TAP Controller Manual
Contents
1. New PREVENTIVE MAINTENANCE Figure 33 Preventative Maintenance By default all preventative maintenance settings are disabled Acceptable entries for Relay Life are 50 000 through 10 000 000 actuations If desired a value of O or a blank can be entered which will disable the relay life preventative maintenance functionality Acceptable entries for Element Life are 40 7 500 hours If desired a value of O or blank can be entered which will disable the element life preventative maintenance functionality Acceptable entries for Thermocouple Life are 10 7 500 hours If desired a value of O or blank can be entered which will disable the thermocouple life preventative maintenance functionality To modify these settings perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS e From Settings Screen press PREVENTIVE MAINTENANCE e For Relay Life select New Relay Life enter new value using virtual keypad Figure 34 Relay Life Entry then press ENTER 31 Please enter Relay Life in actuations Relay Life can be entered in the following format e XXXX Acceptable inputs are values from 50 000 to 10 000 000 Enter O or leave blank to disable Bees oog Baa Figure 34 Relay Life Entry e For Element Life select ELEMENT LIFE tab select New Element life enter new value using virtual keypad Figure 35 Element Life Entry then press ENTER Please enter Element Lifi2. Figure 24 Ramp Rate Entry F e Input Setpoint using the virtual keypad Figure 25 Setpoint Entry F then press ENTER Please Enter segment 1 Setpoint Temperature Valid Entries a EH Max Temp is defined in settings 0 Figure 25 Setpoint Entry F e Input Hold Time using the virtual keypad Figure 26 Hold Time Entry then press ENTER 23 Please Enter segment 1 Hold Time Valid Entries Minutes or Hours Minutes For Example 2 45 is equivalent to 2 hours and 45 minutes Figure 26 Hold Time Entry e To activate a Hold Time Alert select Yes when prompted o Note If this is enabled an Audible and visual Alert will be presented when the Hold Time is 80 complete o Note Ensure Alerts are enabled in settings To verify this refer to Section 6 6 6 Notifications e Toactivate a Setpoint Alert select Yes when prompted o Note If this is enabled an Audible and Visual Alert will be presented when the Setpoint is reached o Note Ensure Alerts are enabled in settings To verify this refer to Section 6 6 6 Notifications e To Enable Auxiliary Output 1 select Yes when prompted o Note Ensure Aux 1 Output is enabled in settings To verify this refer to Section 6 6 1 Auxiliary Output e To Enable Auxiliary Output 2 select Yes when prompted o Note Ensure Aux 2 Output is enabled in settings To verify this refer to Section 6 6 1 Auxiliary Output e To add additional schedule steps repe
3. Information and perform Software Updates All of these items are described in detail in the following subsections S nie i mi Date Time Status 16 Aug 15 430PM Admin DIAGNOSTICS SCHEDULES SETTINGS DEVELOPER SOFTWARE INFO UPDATE lt l Figure 8 Main Menu 6 1 Calibration Calibration is currently disabled in TAP The button will appear grayed out and is not selectable This is a result of varying kiln sizes and characteristics The intent of calibration is to determine the kilns cooling coefficient and apply it across kiln schedules so when a user wishes to view the 11 characteristics of a firing prior to actually executing it TAP will be able to provide a graphical representation of that The problem however is that a kiln firing to 1480 F with no ware inside will cool considerably faster than a kiln packed full of glass or ceramics To adequately predict the cooling rates associated with a kiln we would need to predict the thermal mass associated with a kiln firing We are working on collecting a sufficient sample size such that we can accurately predict the thermal mass and associated cooling rate for any size kiln currently in production We intend to have calibration available with a future update of software SDS Industries is working to have this feature available for Revision 2 targeted for release in December 2015 6 2 Developer Information The developer information accessed from the main menu provides
4. NN N 6 FieWt skoln Ci ju m dd d ddnns n 7 rielr dsscn dul del ci0dks D a D J 7 PIS Se EE CUON UU S g V Nm K I S J 8 FIEWEbsEdt CNedl ss a EE ES Ue N 9 FEU Grapnical VIEW av nunu nom 9 Faure s Man VIENU su on 11 HISUf dsPlagHiOst 6 u ass 12 Figure 10 Event LOB rete E sjan 13 Fig re 11 General Event LOB ercer EE T S S 14 E o AAA a nn n vann V E 14 Figure 13 S Fring LOPS 3s a D S TTS TO 15 Feure 14 Schedule 09 0 S N A 16 FIEUIE Bo E E anne E EE E AA S E E E E N ET 17 Figure 16 Schedule Selector a E 17 Figure 17 Schedule S mmary with Alerts ass d sns 18 Figure 18 Sch dule Summary Wifi nes 18 Figure 19 Schedule Summary with AUX Z occcconccccccncccnconaconnonnncnnonononnnonaconnononnnnnnnnonnnnnnnnnnonanonnnnnnonnnenanionnos 19 Faura 20 NEW SEHNEdUl 4 da 20 Figure 21 New Schedule with Alerts and Aux 1 ssessssseseesssssnserrerssrrnsssreressrereseeresrrenssrereserersseeresereesseerese 20 Figure 22 New Schedule with Aux 1 and AUX 2 ssessssssssessssreserrerssrrerssreressrersrreressrressreresereresreresereesseerene 21 Figure SNOW schedule With AUX ZS a g N N N 21 PICU 2 4 Ramp Rate EN Es on S S nn 23 FEW 2 S GIDOIDVENIV Vs sa D V D NE 23 Reue C Hold Timne D V a a a N S 24 PISS 2 7S SUMING Se d mai dns 26 Figure 28 Auxiliary Outputs Settings distri das 26 Heare 20 COS Der ONM EMS E EE I 28 Heare 30 Kiin Power Enty cees O D 28 rg fd 01 ous seem BY 6 SOU aa 29 Fie r 32Z
5. following steps e From Home Screen press MENU e From Main Menu press EVENT LOGS e From Event Logs Screen press FIRING LOGS e Selecta Firing press VIEW LOG 6 4 4 Schedule Log The schedule log contains a list of all activities associated with schedule creation modification and deletion This log includes the date and time a new schedule is created along with the associated schedule title the date and time an existing schedule is modified along with the associated schedule title and the date and time any existing schedule is deleted along with the associated schedule title The schedule log can be cleared at any time by pressing CLEAR LOG from the Schedule Log Screen Figure 14 Schedule Log 15 Time Status sdsindustries gt 16 Aug 1s 4 37 PM Admin 13 AuUg l2 6 34 PIM Devit deleted 13 Aug 15 8 54 PM Devit created 16 Aug 15 1 22 PM Editing Devit txt 16 Aug 15 1 28 PM Editing Devit txt 16 Aug 15 4 29 PM Editing 96 Full Fuse 6mm txt SCHEDULE LOG Figure 14 Schedule Log To access the schedule log perform the following steps e From Home Screen press MENU e From Main Menu press EVENT LOGS e From Event Logs Screen press SCHEDULE LOGS 6 5 Schedules The schedules landing page accessed from the Main Menu while in administrator mode or from the Home Screen while in execute mode presents the list of available schedules stored in memory by title Schedules are populated in alphabetical order with num
6. quick access to the current software revision and contact information for SDS Industries To access this information perform the following steps e From the Home Screen press MENU e From the Main Menu press DEVELOPER INFORMATION 6 3 Diagnostics Diagnostics provide a real time look into the usage of critical kiln components From the diagnostics screen Figure 9 Diagnostics you can view the actual number of relay actuations the amount of time the heating elements have been on and the amount of time the thermocouples have been exposed to high temperatures Pa Date Time Status sdsindustries 16 Aug 15 430PM Admin Relay 1 Actuations 0 Relay 2 Actuations 0 iemet Relay 3 Actuations 0 Auxiliary 1 Output Relay Actuations 0 Auxiliary 2 Output Relay Actuations 0 afetuv Polay Artuatinme DIAGNOSTICS Figure 9 Diagnostics To access the diagnostics screen perform the following steps e From the Home Screen press MENU 12 e Fromthe Main Menu press DIAGNOSTICS 6 4 Event Logs TAP utilizes several event logs to track activity within the controller and the kiln environment A general event log error log firing log and schedule log can be accessed from the event logs screen Figure 10 Event Logs As loggable events occur they are stored to unigue log files and displayed on their respective log file screens providing user insight to behind the scenes activity within TAP The subseguent subsectio
7. In hours Element Life can be entered in the following format e XXXX Acceptable inputs are values from 40 7 500 Enter 0 or leave blank to disable Song pees oong Figure 35 Element Life Entry e For Thermocouple Life select THERMOCOUPLE LIFE tab select New Thermocouple Life enter new value using virtual keypad Figure 36 Thermocouple Life Entry then press ENTER 32 Please enter Thermocoupl Life Thermocouple Life can be entered in the following form t e XXXX Accept ble inputs are values from 10 7 500 Enter 0 or leave blank to disable Figure 36 Thermocouple Life Entry 6 6 8 Touchscreen Calibration Touchscreen calibration is sometimes required in the event that drifting or inaccurate touch inputs are being produced Touchscreen calibration can be performed at any time with the exception of during firing by holding a finger to the screen for a duration of 10 seconds During touchscreen calibration TAP controller application will close and pass control to the touchscreen calibration application At the completion of touchscreen calibration TAP controller application will begin again and prompt the user to set the current date and time To perform a touchscreen calibration perform the following steps e From any screen other than Execution press finger to screen e Wait 10 seconds e Follow on screen prompts 6 6 9 Themes You are able to personalize the look and feel of TAP by ap
8. Notilic tiOfi sssssss seu mass ain den 30 Figure 33 Preventative Maintenance ccccscccseccseccssececcescceucceueceuccaueceuecsuceeseceueeeueeeaeesseeeseenseeeseeneenes 31 Foure o AR OV Lieli ss oo S S S eran S S D S D 32 Flete mente Enijs o nn 32 Fieur 6 Inermocoubpi Life ENUY unica aida 33 FIEUES 7s S0 Ware Update association ct coi 34 1 Introduction The Temperature Automation by Proportional Integral Derivative TAP controller is the first viable commercially available solution to the art community which incorporates a Graphical User Interface GUI for end to end control of a firing process This controller is designed to take the guess work out of firing schedule creation modification execution and monitoring The intuitive touchscreen interface utilizes a smart phone like UI to enable immediate out of the box use This unique design approach alleviates the need to continually refer back to the User Manual for performing the most basic tasks Your new controller is a full featured device which beyond extraordinary kiln control and temperature following characteristics incorporates functionality to ensure peak performance for the life of your kiln and controller Features such as Diagnostics and Preventative Maintenance Alerts keep you abreast to the status and remaining life expectancy of critical kiln components namely relays thermocouples and heating elements Software Updates available from www kiln
9. RY OUTPUT Figure 28 Auxiliary Outputs Settings To enable disable auxiliary outputs perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS 26 6 6 2 e From Settings Screen press AUX OUTPUT e Select ENABLED or DISABLED for each channel depending on your preference Auxiliary outputs are disabled by default It is possible that your kiln manufacturer has enabled auxiliary outputs prior to delivery to you depending on the kiln configuration Cost Cost settings can be used to provide a realistic approximation of the cost of a firing TAP utilizes the user entered Cost per Kilowatt Hour and Kiln Power Rating to determine the cost of firing Unlike many controllers that assume anywhere from a 50 100 duty cycle for a firing TAP utilizes the amount of time elements are on during a firing to determine the exact duty cycle for the executing firing schedule During firing the accrued cost is displayed on the execution screen Assuming these settings are enabled you will see the firing cost increase as elements are cycled on and off during a firing After firing the actual cost can be found in the firing log The cost per kilowatt hour and kiln power rating are by default set to O displayed as Disabled This disables the cost reporting functionality After these settings are changed they are maintained in memory until default settings are restored or the setting is changed by the user Acceptable ent
10. SETTINGS e Select preferred display settings Fire Mode Fire Mode is set to ensure an inadvertent firing above the kiln manufacturers maximum rated temperature or the maximum thermocouple temperature does not occur This setting may or may not be set by your manufacturer prior to receipt It is possible that this screen will provide a single mode selection either glass or ceramic based on the kiln manufacturers advanced settings By default Fire Mode is set to Glass and has a corresponding maximum temperature of 1700 F To modify the Fire Mode setting perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS e From Settings Screen press FIRE MODE e Select the desired Fire Mode 29 6 6 5 6 6 6 6 6 7 Network Network functionality will be incorporated with future software updates As these updates become available the user documentation to support will also become available Notifications Notifications are used to provide audible and visual indicators to the user Figure 32 Notifications Alerts are used to indicate a process control has been met ie setpoint has been reached or a user defined indication is requested ie hold time alert Pa ier g Date Time Status sdsindustries 16 Aug 15 4 56PM Admin Alerts Enabled Disabled Alarms Enabled Disabled NOTIFICATIONS Figure 32 Notifications Alarms are used to indicate to the user that an abnormal occurrence has tak
11. TAP Temperature Automation by Proportional Integral Derivative JA gt o Hs ki E PF ATR KILN xe INTR OLLER USER MANUAL TAP CONTROLLER USER MANUAL ss gm La LZ sds industries p SDS INDUSTRIES INC www kilncontrolcom info kilncontroLcom August 2015 Contents Me NSO PIEM RI 4 1 go APP A en 5 2 o acc a N S A PEN UE O tone cede 5 3 GUSTAV TAS 7 4 BONN ce ees q S A 10 5 3 21 60 i a o N A 10 6 VIENU a a ERSA N N E PE EE E 11 6 1 CUD O urna cia 11 6 2 Developer Information cccccccccsssesseeecccccccauesseeececeessaeessseeecceeessueuseseceeeeessuaaaseeeceeeesauaaseseeeess 12 6 3 o E PO OEP PE En A EE 12 6 4 EVENTOS 1 N S NE D D A NB S 13 6 4 1 General Evento tas 13 6 4 2 o N 14 6 4 3 FIVE a A E A S bea aaa da ana 15 6 4 4 Snell LOB ooo 15 6 5 uo e En ierasnen seen 16 6 5 1 Schedule S lilf fsas sai ais nui 17 6 5 2 NEWS enc CUS a cs nj 19 6 5 3 KO SCEO da N N N N 24 6 5 4 Delete c NEAU namas 25 6 6 NS ss d coda 25 6 6 1 A A na I PO 26 6 6 2 LOST J 3 ase eee S SEA eee S S a I S none ere ae es a S 27 6 6 3 o 3 S eee eee 28 6 6 4 FN POC ta 29 6 6 5 SI nn 30 6 6 6 NOVIETO a S nju 30 6 6 7 Preventative Maintenance sis eee 30 6 6 8 Touch creen CAlDf fOfd anna 33 6 6 9 IBEm ss 4 V Po ro E E 33 6 7 WODI E o A A 33 7 AO o ol a E E PO o 34 8 A PAP E a on 36 Table of Figures Fie f l Prelimif r B06dt Cf fdasnss ss ss nn 6 fieli 2 eb t TIM ED N V ON
12. TAP KILN CONTROLLER ASSEMBLY INCLUDING THE WARRANTIES OF THE MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE THREE YEAR WARRANTY PERIOD COMMENCING ON THE DATE OF PURCHASE AND NO OTHER WARRANTY WHETHER EXPRESS OR IMPLIED WILL APPLY TO THIS PERIOD To the extent permitted by law SDS INDUSTRIES INC S REMEDY AND BUYER S SOLE REMEDY IS LIMITED SOLELY AND EXCLUSIVELY TO REPAIR OR REPLACEMENT AS SET FORTH HEREIN SDS INDUSTRIES INC SHALL NOT BE LIABLE FOR AND BUYER S REMEDY SHALL NOT 36 INCLUDE ANY INCIDENTAL CONSEOUENTIAL OR OTHER DAMAGES OF ANY KIND WHATSOEVER WHETHERA CLAIM IS BASED UPON THEORY OF CONTRACT NEGLIGENCE OR TORT Buyer shall determine suitability of the TAP Kiln Controller Assembly for the intended use and assume all risk and liability therewith Some states do not allow this exclusion or limitation of incidental or conseguential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which carry from State to State The above limitation does not apply in the event that any TAP Kiln Controller Assembly is determined by a court of competent jurisdiction to be defective and to have directly caused bodily injury death or property damage provided that in no event shall SDS Industries INC liability exceed the greater of 1 200 00 or the purchase price of the specific TAP controller that caused such damage 37
13. as determined that the current temperature is greater than 50F above the current setpoint If this error condition is met the controller will abort the firing and disable all outputs The condition can occur due to e Auser has opened the kiln during a hold for an extended period of time resulting in the kiln attempting to generate significant heat to maintain the loss of temperature Avoid this by only opening the kiln for short periods if necessary e A latched relay resulting in continuous power application to the heating elements A low temperature deviation from the hold temp has occurred Firing continues This condition can occur during a firing If this alarm is presented the controller has determined that the current temperature is less than 50F below the current setpoint If this error condition is met the controller will continue firing The condition can occur due to e Auser has opened the kiln during a ramp or hold for an extended period of time Kiln is failing to heat Firing continues This condition can occur during a firing If this alarm is presented the controller has determined that the kiln cannot generate enough heat to maintain the user programmed ramp rate If this error condition is met the controller will continue firing The condition can occur due to e User programmed Ramp Rate exceeds the capabilities of the kiln Kiln is failing to heat for too long Firing is aborted This condition can occur duri
14. at steps 6 11 above e When schedule input is complete press SAVE 6 5 3 Edit Schedule Schedule editing can be performed while in administrator or execute mode While in execute mode this can be accomplished prior to schedule execution at the schedule selector page or during firing from the execute page It is important to note that schedule steps beyond those that have already been executed as part of a current firing will not be editable To edit a schedule in administrator execute mode perform the following steps 24 e From Home Screen press MENU START e If in administrator mode from Main Menu press SCHEDULES e From Schedules Schedule Selector Screen highlight schedule to be edited then press EDIT SCHEDULE o The Edit Schedule Screen will appear with the Schedule Title Delay Start value and Current Schedule in a tabular format e Highlight values to change e Using the virtual keypad enter new value then press ENTER e Once all editing is complete press SAVE 6 5 4 Delete Schedule Deleting schedules can only be performed in administrator mode If you choose to delete a schedule please do so at your own risk There is no way to recover a deleted schedule To delete a schedule perform the following steps e From Home Screen press MENU e From Main Menu press SCHEDULES e From Schedules Screen highlight schedule for deletion then press DELETE SCHEDULE e At Confirmation Dialog press YES 6 6 Settings TAP includes a host of se
15. bers preceding letters From the Schedules screen Figure 15 Schedules accessed from the Menu or the Schedule Selector screen Figure 16 Schedule Selector accessed from Home users have the ability to create a new schedule edit an existing schedule or summarily view a currently stored schedule da l Date Time Status sdsindustries 16 Aug 15 438PM Admin 96 Full Fuse 6mm SCHEDULE Devit SCHEDULE DELETE SUMMARY Gold Bearing Tints 3mm BE Glass EDIT SCHEDULE NEW SCHEDULE Part Sheet Firing BE Glass SCHEDULES 16 Figure 15 Schedules of Date Time Status sdsindustries 16 Aug 15 478PM Execute p 96 Full Fuse 6mm oe Devit Gold Bearing Tints 3mm BE Glass EDIT NEW a SCHEDULE scHepute Part Sheet Firing BE Glass d SCHEDULE SELECTOR Figure 16 Schedule Selector From the Schedules screen users have the added ability of deleting schedules It is important to note that you cannot start a firing from the Schedules screen accessed from the Menu This screen is intended for administrative action vice progressing to schedule execution From the Schedule Selector screen users have the added ability of starting a firing It is important to note that you cannot delete schedules from the Schedule Selector screen as it is intended as the entry point to schedule execution To access the schedules screen in administrator mode perform the following steps e From Hom
16. ccurred during the course of general controller navigation or schedule execution Section XXX Errors defines all recordable errors probable cause and possible remediation The error log can be cleared at any time by pressing CLEAR LOG from the Error Log Screen Figure 12 Error Log li EEE D te Time Status sdsindustries 16 Aug 15 4 36PM Admin 13 Aug 15 4 14 PM Log cleared d ERROR LOG Figure 12 Error Log To access the error log perform the following steps 14 e From Home Screen press MENU e From Main Menu press EVENT LOGS e From Event Logs Screen press ERROR LOGS 6 4 3 Firing Log The firing log contains the data associated with all past firings These firings are presented in a selectable display box Each firing is identified by the date and time the firing began along with the title of the schedule executed Once a log is selected the user selects VIEW LOG to see a graph of the actual temperature vs elapsed time for the duration of the schedule The bottom of the screen will display the associated firing cost assuming the function was enabled in settings The firing logs can be cleared at any time by pressing CLEAR LOG from the Firing Log Screen Figure 13 Firing Logs of Date Time Status sdsindustries 16 Aug 15 4 36PM Admin 16 Aug 15_1628_96 Full Fuse 6mm 13 Aug 15_2114 Devit 13 Aug 15_ 2054 Devit d FIRING LOGS Figure 13 Firing Logs To access the firing log perform the
17. control com ensure that you always have an up to date device Software updates are deployed semi annually and incorporate product enhancements based on user feedback along with any necessary bug fixes 2 Startup You ve got TAP and it s been installed GREAT Now let s get started quickly When you apply power to TAP the controller will go through a sequence of startup events prior to being usable When power is initially applied TAP begins to run through a complex initialization period in which it configures all the inputs outputs and the underlying file system The first thing you will see is the preliminary boot screen Figure 1 Preliminary Boot Screen This screen is the first indication to you that power is applied and the controller is booting up This boot screen will be present for 5 10 seconds as it configures the inputs and outputs Figure 1 Preliminary Boot Screen After this the screen will display the SDS Industries logo for 10 20 seconds DO NOT WORRY this is perfectly normal During this time the controller is initializing all the peripherals such as USB and Ethernet as well as optimizing the display resolution and color settings The next screen you will see is a Date Time screen Figure 2 Date Time Entry in which you are requested to enter the current Date and Time Time should be entered in a 24 hour clock format i e 1 15PM is entered as 13 15 00 Once you have entered the Date and Time press Done
18. cute press START This will begin the firing process During this stage of execution you will be viewing the execution screen Figure 5 Execution Status in which the following information will be available Currently Executing Schedul Current Step of Total Steps Current Board Temperature Current Kiln Temperature Current Step Ramp Rate Current Step Setpoint Current Step Hold Time Current Firing Elapsed Time Current Firing Accrued Cost e Title fade m sdsindustries VIEW GRAPHICAL EDIT SCHEDULE SCHEDULE SUMMARY Date Time Status 16 Aug 15 4 78PM Execute Schedule 96 Full Fuse 6 Current Stej 1 of 4 Ambient Te 74 2 F Kiln Temp 142 9 F Ramp Rate 500F Setpoint 1100F EXECUTE 96 Full Fuse 6mm Figure 5 Execution Status If during the sequence of firing you want to modify the schedule press EDIT SCHEDULE Once EDIT SCHEDULE is pressed you will be transitioned to the EDIT SCHEDULE screen Figure 6 Edit Schedule This will give you the opportunity to modify any schedule steps beyond those that have already been executed For more details on how to edit a schedule refer to Section 6 5 3 Edit Schedule J sdsindustries ndustries Date Time Status 16 Aug 15 4 79PM Execute Delay Start Step tame Setpoint Time Alert Alert 500 1100 30 No No 2 AFAP 1480 10 Yes Yes 3 AFAP 900 00 No No 4 AFAP 100 0 No No EDIT SCHEDULE Figure 6 Edit Schedule If at any point dur
19. e Screen press MENU e From Main Menu press SCHEDULES To access the Schedule Selector screen in execute mode perform the following steps e From Home Screen press START 6 5 1 Schedule Summary Schedule Summary provides quick access to a tabulated format of any schedule maintained in memory Schedules and steps cannot be edited created or deleted while viewing a schedule summary To make modifications to a schedule refer to Section 6 5 2 New Schedule Section 6 5 3 Edit Schedule or Section 6 5 4 Delete Schedule The contents of the Schedule Summary will differ based on user defined settings 17 If alerts are enabled Schedule Summary will display Setpoint Alert and Hold Time Alert columns Figure 17 Schedule Summary with Alerts along with their associated user defined parameter sdsindustries gt 16 Aug 18 4 39 PM Ramin Title 96 Full Fuse 6mm Delay Start 0 Minutes 1 500 1100 30 No No 2 AFAP 1480 10 Yes Yes 3 AFAP 900 1 00 No No 4 AFAP 100 No No 7 SCHEDULE SUMMARY Figure 17 Schedule Summary with Alerts If Auxiliary Output 1 is enabled Schedule Summary will display an aux output 1 parameter Figure 18 Schedule Summary with Aux 1 for each schedule step sdsindustries 16 Aug ls 440PM Admin Title 96 Full Fuse 6mm Delay Start 0 Minutes Step rets setpoint cie Aux 1 1 500 1100 30 No 2 AFAP 1480 10 No 3 AFAP 900 1 00 No 4 AFAP 100 0 No SCHEDULE SUMMARY Figure 18 Schedule Summary
20. en place and some corrective action is required For a list of conditions that generate alarms refer to Section 7 Alarm Conditions If Alerts and or Alarms are set to disabled in this section no alerts and or alarms will be presented regardless of the users request to display them during process control By default alarms are set to enabled and alerts are set to disabled It is recommended that alarms remain enabled however if they are disabled and an error condition that requires a firing schedule be aborted occurs the firing will still be aborted though no indication to the user will be present To modify the notification settings perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS e From Settings Screen press NOTIFICATIONS e Select preferred notification settings Preventative Maintenance Preventative Maintenance settings Figure 33 Preventative Maintenance are utilized in conjunction with TAP s recorded diagnostics to ensure peak performance over the lifetime of your 30 kiln Preventative maintenance settings are used as a reference point for when alerts should be presented to the user and act as a reminder that it is time to perform regular maintenance on the kiln These settings cover relay life element life and thermocouple life a Date Time Status sdsindustries 16 Aug 15 4 56PM Admin Element Life Thermocouple Life Relay Life Current Disabled
21. for 10 minutes ie no button presses the controller will enter a sleep state in which the display will turn off To wake the controller back up simply tap anywhere on the screen Sleep mode will only be entered in Standby and Admin modes The screen will not turn off during a firing The home screen is also the entry point to kiln schedule execution and the myriad menu items available To enter execute mode and begin a firing press START To enter administrator mode and access the menu press MENU 5 Execute The execution screen is the display which will be present for the duration of a firing schedule in execution The screen provides all pertinent information with respect to current firing as well as certain control features The following is a list of information presented during a firing e Currently Executing Schedule Title e Current Step of Total Steps e Current Board Temperature e Current Kiln Temperature e Current Step Ramp Rate e Current Step Setpoint e Current Step Hold Time e Current Firing Elapsed Time e Current Firing Accrued Cost The following is a list of control functions available during a firing e Skip Step e Schedule Summary e View Graphical e Edit Schedule e Abort Skip Step will transition the controller to the next step in the firing schedule A confirmation dialog will be presented after Skip Step is pressed to ensure the selected operation is intended 10 Schedule Summary will bring up a new
22. igations under this limited warranty within 7 business days Limited warranty services may be obtained by delivering the TAP Kiln Controller Assembly during the warranty period to your TAP Kiln Controller Supplier or to SDS Industries INC 37 Nobody s Road Cheshire MA 01225 and providing written proof of purchase and a description of the defect or problem Buyer will be responsible for shipping and handling incurred by SDS Industries in returning the TAP Kiln Controller Assembly to the Buyer after completion of limited warranty service This warranty does not apply to any damage to the TAP Kiln Controller Assembly resulting from e Operation beyond electrical rating e External sources including but not limited to chemicals heat abuse and improper care e Improper or inadequate maintenance by Buyer e Parts or equipment not supplied by SDS Industries e Unauthorized modification or misuse e Operation outside environmental specifications e Improper installation e Over firing melting of materials being fired regardless of the cause of the over firing TAP Kiln Controller Assemblies returned for service where no warranted defect is found will be subject to service and shipping fees If the TAP Kiln Controller Assembly is not in good working order as warranted above Buyer s sole remedy shall be repair or replacement of the TAP Kiln Controller Assembly as provided above To the extent permitted by law ALL EXPRESS AND IMPLIED WARRANTIES FOR THE
23. ing the firing you want to advance the kiln schedule to the next step simply press SKIP STEP This can be performed at any point during a firing When you press SKIP STEP you will be presented with a confirmation dialog To complete the action and skip to the next step you must press YES at the confirmation dialog During execution of a firing you also have the ability to view a graphical representation of what has previously occurred By pressing VIEW GRAPHICAL you can view a chart that displays the schedule execution Figure 7 Graphical View To return to execution status simply press the back arrow on the view graphical screen Data is populated into the view graphical screen every 1 minute so no data will be present until the Current Firing Elapsed Time is in excess of 1 Minute Figure 7 Graphical View You can also cancel the firing at any time by pressing ABORT When you press ABORT you will be presented with a confirmation dialog To complete the action and abort the firing you must press YES at the confirmation 9 dialog If you choose to abort a firing you will be returned to the Home Screen The firing progress through the point of cancellation will be available via the Firing Logs 4 Home The home screen is the kickoff point for all controller activity This screen provides the current date and time and kiln temperature This screen is displayed when the controller is in standby mode If the controller is inactive
24. n will be presented to the user for 60 seconds or until acknowledged Hold Time Alerts can be enabled or disabled on a per step basis If enabled an audible and visual indication will be presented to the user for 60 seconds or until acknowledged Aux 1 Output can be enabled or disabled on a per step basis If enabled the auxiliary output will be enabled for the duration of the step at which it is specified Aux 2 Output can be enabled or disabled on a per step basis If enabled the auxiliary output will be enabled for the duration of the step at which it is specified To enter a new schedule in administrator execute mode perform the following steps e From Home Screen press MENU START e lf in administrator mode from Main Menu press SCHEDULES e From Schedules Schedule Selector Screen press NEW SCHEDULE e Highlight SCHEDULE TITLE and input your chosen title using the virtual keyboard e Highlight DELAY START and input your chosen delay start time using the virtual keypad e NOTE This is not a required step If you leave delay start blank TAP will use O for a delay time and will start firing immediately after schedule is selected and advanced to execute e Press ADD STEP e Input Ramp Rate using the virtual keypad Figure 24 Ramp Rate Entry F then press ENTER 22 pon J DU Segment 1 Ramp Rate Valid Entries 0 1 1500 9999 Full power is 9999 AFAP a 2 Temperature should be entered in units defined in settings O
25. ndustries Jeng 4 43PM Admin la M Delay Start inutes Ramp Hold Rate Setpoint Aux 2 om Time NEW SCHEDULE Figure 23 New Schedule with Aux 2 Users may define any combination of these settings and the user interface will update accordingly During schedule creation the user has largely unlimited options as to the ramp rates setpoints hold times and alerts produced These settings can be modified at any time after initial schedule creation by performing the steps identified in Section 6 5 3 Edit Schedule Ramp Rates and Setpoints should be entered in the units defined in settings Fahrenheit or Celsius 21 Ramp Rates can be entered from 0 1 to 1500 F Hr 0 05 to 815 C Hr Additionally users can enter 9999 which will ramp the kiln as fast as possible AFAP If the ramp is used as a ramp up this will equate to full power until the setpoint is reached If the ramp is used as a ramp down this will equate to no power until the setpoint is reached Setpoints can be entered from 70F to the Kiln Max Temp Glass Mode is 1700F by default Ceramic Mode is 2300F by default Hold times can be entered in Minutes or Hours and Minutes If a hold time is entered in the format XXXX the value will be interpreted as minutes If a hold time is entered in the format XX XX the value will be interpreted as Hours Minutes Setpoint Alerts can be enabled or disabled on a per step basis If enabled an audible and visual indicatio
26. ng a firing If this alarm is presented the controller has determined that the kiln is not heating or the input is invalid If this error condition is met the controller will abort the firing and disable all outputs The condition can occur due to e Disconnected Thermocouple e Thermocouple not present e Broken Element s 35 8 Warranty This limited warranty is given only to the immediate purchaser Buyer of the TAP Kiln Controller Assembly 5358440 1 This limited warranty is not transferable SDS Industries warrants the controller Main Board CPU Module Display Board and LCD Screen installed in the TAP Kiln Controller Assembly to be in good working order under normal operating conditions for a period of three 3 years from the date of purchase Should the TAP Kiln Controller Assembly fail to be in good working order at any time during the stated three 3 year period SDS Industries will at its option repair or replace the TAP Kiln Controller Assembly as set forth below The liability of SDS Industries is limited to replacement and or repair at its factory of the TAP Kiln Controller Assembly that does not remain in good working order Repair parts will be furnished on an exchange basis and will be either refurbished or new All replaced parts or products become the property of SDS Industries Following receipt of notice from Buyer of a valid warranty claim and the TAP Kiln Controller Assembly SDS Industries will perform its obl
27. ns provide detail as to the contents of each unigue log and the method to access each a e Date Time Status 16 Aug 15 4 35PM Admin GENERAL EVENT LOG FIRING SCHEDULE CLEAR ALL LOGS LOG L GS EVENT LOGS Figure 10 Event Logs All logs can be cleared by pressing CLEAR ALL LOGS from the Event Logs Screen Note This action cannot be undone If you choose to clear all logs the data will not be recoverable 6 4 1 General Event Log The general event log contains information relevant to the TAP general functionality The log records information related to controller power up power down mode transitions and software updates Each record is stored with the time and date of occurrence to assist in troubleshooting should the need arise The general log will maintain the last 1000 recordable events The log can be cleared at any time by pressing CLEAR LOG from the General Event Log Screen Figure 11 General Event Log 13 Fara ii Date Time Status sdsindustries 16 Aug 15 4 35PM Admin 16 Aug 15 4 35 PM Navigated to Menu 16 Aug 15 4 35 PM Navigated to Event Logs 16 Aug 15 4 35 PM Navigated to General Log d GENERAL LOG Figure 11 General Event Log To access the general event log perform the following steps e From Home Screen press MENU e From Main Menu press EVENT LOGS e From Event Logs Screen press GENERAL EVENT LOG 6 4 2 Error Log The error log contains information relevant to errors that have o
28. on the screen You will now be transitioned to the Home Screen the starting point for all remaining controller activities sdsindustries Please set the current date and time Figure 2 Date Time Entry 3 Quick Start This section will guide you through the process to begin a kiln firing with a stored or custom schedule in no time flat From the Home Screen Figure 3 Home Screen press START This will transition you to the schedule selector screen Figure 4 Schedule Selector d Tp Date Time Status sdsindustries 16 Aug 15 427PM Standby Ambient Kiln 74 2 F 142 9 F HOME Figure 3 Home Screen e ede Fep Date Time Status 16 Aug 15 428PM Execute 96 Full Fuse 6mm SCHEDULE iS SUMMARY 1 Devit Gold Bearing Tints 3mm BE Glass EDIT NEW a SCHEDULE scHeoule Part Sheet Firing BE Glass 4 SCHEDULE SELECTOR Figure 4 Schedule Selector Note Figure 4 Schedule Selector most likely will not match your display as it is largely dependent on the schedules you have loaded Note You ll know you re at the home screen when System Status says Standby This is also the first screen you ll see after setting the date and time From the schedule selector screen select a pre populated schedule or create your own by pressing NEW SCHEDULE If you choose to enter your own schedule please refer to Section 6 5 2 New Schedule After you have selected the schedule you wish to exe
29. plying various themes Additional themes will become available with future software updates 6 7 SW Update Semi annual software updates are available from www kilncontrol com These updates incorporate additional planned functionality software enhancements as requested by users and any bug fixes that may be identified To update software perform the following steps e Download the latest version of available software from www kilncontrol com e Extract the contents of the zip file to a USB thumb drive o Note It is critical that this be placed at the root level of the USB flash drive ie do not extract to a personally created directory e Insert USB thumb drive into USB port on TAP e From Home Screen press MENU 33 e From Main Menu press SOFTWARE UPDATE Figure 37 Software Update e i ii Date Time Status sdsindustries 16 Aug 15 4 59PM Admin Current Software Version 1 0 Available Versions 20150623 TAP_controller_R1 20150723 TAP controller_R1_1 20150823 TAP controller _R12 E 20150923 TAP controller_R1_1 SOFTWARE UPDATE Figure 37 Software Update e Select the desired software from the available software list then press UPDATE SOFTWARE e At confirmation dialog press YES 7 Alarm Conditions Kiln Maximum Temperature has been exceeded Firing is aborted This condition can occur during a firing If this alarm is presented the kiln temp has exceeded the maximum defined kiln temperature The default value fo
30. r Glass Mode is 1700F The default value for Ceramic Mode is 2300F If this error condition is met the controller will abort the firing and disable all outputs This condition can occur due to e Auser programming a schedule with a firing temp exceeding the max temp e A latched relay resulting in continuous power application to the heating elements Kiln is not cooling at defined ramp rate Firing continues This condition can occur during a firing If this alarm is presented the kiln cannot cool at the defined rate This alarm most commonly occurs when a user enters a cooling rate that the kiln is incapable of producing If this error condition is met the controller will continue the firing The condition can occur due to e Kiln insulation and ambient temperature does not permit cooling at the specified rate Kiln is failing to cool Firing is aborted 34 This condition can occur during a firing If this alarm is presented the controller has determined that the kiln is not cooling If this error condition is met the controller will abort the firing and disable all outputs The condition can occur due to e A user defined temperature that is below the room s ambient temperature e A latched relay resulting in continuous power application to the heating elements A high temperature deviation from the hold temp has occurred Firing is aborted This condition can occur during a firing If this alarm is presented the controller h
31. ries for Cost per Kwh are SO through 9 99 If desired a value of O or a blank can be entered which will disable the cost reporting functionality Acceptable entries for Kiln Power are 100 through 100 000 Watts Most kilns are delivered with Power Ratings in Kilowatts To convert from Kilowatt to Watt multiply the Kilowatt value by 1000 It is imperative that kiln power is entered in Watts as any other unit of entry will result in incorrect cost reporting If desired a value of O or a blank can be entered which will disable the cost reporting functionality To modify the cost settings perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS e From Settings Screen press COST e Select the Cost KWh box e Using the virtual keypad Figure 29 Cost per KWh Entry enter the new Cost per Kilowatt Hour in dollars and press ENTER o Note This value can be obtained from your monthly utility bil o Note If your Cost per Kilowatt Hour is 22 Cents enter 0 22 alternatively 22 in Cost KWh field 27 Please enter Cost per KW Cost can be entered in the following formats ex XX e XX Xx Acceptable inputs are values from 0 01 to 9 99 Enter 0 or leave blank to disable cost ERE gog NODO Figure 29 Cost per KWh Entry e Select the Cost Power Rating e Using the virtual keypad Figure 30 Kiln Power Entry enter the Kiln Power Rating in Watts then press ENTER o Note This value can be ob
32. screen in which the currently executing firing can be viewed in a tabular format No editing is allowed in this mode View Graphical will bring up a new screen in which the currently executing firing data points can be seen from the time the schedule started to the current time Data points are populated every 1 minute and as such View Graphical will not show any data points if the firing has just begun Edit Schedule will bring up a new screen similar to Schedule Summary The currently firing schedule can be edited at this point Any unexecuted segment step can be modified by pressing the corresponding table cell Depending on the selected cell you will either be prompted with an input instruction message and keypad Ramp Rate Setpoint Hold Time or a Yes No selection Setpoint Alert Hold Time Alert Aux 1 Aux 2 Abort will cancel the currently executing schedule A confirmation dialog will be presented after Abort is pressed to ensure the selected operation is intended When abort is pressed and the action is confirmed execution will halt at that point in the schedule and the controller display will return to the Home Screen 6 Menu The menu on TAP provides access to many features and settings within the controller This menu is access by selecting MENU from the home screen Once the menu is entered Figure 8 Main Menu the controller is set to Administrator mode and allows the user to modify Settings read Event Logs access Developer
33. t to use unique titles when inputting new schedules If you have input a schedule title that is already in use TAP will OVERWRITE the existing schedule entry 19 q TIES Q UJUNI UA III Dat Time Status sdsindustries 16 Aug 15 4 42PM Admin Title ES O CANCEL a Delay Start Minutes Ramp m F Hold Setpoint Hold Rate a Time Alert Alert Step Aux 1 Aux 2 NEW SCHEDULE Figure 20 New Schedule The contents of the New Schedule creator will differ based on user defined settings If alerts are enabled New Schedule will display Setpoint Alert and Hold Time Alert columns Figure 21 New Schedule with Alerts and Aux 1 along with their associated user defined parameter ate Time Status sdsindustries 16 E 15 4 42PM Admin ADD ds STEP Ramp i Hold Setpoint Hold Rate tm Time Alert Alert Step Aux 1 NEW SCHEDULE Figure 21 New Schedule with Alerts and Aux 1 If Auxiliary Output 1 is enabled New Schedule will display an aux output 1 parameter Figure 22 New Schedule with Aux 1 and Aux 2 for each schedule step 20 m D te Time status sdsindustries AD 15 4 43PM Admin ES O CANCEL F Delay Start Minutes Ramp Hold Rate Setpoint Time Aux 1 Aux 2 Step NEW SCHEDULE Figure 22 New Schedule with Aux 1 and Aux 2 If Auxiliary Output 2 is enabled New Schedule will display an aux output 2 parameter Figure 23 New Schedule with Aux 2 for each schedule step SEA D s sdsi
34. tained from your kiln manufacturer o Note If Kiln Power Rating is 10KW enter 10000 in Cost Power Rating field Please enter Kiln Power in Watts Power can be entered in the following format e XXXX Acceptable inputs are values from 100 100 000 Enter O or leave blank to disable cost pees gong Song Figure 30 Kiln Power Entry 6 6 3 Display Mode Display Settings control how data is displayed to you on the various screens throughout TAP Within Display Settings the user has the ability to control the temperature format the date display format and the time display format Figure 31 Display Settings These settings are 28 6 6 4 maintained in a file stored in memory and will be retained in the event that power is lost to TAP The default settings are Fahrenheit temperature display DD MMM YY date display and 12 Hour clock format Pa vii IET Date Time Status 16 Aug 15 4 55PM Admin Display Mode Fahrenheit Celsius Date Format MM DD YY DD MMM YY DD MM YY Time Format 12 Hour 24 Hour DISPLAY Figure 31 Display Settings Temperature can be displayed in either Fahrenheit or Celsius Date can be displayed as MM DD YY DD MMM YY or DD MM YY Time can be displayed in either 12 Hour XX YY AM PM or 24 Hour XX YY format To modify the display mode settings perform the following steps e From Home Screen press MENU e From Main Menu press SETTINGS e From Settings Screen press DISPLAY
35. ttings to make your life easier and to ensure that the data you want to see is available and in the format you prefer There are also settings which ensure your kiln will continue to operate at peak performance for its entire lifetime Any time a setting is changed the value is written to a file This ensures that in the event of loss of power your settings are remembered when the controller is restarted To access Settings Figure 27 Settings perform the following steps e From Home Screen Press Menu e From Main Menu press SETTINGS 25 e Fri Date Time Status sdsindustries 16 Aug 15 4 47PM Admin AUX DISPLAY OUTPUT SETTINGS FIRE MODE ADVANCED PREVENTIVE CURRENT MAINT SETTINGS NOTIFICATIONS SETTINGS Figure 27 Settings 6 6 1 Auxiliary Output Auxiliary Outputs can be used to control external devices such as blowers lid lifters or external alarms TAP offers two auxiliary outputs which each control a 12 Volt signal When these settings are enabled TAP drives the respective auxiliary output signal high when instructed to do so by the controlling firing schedule and in turn activates the relay you have controlling the external device The auxiliary outputs are independently controllable Figure 28 Auxiliary Outputs Settings cd i i Date Time Status sdsindustries gt 16 Aug 15 452PM Admin Auxiliary Output 1 Enabled Disabled Auxiliary Output 2 Enabled Disabled AUXILIA
36. with Aux 1 If Auxiliary Output 2 is enabled Schedule Summary will display an aux output 2 parameter Figure 19 Schedule Summary with Aux 2 for each schedule step 18 6 5 2 sdsindustries gt 16 Aug ls 441 PM Admin Title 96 Full Fuse 6mm Delay Start 0 Minutes Step oe Setpoint ienes Aux 2 1 500 1100 30 No 2 AFAP 1480 10 No 3 AFAP 900 1 00 No 4 100 0 SCHEDULE SUMMARY Figure 19 Schedule Summary with Aux 2 Users may define any combination of these settings and the user interface will update accordingly To access the schedule summary screen in administrator mode perform the following steps e From Home Screen press MENU e From Main Menu press SCHEDULES e From Schedules Screen select an available schedule e After an available schedule is selected press SCHEDULE SUMMARY To access the schedule summary screen in execute mode perform the following steps e From Home Screen press MENU e From Schedule Selector screen select an available schedule e After an available schedule is selected press SCHEDULE SUMMARY New Schedule New Schedule creator Figure 20 New Schedule allows the user to input a new schedule while in administrator mode or while in execute mode in preparation for a firing Schedule storage is virtually unlimited There is no limit to the number of steps that can be included in a specific schedule Schedules are stored using the Schedule Title as the identifier therefore it is importan
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