wish to re.4. After approximately 1 hour 45 minutes remove lid wedge and close the lid.5. Allow kiln to re until it shuts off.

A partially loaded kiln res faster than a full one, so when ring partial loads, increase the lengthon LOW and MEDIUM to extend ring time.

Firing Ceramic Bisque

(A ceramic piece which has been red, but not glazed.)Bisque ring allows the clay to mature, and burns out any impurities which may be present. Ared piece is less likely to absorb moisture, which will cause cracking or crazing of the glazeduring the glaze ring. Bisque should be red at least one cone hotter than glaze (usually cone 05or 04). Pieces likely to be subjected to thermal shock, such as cups and plates should always bered to cone 04.

Most cast pieces can be red satisfactorily on a fast ring schedule. Heavy or thick pieces requirea much longer ring schedule.


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Firing UnderglazeIf the underglaze is applied directly to the greenware, the cone 05-04 bisque re will also serve asthe underglaze ring. Underglaze applied to bisque, should be red within a range of cone 019-04 before the application of a glaze.

Firing Low Fire Glaze(A coating of glass, which is fused to the surface of a clay body during ring. It serves to preventthe penetration of liquids, present a good wearing, easily cleaned surface, and decoration.)Ceramic glaze res like ceramic bisque except it should be red one cone lower. Glaze ring canusually be accomplished faster than bisque ring since the critical moisture release has alreadyoccurred.

Check the glaze manufacturers ring recommendations for the proper ring cone. Some glazesmay require modication of the standard ring schedule to obtain satisfactory results. Forexample, red family glazes tend to come out better if the kiln is vented and red rapidly.

Firing OverglazeOverglazes are red only to the softening point of the glaze, and are red to lower cones thanregular glazes. Most china paints, metallics and lusters are red from cone 021 to 018.

China PaintsCheck the manufacturers cone recommendations for each color and type of ware being red.Different china paint colors do not mature at the same cone even when red on the same pieceof ware. It is necessary to re the colors maturing at the highest temperatures rst, and add lowertemperature colors and re again. Colors mature at lower temperatures on ceramic pieces than onporcelain or stoneware due to the lower melting temperature of the host surface.

Firing Porcelain Bisque and GlazePorcelain is usually red to cone 5 or 6. Porcelain bisque should be red slowly. Porcelain maybe bisque red more than one time or soaked (hold time) for 30 minutes to obtain additionaltranslucence. Porcelain glaze is not red as high as porcelain bisque. Usually cone 3 is sufcient.Porcelain does not need to be supported to prevent warping during glaze ring but must be dryfooted (removing all glaze from the bottom of the piece before ring).

Overglaze red on porcelain is just like overglaze red on ceramics only several cones hotter,usually cone 017-015. Overglaze may also be applied directly to porcelain bisque.

Firing StonewareStoneware is usually bisque red to cone 016-04 before glazing with an extended ring time toallow for the extra thickness of most stoneware pieces. Stoneware glaze applied to a bisque redpiece is red on a normal heating cycle since the moisture has already been removed. Firingtemperatures depend upon the glaze and stoneware body, however cone 1 to cone 8 are the most

commonly used.

Kiln Cooling and UnloadingYour kiln is designed to cool best when untouched after it shuts off. Forced cooling such aswithdrawing the observation plugs or opening the kiln door while the kiln is still hot, greatlyincreases the risk of damage to both the ware and the kiln.

The kiln should cool at least twice as long as it red. Pieces should be removed from the kiln onlyafter they are cool enough to handle with bare hands. If the ware is under red, it may be redagain to maturity.


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The life of the kiln can be extended for many extra trouble-free yearsof service if routine maintenance is performed. This maintenanceshould include, but not limited, to the following suggestions.

Every FiringExamine the interior of the kiln to insure it is clean and free of dust.

Check the lid and wall brick for loose fragments, which might fallon the ware. If possible, vacuum the interior to remove all dust andforeign material from the elements. Check the oor of the kiln, andthe kiln shelves to be sure the coating of the kiln wash is adequate forglaze or glass rings. Also check for any warping or cracks in the kilnshelves that might affect your ring.

Standard ModelsExpansion and contraction of the kiln during ring will eventually cause the stainless steel jacket/ringsto loosen and cause the kiln to get out of alignment. To prevent this, the clamps on the jacket, lid andbottom of the kiln should be tightened occasionally with a screwdriver when the kiln is warm. Careshould be taken not to strip the clamps. By following this procedure you will eliminate wires being

stretched and burned out requiring you to purchase new parts.

Remove any glaze or glass from the walls, bottom or shelves of the kiln prior to the next ring. If this isnot done, glaze or glass will melt and spread with each ring, causing contamination to the elements,thermocouple and deterioration of the rebrick.

Be very careful of the inter-connection of kiln rings when assembling or disassembling a kiln built insections. Make sure the plug and receptacle are aligned before placing the rings together.

RepairsMany repairs can be accomplished on your kiln simply by removing an old or damaged part and

inserting a new one. For more complex repairs, and certainly for troubleshooting, a volt-ohm meter(VOM) is a valuable tool. A VOM can check the continuity of your kiln, pick out weak elements, revealfaulty switches, or check for proper voltage from the wall receptacle. The VOM allows the troubleshooterto proceed in a logical sequence through the kiln for the source of an electrical problem.

When doing replacement repairs, install the new part in the same position as the old part. Transferwires one at a time from the old to the new part. All connections must be clean and bright. Replaceany discolored connection or clean with either sandpaper or steel wool until clean and bright. If this isnot done, a bad connection will result.

NOTE: To insure you receive the correct element or part, order from Olympic Kilns. Elements andparts ordered from other sources may not function correctly in your kiln.

Kiln Maintenance


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Removal of Electrical Box Unplug or unwire kiln if direct wired Stackable kilns remove rings in order to disconnect interconnections between rings

After the electrical box or boxes are removed from the kiln, the following repairs can beaccomplished.

Switch Replacement1. Do not cut any wires.2. Remove the knob from the switch.3. Remove the pal nut from the switch with a wrench.4. Transfer the wires from the old switch to the new switch, one wire at a time. Tighten all

terminal screws rmly.

5. Put the pal nut on the switch and tighten.6. Put the knob on the switch.7. Attach the electrical box to the kiln.

Switches, Relays and TransformersThese parts are all replaced by removingthe slip-on connection from the old partand replacing slip-ons to the new part.

Remove the screws attaching theelectrical box to the heat shield Pull the box away from the kiln. When

removing the electrical box that containsthe pyrometer or electronic controller, becareful to pull the box straight out so that

the thermocouple does not break the brick.

Slip-on Connectors

Replacing Parts


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Wiring Schematic for12, 120 & 240 Volt Relay

COIL

RELAY

POWERIN

POWER OUT

Wiring Schematic208/240 Volt Transformer

120 Volt Power in 4 & 3 or 1 & 2

WHITE

BLUE

ORANGE

8 7 5

4 3 2 1

POWERIN

Wiring Diagram for 3 Position Switch 120 volt 240 voltInnite Switch Schematic

Wiring Schematics for Parts Replacement


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Remove the electrical box that contains the part that needs replacing. Loosen the screws holding theinterconnection to the electrical box. Note the position of the prongs and reinstall the new part in thesame position. The interconnecting plug and receptacle can be ordered pre-wired and to replace the oldpart with new, remove and replace one wire at a time.

Standard Interbox Plug & Receptacle Twist 'n' LockInterbox Plug & Receptacle

Element Re-PinningElements become very brittle after a few rings; so if re-shaping or re-pinning is necessary, heat theelement either by turning on the kiln, or with a torch to a dull red glow. Unplug or unwire the kiln, andreposition the hot element using needle nose pliers. A brittle element normally will not break if it is above500 degrees F.

Replacing Elements1. Turn off kiln and unplug or unwire, if direct wired, and remove all pins

holding the defective element in the grooves.2. Gently remove the old element taking care not to break or chip any

bricks. Long needle nose pliers can help in this job.

3. Insert one twisted pigtail of the new element through the terminal brickand then work toward the other end by carefully placing the new elementin the trough of the brick. Make a slight bend at each corner so that theelement takes the shape of the kiln. When the entire element is in thetrough, it may be necessary to slightly stretch or compress it to obtain thelength necessary to allow the pigtail to pass through the brick.

4. Re-pin the element at each corner with Kanthal pins. The pins should hold theelement down while the lip of the element groove holds the element in.

Replacement of Interconnecting Plugs and Receptacles on Stackable Electric KilnsThe interconnecting plugs and receptacles have changed over the years. To order replacement partsOlympic Kilns requires the model and serial number of the kiln and a description of the type inter-boxplug and receptacle your model has.


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ELEMENT REPLACEMENT TIPS FOR ELECTRIC RAKUSThe best way to replace elements in an electric raku kiln is to remove the ring chamber from theframe. Once the ring chamber has been removed from the frame, loosen the stainless steel band,remove the top from the ring chamber and follow the steps for element replacement. After theelements have been installed, replace the lid of kiln on the ring chamber and reinstall the ringchamber to the kiln frame.

5. Reinstall the porcelain insulators overthe twisted pigtail. Pull the pigtail outgently until it is tight, then clip it 5/16inch beyond the insulator.

6. Place a high temperature connector inthe jaws of the crimping tool and holdit lightly. Reach inside the kiln withthe other hand and push the pigtailout. Slip the connector on the pigtailand crimp rmly in two spots.

7. Strip 5/16 inch from the wiresconnecting the switch or relayto the elements. Polish with

ne sandpaper if the wires arediscolored, then rmly re-crimp.

It is important to stress that the wire in a crimped connection beclean and bright. All crimps must be rmly applied.

Hi Temp Connectors

Crimping Tool


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Thermocouple ReplacementThis thermocouple replaces all previous types. You may need to enlarge the hole the thermocouple isinserted if you had a different style, or you may need to use ber to ll the opening if this new thermocoupleis smaller than the one you had previously installed.

Thermocouple Installation:Remove the four screws that attach the electrical box, with the electronic controller in it, to the kiln.Strip the yellow and red wires 3/8 of an inch that are attached to the thermocouple. Disconnect defective

thermocouple and insert the new thermocouple through the opening in the kiln brick. Set thermocoupleapproximately 1 inside kiln ring chamber. Attach yellow wire to the positive connection on the electronicboard and the red wire to the negative connection.

1


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Brick RepairsThe bricks used in your kiln will withstand many rings without deteriorating.Brick replacement is complicated by the risk of breaking a brittle element. Oftentemporary repairs can be made until the time that an element needs replacing.

It is difcult to cement bricks together when they break, however, large pieces suchas the element groove lip, can be pinned with Kanthal pins to hold it in position. Ifthe brick cannot be pinned, the element may be held in position with pins, even ifthe supporting brick below the element is missing.

Foreign material such as glaze or glass spots on the brick can be dug out with ascrewdriver or knife.

Brick Replacement Make sure you order the correct brick(s) that need replacing. Provide the kiln model number and thickness of the brick, 2 1/2 or 3 thick. Straight notched bricks are the bricks that the elements run through. Terminal brick is the brick that the element runs through to the electrical box. Observation brick has the observation hole in it. Blank brick is not grooved for element placement.

Terminal bricks are best replaced when elements need replacing as well.

1. Remove the Kanthal pins securing the element at each end of the damaged brick.2. The kiln lid must be removed by unscrewing the large hinge parts attached to the kiln jacket on single

section top loading kilns, and brick being repaired in the top section of stackable kilns. If the kiln isbuilt in sections, place the ring with the broken brick on a at surface with the damaged side up.

3. Loosen the hose clamps until the bricks are loose. If the kiln is in one section and the brick repair isbeing made on a section other than the top row, the entire stainless steel jacket must be opened.

4. Gently lift the elements from the trough with needle nose pliers, and carefully bow them far enoughinto the ring chamber to allow removal of the brick. Insert the new brick with the element trough tothe bottom of the kiln.

5. Set the elements into the groove and pin down.6. Tighten the jacket clamps taking care to align observation holes. Replace all screws and replace the

kiln lid, if it was removed.7. Use sandpaper over a wooden block to sand the brick down until it is even with the adjoining brick.8. Vacuum the kiln.9. Tighten the stainless steel jacket of the kiln again during ring, while the

kiln is hot.

Floor RepairsThe easiest repair to make when the oor is damaged is simply to turn it over.A one-piece kiln must be turned upside down and the hose clamps on the

jacket loosened, allowing the oor to be lifted out of the kiln. The oor canthen be turned over and reinstalled.

Holes in the oor can be patched with kiln wash mixed to the consistency of paste, then scraped ush,and allowed to dry before ring. Kiln mortar can also be used, by spreading it thinly over the area to keepit sealed.

Lid RepairsIf the lid becomes chipped or damaged, simply smooth the surface of the hole with sandpaper and blowor vacuum clean. Kiln mortar may be spread thinly over the exposed brick to seal it and prevent dusting.


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Olympic Kilns 39

Kiln TroubleshootingKiln does not start.Check to see that kiln is plugged in and turned on.

Kilns equipped with an electronic controller, the controller display must read Idle to begin programming thekiln. If the controller display does not light up, check fuse to determine if it needs replacing. If the fuse is in goodcondition, a transformer may need replacing.

Fuse or breaker fails after the kiln has been on for some time.

Check chart to insure the correct breaker size is being used with the kiln. Replace breaker or fuse if necessary.

Kiln makes popping noises when ring.Normal due to the contraction of kiln parts, which are enlarged from thermal expansion. Innite switches willclick when cycling.

Element pops loose from groove.Elements pop loose because element pins loosen when the element expands and contracts during heating andcooling. Re-pin element. Be sure to heat element to 500 degrees Fahrenheit to avoid breaking due to brittleness.Increase in ring time.Possible causes element(s) needs replacing; defective switch or relay.

To determine if the elements need replacing, do this simple test. Turn the kiln on and place pieces of paper in eachelement trough. If the paper burns then the element is working. Where the pieces of paper do not burn, the elementneeds to be replaced.

If two elements are out in the one section of the kiln, it may be due to a faulty relay.

Kiln heats but pilot light will not illuminate.Kilns equipped with electronic controllers if controller display is off, check the fuse. If the fuse is working, thetransformer needs to be replaced.

Kiln over res.Most likely a defective thermocouple that needs replacing.

Electronic Controller Error Codes3 Key-Cone Fire Controller

ERR 1: Element or Voltage Problem (Conduct a paper test and make sure voltage is correct for kiln; i.e. 240 voltsneeds 240 not 220 volts.) Paper test - Turn the kiln on, place scrap pieces of paper in each element trough and see ifthe paper burns. Elements need replacing where the paper doesnt burn.

ERRP: Indicates a long-term power outage. Press 1 to clear display.

FAIL or a Negative Temperature is Displayed: Check to see that thermocouple is properly connected; (lead wiresmay need reversing) or may need thermocouple replacement.

tC FAILtC alternating with FAIL: Indicates the thermocouple has failed. Replace the defective thermocouple.To clear the error, press any key.

ErrP ErrP is displayed whenever there is a power interruption that is long enough to stop the ring. Ifthe power interruption is brief the kiln will continue to re when power is restored; in this casethere will not be any indication of a power failure. To clear the error, press any key.

tC- - The red and yellow thermocouple wires are reversed.


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Olympic Kilns40

technical support: [email protected] information: [email protected]

Messages CPLt Firing Cycle Complete (ring time is alternately displayed). dELA Delay. Displays when entering the delay time (hour:minutes) until the start of the ring. DLy Delay. Alternates with the remaining delay time until the start of the kiln. F # Segment temperature in F Set temperature for a user program. C # Segment temperature in C Set temperature for a user program. A decimal point will

display in lower right corner. EdIt Edit the default options (beeping at complete, temperature scale, cone re, delay, maximum

programmable temperature)

ErrP There has been a power interruption that has stopped the ring. Press any key to clear. FULL Beeps continuously at end of ring until a key is pressed. HLd# Soak time in hours:minutes at a hold temperature. OFF No beeping when ring is complete. On Beeps for 15 seconds at end of ring. rA # Ramp Number (rate per hour of temperature increase or decrease). rEdl Ready to re current program. Press START to begin ring. SEG Short for Segments. You can enter up to 8 segments in a program. SStP Skip Step (used to advance to the next ramp) StOP The kiln is at idle and ready to be programmed. Stop alternates with the current kiln temperature.

USr # User program number displayed

V6-CF & RTC-1000 Controller

ERR 1: Element or Voltage Problem (Conduct a paper test and make sure voltage is correct for kiln; i.e. 240 voltsneeds 240 volts not 220 volts.) Paper test - Turn the kiln on, place scrap pieces of paper in each element trough andsee if the paper burns. Elements need replacing where the paper doesnt burn.

ERR 6 or FAIL: Check to see that thermocouple is properly connected; may need thermocouple replacement.

ERR 8: Indicates the kiln is cooling while the controller is attempting to raise the temperature. The cause may be: 1)an element has failed; 2) one incoming power source has been disconnected on three phase; 3) if the kiln has a kilnsitter it may have shut off while the controller is heating; or 4) the lid lock has been released or the lid opened duringring. The error only occurs with cone re mode.

ERRP: Indicates a long term power outage. Press 1 to clear display.

ERR-: Power loss to controller while entering a program. Recheck the selected program and reenter if necessary.

ERRE or ERRT: Hardware error. Return controller for service. See Bartlett address below.

ERRD: Normally caused by an output or thermocouple switch to the wrong zone. 1) May be a stuck relay; or 2) turnoff error codes (how to in the controller instruction manual).

ERRA: Invalid program. The Error A means that in one of the segments of the User program you are using, a tempera-ture F1, F2, F3, is entered that is higher than the kiln is designed to go. Go to the User program you are receivingthe error from and enter a program for 8 segments. In each segment make sure the target temperature is not greaterthan 1700F. This doesnt have to be a real program that you use, just enter one that will clear the error message out.

Once you have entered the new program the Error A will be removed and you can enter your program of choice.

For additional questions about your Bartlett controller contact Bartlett Instruments:

Bartlett Instrument Co.14th & Avenue MP. O. Box 445 Fort Madison, IA 52627319-372-8366


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Olympic Kilns 41

Glaze DefectsProblems with red ceramics can usually be traced to improper ring, poor color application, orsome other correctable fault.

Black Specks Usually the result of contamination from dirt. Contamination can be introduced byseveral things - a dirty brush, dirty green ware, dirty bisque, a dirty glaze container, or a dirty kiln.Make sure all of the above-mentioned are kept clean.

Blistered and Bubbled Glaze This condition is the result of bubbles frozen in the glaze as the kiln

cools. The bubbles are caused by gases released from under red bisque or glaze. The bubblesand blisters can be sanded down, covered with a thin coat of glaze, and re-red to a hotter cone.The piece may be soaked (hold time) for 30 minutes at the conclusion of the re-ring.

Color Peels Off This condition is usually the result of too heavy an application of the glaze, dirtybisque, most likely from oil or grease preventing adhesion of the glaze, or too rapid cooling.

Cracks Cracks are sometimes caused by uneven or too rapid heating or cooling of the kiln.Check the crack to see if it was caused during the heating or cooling. If the edges of the crackare sharp, it was made during the cooling of the kiln. If the cracks are rounded or smooth, thisindicates the crack occurred when heating. To prevent this in future rings, slow the heating rate,

do not pull the observation plugs while the kiln is hot and never force cool the kiln.

Cracking sometimes is caused by glazes that are not compatible, such as a mug or vase with clearglaze on the inside and colored glaze on the outside.

Craters Craters are due to under red glaze, and can be salvaged by dabbing glaze in the cratersand re-ring to a hotter temperature.

Crazing This is a ne network of cracks on the glazed surface. It is caused by under red bisque,incompatible thermal expansion between the clay and glaze, or cooling too rapidly. Crazing canbe corrected by re-ring the piece one cone hotter than the original ring. Some crazing will notoccur for several months after the ring. The solution is still to re-re the piece.

Faded Decals Check the decal manufacturers ring recommendation. Fading is either from overor under ring. If under ring is the problem, re-re to the proper cone. Little can be done to savean over red decal.

Glaze Creeps Bare spots appear in glaze surface after ring. This can be the result of dusty, dirtybisque, or oil and grease from dirty hands. The latter causes the glaze to repel from these spots.Under ring or ring the piece before the glaze dries will also cause creeping. To save the piece,apply additional glaze to the bare spot and re-re.

Luster Problems Lusters will ake or peel if too thickly applied, and will frost if over red. Tosalvage the piece, re to cone 06 to burn off the luster. Reapply the luster and re-re.

Metallic Problems Metallics will appear dull if applied too sparingly or under red. Over ringor too heavy an application of glaze will result in cracking. Under red metallics can be re-red tothe proper cone, while over red metallics must be burned off at cone 06, reapplied, and re-red.

Pinholes and Pitting As glazes and clay bodies mature, volatile materials are released, resultingin boiling and agitation of the glaze. An incomplete ring cycle causes these bubbles to freeze,causing pinholes and craters. Pinholes can be caused by too rapid heating or cooling of the kiln.


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LIMITED KILN WARRANTY

HaugenManufacturing,Incorporatedguaranteestotheoriginalpurchaserthatanydefects

inOLYMPICKILNSwhichbecomeapparentwithintwoyears(oneyearfortheDawsonKiln

SitterandsafetytimerwhichiscoveredbywarrantyfromW.P.Dawson,Inc.andkilnsratedat

cone10)willberemediedasspeciedbelow.

Ourwarranty,ofcourse,doesnotcoveranykilndamagedoralteredbyyouorothersafter

itleavesourfactory.Ourwarrantydoesnotcoverdamageduetoreductionorsaltring,

over-ring,exceedingthemaximumconeortemperatureratings,improperinstallation,useof

electricalvoltagesdifferentthanthosespecied,orringmaterialotherthanceramics.

Ifadefectofmanufacturerbecomesapparent,andyourretailerdoesnotresolveittoyour

satisfaction,wewillinthefollowingmanner:Within(6;)daysoftherstindicationofadefect,tell us in writing of defect, and the date, place and proof of the your purchase. We will contactyou to determine what parts seem to warrant repair and to instruct you as to shipment of thekilnparts.Youwilldismantle,package,andshipthepartswerequest(andnoothers),tous

atyourcost,freightprepaid.Ifthekilnhasadefectofmanufacturewewillrepair,replaceor

refundasisappropriate,within(30)days.Wewillshiptoyouatourcostinyourpackage,

foryoutoreinstallatyourcost.Ifthepartsshippedbyyoutousareinneedofrepairor

replacementforsomethingwhichisnotcoveredbythiswarranty,wewillnotperformthework

untilyouhaveauthorizedtheworkandmadearrangementsforpayment.Ifsubstantiallyan

entirekilnisreturnedforrepairunderwarranty,youwillprepaythecostofpackagingand

shipping both to and from the factory.

We shall in no event be liable for injuries to persons or property or for incidental, contingent,specialorconsequentialdamagesarisingfromtheuseofourproducts.Somestatesdo

notallowtheexclusionorlimitationofincidentalorconsequentialdamages,sotheabove

limitationorexclusionmaynotapplytoyou.Thiswarrantygivesyouspeciclegalrights,and

you may also have other rights which vary from state to state.

HAUGENMANUFACTURING,INC.

P.O.BOX1347

4225THURMONTANNERPARKWAY

FLOWERYBRANCH,GA30542

This Warranty Is Applicable to All Kilns Manufactured by Olympic Kilns That Are Used for Ceramics,

Pottery and Glass. Cone 10 Kilns Have a One-Year Warranty and All Other Kilns Have a Two-Year

Warranty. Certain Parts, Thermocouple, Kiln Sitter Tube Assembly, Are Not Covered Under Warranty, Nor

Is Kiln Furniture.

Documents

Standard Electric Kilns