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AutofirePlusUnitemp manual - Edward Orton Ceramic Foundation

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2. properly These also give a permanent record of your firing Orton cones bend when a specific amount of heatwork has been received Bending temperatures will be different when the heating rate is changed During the last 60 to 90 minutes the AutoFire controller always heats the kiln at 108 F hr 60 C hr during a selected Conefire firing If the kiln cannot maintain this heating rate then a lower shut off temperature is calculated to minimize overheating of the ware The overall firing time of the program will be longer This occurs when the final firing temperature at the time of completion is lower then the anticipated temperature AutoFire Kiln Controller User s Guide Pyrometric cones and their use is explained fully in Appendix B while a Temperature Equivalent chart is included in Appendix C AutoFire KILN CONTROLLER MODELS The Orton AutoFire family of kiln controllers includes four models to meet most users needs The features unique to each model is given below AutoFire Plus Control With a Single Type K N or S Thermocouple Power Output to Mechanical Relay s for Heating Element Control Power Output to a Mechanical Relay for Vent Fan Control option AutoFire Pro Control With a Single Type K N or S Thermocouple Power Output to Solid State Relay for Heating Element Control Power Output to a Mechanical Relay for Safety Shut off Power Output to a Mechanical Relay for Vent Fan Control option AutoFire UniT
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4. Type S The tC feature enables the user to select from type K N or S thermocouples The controller uses this information to apply the correct thermocouple calibration information to the millivolt signal received from the thermocouple The factory default thermocouple type is type S in order to keep kiln from overheating if electronics are reset to factory default settings The selected type is saved in memory Id Specify RS 485 Node Identification Default Setting 0 The Id feature is used to specify the kiln controller node for recognition by the computer This is an identification number from 0 to 15 when the controller is one of up to 16 controllers in a network connected to a personal computer using Orton s ControlMaster software product For more information about ControlMaster refer to page 29 on Remote Control and Monitoring The factory default RS 485 node identification is 0 The selected setting is saved in memory If multiple kilns are used in a system the last controller in the network needs jumper JPR1 installed page 40 all other controllers should have it removed tEdE Specify Alarm Value Default Setting 100 F 56 C The tEdE feature enables the user to select a temperature deviation value at which an audible and visual alarm will occur The temperature deviation applies to the following alarms FtH FtC LtdE and HtdE When active the alarm displays the type of deviation and sounds th
5. Bisque and Earthenware Firings Cone 04 010 01 Hi Fire Stoneware and Porcelain Firings Cone 6 1 12 AutoFire Kiln Controller User s Guide The Test Firing Completing a test firing with your new AutoFire Kiln Controller will help you become familiar with the operation and features of the controller as well as determine that the controller is performing as expected Follow your kiln manufacturer s Instruction Manual for setting up your kiln and firing to properly break in the kiln s heating elements For an AutoFire Plus or Pro model place a set of Orton Self Supporting Cones on the middle shelf in your kiln so that they can be seen through the kiln peephole If you have the AutoFire UniTemp model controller also place cones on the top and bottom shelves of kiln to examine temperature uniformity within your kiln Use a series of cones close to the temperature that you plan to fire to during an actual firing A three cone firing set up is recommended a Guide Cone Firing Cone and a Guard Cone For example if you were firing to a 1945 F Cone 04 you would use a Cone 03 Cone 04 and a Cone 05 to do the test firings To evaluate heat distribution place a set of witness cones on each shelf during the test firing Most kilns fire more uniformly at Cone 6 than they do below Cone 06 With the UniTemp cones should bend similarly no matter what the firing temperature Provide ventilation for the kiln in accordance with your k
6. Bottom termocouple failure Unitemp tEdE Temperature Deviation default 100 corresponding alarm is FtH FtC HtdE LtdE rEtn Return tC Select Thermocouple Type K N or S tCnt Factory Use Only Un Program Lock Off all programs and parameters can be modified Usr User Program 1 4 11 AutoFire Kiln Controller See next page for alarm messages and rest of manual for explanation User s Guide 12 AutoFire Kiln Controller User s Guide Alarm Reference The following is a reference guide to the alarm conditions that may be encountered while using your AutoFire Kiln Controller refer to page 20 Audible Alarm Only Display Meaning ALAr Kiln Threshold Temperature reached threshold temperature alarm set by user FtH Fail to Heat kiln unable to heat at program ramp temperature is below set point by deviation amount FtC Fail to Cool kiln unable to cool at program ramp temperature is above set point by deviation amount HtdE High Temperature Deviation kiln above set point by deviation amount LtdE Low Temperature Deviation kiln below set point by deviation amount LBAt Low Battery tC 0 Top Thermocouple has failed during firing UniTemp Models Only tC 1 Bottom Thermocouple has failed during firing UniTemp M Models Only tCdE Thermocouple Deviation Alarm Factory Set for gt 60 C UniTemp Models Only temperature deviation alarms occur when the kiln temperature differs from the set poi
7. fan automatic control e Built in communications port e Temperature Accuracy 2 C Service Should your AutoFire quit working or a display message which indicates your controller requires service please call the service number listed below Do not return any units or parts for service without first calling the service number 1 800 999 5442 To Return Unit for Service Receive an RMA for returning your controller Wrap the controller in protective packaging and securely pack in sturdy box Ship the unit prepaid to Orton with a complete description of defect or problem and your name address and telephone number Upon receipt by Orton your unit will be examined and any defective or damaged parts will be repaired or replaced For units not under warranty an estimate will be provided upon request before repairs are made See Warranty on the next page for complete details Thermocouple replacement Orton Ceramic Foundation sells replacement thermocouples To order a replacement call and specify the size type and quantity required 31 AutoFire Kiln Controller User s Guide WARRANTY The Edward Orton Jr Ceramic Foundation Orton Ceramic Foundation warrants the panel mount kiln controller hand held kiln controller or wall mount kiln controller with or without associated power supply and power switching components to be in good working order for a period of two 2 year from the date of purchase from Orton Ceramic
8. hold Hold times are in 5 minute increments Selects the displayed hold time Display 06 1828 022 1086 to 12 2382 Hd 0 0 5 10 15 20 25 30 IdLE At this point additional options can be selected such as delay start firing speed or cone offset STOP START STOP START Starts the selected cone firing The current kiln temperature is displayed during an active firing cycle When the active firing cycle is completed The final temperature reached by the kiln will be alternately shown as CPLt in the display Acknowledges completion of the firing cycle and returns to ILE mode Also functions as Abort Abrt during a firing process XXXX where XXXX is current temperature CPLt Final Temperature IdLE Abrt For more information on additional features and options refer to the appropriate sections in this User s Guide AutoFire Kiln Controller Cone Fire Example Fire to Cone 6 increase firing speed 20 and add a 15 minute hold controller temperature is displayed in F Just follow these simple steps Step 1 2 10 11 12 13 14 Press CONE FIRE UP ARROW ENTER UP ARROW ENTER OPTIONS ENTER RIGHT ARROW ENTER UP ARROW ENTER STOP START Note STOP START Description ________ UU U Enters the Cone Fire mode Press UP ARROW 11 times Scrolls to display of 6 Cone Number Selects cone number 6 Press UP ARROW 3 times Scrol
9. mode The controller is not capable of starting a firing cycle if an open thermocouple condition exists tC0 tC1 Open Thermocouple UniTemp Models Only The Open Thermocouple Alarm is activated when an open thermocouple is detected When this condition is detected during an active firing cycle the controller continues the firing cycle and indicates tC on the display to indicate the failed thermocouple The Open Thermocouple Alarm applies to both preset cone programs and user programs A UniTemp controller can operate on one thermocouple during an active firing Electronic Hardware Alarms EtH LBAt PLoG The Electronic Hardware Alarms apply to both preset cone programs and user programs EtH Electronics Temperature Threshold The Electronics Temperature Threshold Alarm is activated when the electronics temperature is greater than or equal to the factory specified electronics temperature threshold 85 C or 185 F When this condition is detected during an active firing cycle the controller aborts the firing cycle and indicates EtH on the display The controller is not capable of starting a firing cycle if an Electronics Temperature Threshold condition exists Verify that the ambient temperature at the controller is not higher than 85 C If the controller is in a cool location most likely the electronics board is experiencing interference from the AC power lines or element wires LBAt Low Battery The Low Battery Alarm is
10. ordered without Cone Fire programs thus on some models the keypad may not show the Cone Fire button Those working in glass do not need Cone Fire programs but will still benefit by the advanced features of the AutoFire AutoFire Kiln Controller User s Guide Cone Fire using your controller for preset cone programs e The Up Arrow A increments the value 0 9 or scrolls through selections one at a time e The Right Arrow shifts editing digit to the right or scrolls through selections one at a time The AutoFire family of kiln controllers feature easy firing to any cone number Just follow these simple steps Step 1 Press CONE FIRE UP ARROW RIGHT ARROW ENTER UP ARROW RIGHT ARROW ENTER Controller temperature is displayed in F Description ______ U U Enters the Cone Fire mode The 06 is the cone program name and the 1828 is the corresponding cone deformation temperature at a 108 F hr ramp Scroll to the desired cone number The desired preset cone program name and the corresponding cone deformation temperature at the 108 F hr ramp will be alternatively displayed Selects the desired cone number currently displayed Then advances to Hold Time Hd Use arrows to select up to 30 minutes of hold time at the end of Cone Fire program If no hold time is desired then simply press ENTER The controller returns to Idle mode Scroll to the desired hold time The default is 0
11. programs These alarms occur when the measured kiln temperature differs from the controller set point temperature by more than the alarm value This deviation is typically factory set at 100 F 56 C It does not apply to tCdE or FtL It is changed through Options Level 2 tEdE EtH Electronics Too Hot verify that the temperature at controller is not higher than 85 C 185 F If controller is cooler most likely the electronics board is experiencing electrical interference FtH Failure To Heat The alarm is caused by a temperature deviation during a ramp up segment This alarm occurs due to the difference between the controller set point temperature and the measured kiln temperature FtC Failure To Cool The Failure to Cool alarm is activated if the measured cooling rate is greater than the programmed rate by the amount of the alarm difference LtdE Low Temperature The temperature deviation alarm occurs due to a low temperature deviation during a ramp down or in a dwell segment HtdE High Temperature The temperature deviation alarm occurs due to a high temperature deviation during a ramp up or a dwell segment TCdE TC Deviation Alarm UniTemp Models Only A temperature deviation alarm which occurs when the deviation between the top and bottom thermocouples is equal to or greater than 60 C 108 F FtL Firing Too Long The Firing Too Long Alarm occurs when the measured heating rate is less than 15 C hr AND the actual
12. 0000 Repeat Steps 4 14 for each ramp dwell temperature and dwell time desired STOP START STOP START STOP START Acknowledges completion of the completed program and stores the current program into memory Starts the current user program just entered Aborts firing cycle if necessary during firing IdLE XXXX current kiln temperature Abrt AutoFire Kiln Controller User s Guide Or acknowledges completion of the firing cycle IdLE and returns to the main display Using a Pre Programmed USER Program After you have stored a custom user program the controller retains the program in memory for easy recall later You may select and run any of the pre programmed user programs in 4 easy steps While the controller is in J LE mode Press USER PROGRAM Use the RIGHT ARROW to scroll through the four user programs Press USER PROGRAM again to select the desired user program Press STOP START to start the program immediately or DELAY START to start later qoM W S The DELAY START allows user to specify in minutes a time to delay before starting the firing When selecting this feature simply press DELAY START and enter into the display the number of minutes of delay time i e 0120 2 hours then press ENTER to store the value To then start the delay sequence press STOP START The controller will then display d ELA and the delay time remaining before controller will automatically start To review a pr
13. 16 1971 108 2124 5 360 1031 180 1103 216 2014 108 2167 6 360 1031 180 1103 216 2079 108 2232 7 360 1031 180 1103 216 2109 108 2262 8 360 1031 180 1103 216 2127 108 2280 9 360 1031 180 1103 216 2147 108 2300 10 360 1031 180 1103 216 2192 108 2345 11 360 1031 180 1103 216 2208 108 2361 12 360 1031 180 1103 216 2230 108 2383 28 AutoFire Kiln Controller User s Guide Preset Cone Fire Schedules Con t LowFire Degrees C Cone Ramp 1 Setpoint 1 Ramp 2 Setpoint 2 022 300 526 60 586 021 300 540 60 600 020 300 566 60 626 019 300 618 60 678 018 300 655 60 715 017 300 678 60 738 016 300 712 60 772 015 300 731 60 791 014 300 747 60 807 013 300 777 60 837 012 300 801 60 861 011 300 815 60 875 MidFire Degrees C Cone Ramp 1 Setpoint 1 Ramp 2 Setpoint 2 Ramp3 Setpoint3 Ramp 4 Setpoint 4 010 200 555 100 595 165 818 60 903 09 200 555 100 595 165 835 60 920 08 200 555 100 595 165 857 60 942 07 200 555 100 595 165 891 60 976 06 200 555 100 595 165 913 60 998 05 200 555 100 595 165 946 60 1031 04 200 555 100 595 165 978 60 1063 03 200 555 100 595 165 1001 60 1086 02 200 555 100 595 165 1017 60 1102 01 200 555 100 595 165 1034 60 1119 HiFire Degrees C Cone Ramp 1 Setpoint 1 Ramp 2 Setpoint 2 Ramp 3 Setpoint 3 Ramp 4 Setpoint 4 1 200 55
14. 5 100 595 120 1052 60 1137 2 200 555 100 595 120 1057 60 1142 3 200 555 100 595 120 1067 60 1152 4 200 555 100 595 120 1077 60 1162 5 200 555 100 595 120 1101 60 1186 6 200 555 100 595 120 1137 60 1222 7 200 555 100 595 120 1154 60 1239 8 200 555 100 595 120 1164 60 1249 9 200 555 100 595 120 1175 60 1260 10 200 555 100 595 120 1200 60 1285 11 200 555 100 595 120 1209 60 1294 12 200 555 100 595 120 1221 60 1306 AutoFire Kiln Controller User s Guide REMOTE MONITORING AND CONTROL Each AutoFire Kiln Controller has a serial communications capability to allow for remote control and monitoring from a personal computer The Orton ControlMaster software package enables the user to control and monitor up to 16 kilns or furnaces simultaneously from a remote personal computer The file can be saved so that a temperature graph or table can be generated after the firing ControlMaster is an easy to use Window based software package It is compatible with any industry standard IBM compatible personal computer and Microsoft Windows 3 1 3 11 or 95 98 Connections between individual controllers and the computer are made using twisted pair telephone cable If more than one AutoFire controller is to be connected the cable is connected between controllers and then to the computer Only one wire cable is run from the kiln room to the computer where input is made through the computer s RS 232 port Most home cente
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16. AutoFire Kiln Controller User s Guide AutoFire Plus AutoFire Pro AutoFire UniTemp AutoFire UniTemp Solid State Relay Option Orton Ceramic Foundation Electronic Control amp Monitoring Products Orton Ceramic Foundation 6991 Old 3C Highway Westerville Ohio 43082 9026 Telephone 614 895 2663 Fax 614 895 5610 Revision 5 0 September 1999 Table of Contents Introduction AutoFire Kiln Controller Models Features and Benefits Firing Your Kiln Test Firing Quick Reference Section 6 Cone Fire Program Cone Fire Example User Program Using A User Program Display Reference Alarm Reference Options Available Level 1 Level 2 Alarm Descriptions PLOG Diagnostic Error Codes Power Recovery 23 Preset Cone Fire Programs Preset Cone Firing Schedules Remote Monitoring Technical Specifications Warranty Appendices A Reproducible User Program Sheets B Pyrometric Cones C Temperature Equivalents D Vent Fan Options Available E Connecting Thermocouples F Typical Wiring Diagrams G Program Lock Instructions on 10 11 12 13 13 17 20 22 25 27 29 30 31 32 33 34 35 37 38 41 AutoFire Kiln Controller User s Guide INTRODUCTION Congratulations on purchasing Orton s AutoFire controller You now have the finest controller available for use in firing glass and ceramics It will provide more precise control and many valuable features not available wi
17. ELEC Display Electronics Temperature Fail Thermocouple failure Fn Vent Fan mode of operation Hd Soak Time in minutes 1 10 set time for controller to hold temperature HIF Hi Fire display used when reviewing program during a cone firing Id Specify RS 485 Controller Identification Node number IdLE Controller in Idle mode ready to program or to start a firing Lo Program Lock On Cone Fire and User Program cannot be modified Lo F Lo Fire display used when reviewing program during a cone firing LoUn Program Lock Mode use to secure program settings from being changed IdF Mid Fire display used when reviewing program during a cone firing odl Display Model Number i e 0000 Plus 0003 UniTemp nnnn Factory Use Only oFSt Cone Offset allows for adjusting display temperature to match witness cones P1 Bad Firing thermocouple opened just prior to loosing power P2 Temperature Invalid Prior To Power Loss greater then 255 P3 Power Loss Too Long greater then 60 minutes ProG Program Review use to review active firing program Cone fire or User Program rA Ramp 1 10 rate per hour of temperature increase decrease rHEo Middle Zone Rheostat adjustment UniTemp Models Only rEL Relays 1 2 or 3 UniTemp Models Only Ser Display Serial Number SoFt Display Software Version Spd Firing Speed Std or 40 SStP Skip Step used to advance to next ramp tCo Top thermocouple failure Unitemp tC1
18. ENTER RIGHT ARROW UP ARROW ENTER controller temperature is displayed in F p play Description _________ UUU Enters the User Program mode Allows the entering of a New program or editing of an existing one Scroll to the desired User Program Selects the desired User Program Displays the first program segment name Ramp 1 Selects the digit to be modified The selected digit will flash Scroll the selected digit to the desired value Repeat steps 4 amp 5 till desired value is displayed Stores the new value and displays the next program segment name Dwell Temperature F 1 or C 1 Selects the digit to be modified The selected digit flashes Scroll the selected digit to the desired value Repeat steps 8 amp 9 till desired value is displayed Stores the new value and displays the third program segment name Dwell Time 1 Hd 1 Selects the digit to be modified The selected digit will flash Scroll the selected digit to the desired value Repeat steps 11 amp 12 till desired value is displayed Stores new value and displays the next program ramp segment Skip to Step 17 if no more ramps are desired Display Usr where is a value of 1 2 3 or 4 USr1 2 3 or 4 rA 1 xxxx where xxxx is the ramp rate XXXX Oxxx 0360 ramp of 360 hr F 1 xxxx where xxxx is dwell Temp XXXX 1xxx 1032 dwell temp of 1032 F Hd 1 0 000 0 000 0 120 2 hour hold rA 2
19. Foundation If this product fails to be in good working order due to materials or workmanship at any time during this two 2 year period Orton Ceramic Foundation will at it s option repair or replace this product as set forth below The liability of Orton Ceramic Foundation is limited to replacement and or repair of the controller at it s factory that does not remain in good working order under normal operating conditions Repair parts or replacement products will be furnished on an exchange basis and will be either reconditioned or new All replaced parts and products become the property of Orton Ceramic Foundation Limited warranty service may be obtained by delivering the unit during the two 2 year warranty period to THE EDWARD ORTON JR CERAMIC FOUNDATION 6991 OLD 3C HIGHWAY WESTERVILLE OH 43082 9026 USA and providing written proof of purchase and description of defect or problem The buyer must insure the unit or assume the risk of loss or damage in transit prepay shipping charges to the service location and use the original shipping container or equivalent The buyer will be invoiced for shipping and handling changes incurred in returning the unit after service Service may also be obtained on units no longer under warranty by returning unit prepaid to Orton Ceramic Foundation with a description of the problem and buyer s name address and telephone number The buyer will be contacted with an estimate of the service charges be
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21. LoUn Program Lock Lock or Unlock the current program odl Display Model Number Displays the controller model number SoFt Display Software Version Displays the version of the control software Ser Display Serial Number Displays the serial number of the controller rEtn Return Return to idle or run mode To enter the Level 2 Options mode follow these steps Step Press Description Display 1 OPTIONS Enters the Basic Options mode SPd 2 UP ARROW Scroll to the Return rEtn Option rEtn 3 OPTIONS Enters the Level Two Options mode The first CHG option is displayed 4 UP ARROW Scroll through available Level Two options XXXX RIGHT ARROW 5 ENTER Enables editing of currently displayed option XXXX 6 UP ARROW View parameter s for selected option XXXX RIGHT ARROW 7 ENTER To exit viewing editing of current parameters XXXX Repeat steps 4 7 to continue viewing editing options Where xxxx is one of the level 1 options available or the associated parameters Controller automatically returns to IdLE or run mode after 20 seconds of inactivity IdLE CHG Change Temperature Units Default Setting F The CHG feature enables the user to change the temperature units between degrees Fahrenheit F and degrees Centigrade C The selected setting is saved in memory When C is selected the right most decimal point on the display is lit 18 AutoFire Kiln Controller User s Guide tC Select Thermocouple Type Default Setting
22. OHAd NOLHO HOA d SIN31VAInO3 38n1VH3dW3 2 SAN3TIVAInO3 3HnivHadWa l AutoFire Kiln Controller 36 AutoFire Kiln Controller User s Guide Appendix D Vent Fan Options Available Vent fan control is an Option for which the controller is configured at the factory when ordered Control of electrical power to the vent fan needs to be controlled by the controller by turning a relay on or off Therefore either the kiln or the controller power box needs to be wired with an electrical connection for the vent to be plugged or wired into this relay This option may not be installed on your AutoFire controller Vent Fan Modes The user may specify the mode of operation through the OPTIONS menu by selecting any one of the following modes Cone Program Off Vent fan off all the time On Vent fan on all the time OptA Option A temperature thresholds OptB Option B temperature thresholds User Program Fn Vent fan can be turned on or off during each ramp segment of user program Description of Vent Fan Modes For vent fan operation for increasing ramps For vent fan operation for decreasing ramps T1 the vent fan turns on at 100F T3 the vent fan turns on at 1000F T2 the vent fan turns off at 1450F T4 the vent fan turns off at 300F Mode OPtA The vent fan shall be on during increasing heating ramps of an active firing cycle if Kiln temperature is greater than or equal to T1 and less than T2
23. STOP START to get back to IdLE mode P2 If the thermocouple failed just prior to the power loss the controller will display the error code P2 If once the error code is acknowledged by pressing STOP START the display should show IdLE and current kiln temperature alternately But for an open thermocouple the temperature would be replaced with four dashes because a valid temperature would not register P3 If the duration of time since previous valid temperature is greater than 60 minutes then the controller terminates the firing cycle and displays the error code P3 in the display To acknowledge the error code simply press STOP START to get back to IdLE mode 24 AutoFire Kiln Controller P User s Guide ower Interruption Recover The flow diagram below shows how the software decides whether to restart kiln after a power interruption If the firing was near completion or the temperature fell too much during the outage then the firing will terminate Controller Automatically Stops the Firing Has Temperature Dropped More Than 255 F START Controller Automatically Stops Is Elapsed Time of Power Failure less than 60 minutes the Firing Was Temperature Before Power Failure Within 100 F of Final Temperature and Was Final Segment Ramp Rate 108 F hr 60 C hr Has Temperature Dropped More Than 100F Resume the Firing Establish
24. The vent fan shall be on during decreasing cooling ramps of an active cycle if Kiln temperature is less than T3 and greater than or equal to T4 If the kiln temperature is invalid open thermocouple for example the vent shall be off Mode OPtB The vent fan will be on during increasing ramps heating of an active firing cycle if Kiln temperature is greater than or equal to T1 The vent fan is on during decreasing ramps cooling of an active cycle if Kiln temperature is greater than or equal to T4 If the kiln temperature is invalid open thermocouple for example the vent fan shall be off 37 AutoFire Kiln Controller User s Guide Mode User Program The Vent Fan Option is activated under Level 2 Options if the controller was ordered with this option If the USER program ramp option is not active then the vent fan is off If Vent Fan is active the vent fan operation is controlled by the 4 segment in the User Program The User determines during programming whether the Vent Fan is on or off for each ramp segment 1 If the user specifies that the Vent Fan should be off then the vent fan is off with no other conditions evaluated 2 If the kiln is programmed to heat up then the vent fan is on regardless of whether the controller is in the ramp dwell recovery or hold states 3 If the controller is in a power recovery mode and heating up then the ve
25. a New Set Point from the Current Kiln Temperature Controller Automatically Resumes Is the Controller to Resume a Ramp Ramp Rate see Entering a Ramp Rate The Controller Resumes a Dwell The Ramp Dwell Time is not Advanced During Recovery Ramp see Entering a Ramp Rate 25 AutoFire Kiln Controller User s Guide PRESET CONE FIRE PROGRAMS Lo Fire Decals or lusters are normally applied following the second or third firing They add to the final beauty and value of the object These firings are done at low temperatures around Cone 019 and normally produce a distinct odor Firings can be made relatively fast The presence of oxygen throughout the firing is essential Good ventilation of the kiln is also necessary as oils and other organic materials are burned off Some decals lusters and gold have a limited firing range If too large of a temperature distribution exists inside the kiln the firing capacity or load placement must be altered or limited The preset firing program for Lo Fire is shown below The standard firing time is about 3 hours 20 minutes depending on load and other variables 540 F hour 300 C hr for about 2 hours 108 F hour 60 C hr for about 1 hour 20 minutes The firing speed based on load size adjustment will vary the firing times from about 2 hours 40 minutes to about 4 hours 10 minutes Mid Fire This firing range is used to fire earthenware and packaged glazes W
26. a result of an error condition that terminated the firing cycle 38 AutoFire Kiln Controller User s Guide Appendix E Connecting Thermocouples Expanded View of Thermocouple Configuration Thermocouple Input Thermocouple Color Chart Block Configurations Type K Chromel Alumel Sheath Yellow AutoFire Plus or Pro Wires red and yellow One 2 wire Thermocouple Type N Microsil Misil Sheath Orange Wires red and orange Type S Platinum Rhodium Platinum Sheath Green Wires red and black AutoFire Plus or Pro One 3 wire Thermocouple Jumper Off AutoFire UniTempTM Two 2 wire Thermocouples Jumper Off A 8 JPR2 J6 TiC T C T C TIC TC TC1 Top Bottom AutoFire Kiln Controller User s Guide Appendix F_ Typical Wiring Diagrams Common 12Vdc Typical Wiring of an AutoFire PLUS Model 7 Pin Output Power 2 Pin Serial Connector Connector R5485 AutoFire Controller Backside JPR1 Eg R5485 Termination 12 Volt DC po 5 To Kiln Elements ps e s isis 3 6 Pin Input Power gine pe Kl N Connector u Terminals 8 amp 11 must be jumpered Transformer EWC A41 25 20419 or equivalent 208V 240Vac Input Fuse 250V 0 254 AutoFire Kiln Controller Typical Wiring of an AutoFire PRO Model Safety Cutoff 0 0 3 24Vdc Input Solid State Relay 240Vac Output To Kiln Eleme
27. activated only if a power loss occurred during the previous firing cycle and the battery voltage is actually low In this case the controller aborts the resumed firing cycle and indicates LBAT for low battery The only time that the battery is used for the electronics is to determine whether or not to resume a firing cycle that was in progress when a power loss occurred Thus as long as the controller is performing firing cycles without power losses then there is no indication as to the state of the battery If a Low Battery Alarm is activated contact your factory technician kiln manufacturer or kiln service technician for replacement Hardware Embedded Self Diagnostics Error PLOG 0000 0018 and 0128 0255 The electronics contain a series of self diagnostic error alarms that are activated when the microcontroller fails the self diagnostics test performed during controller power up or during actual controller operation When an error condition is detected the microcontroller stores the error in memory and resets the microprocessor Each time the microprocessor is reset it first checks if an error has been stored and if so alternately indicates PLoG and the error number on the display 22 AutoFire Kiln Controller User s Guide PloG Error Codes Display Meaning 18 Thermocouple inputs too noisy AC power wires may be too close to the thermocouple lead wires or the electronics board Try isolating the AC power wires away f
28. ant to skip to the next ramp in a User Program Use Cone Offset to adjust the kiln to fire to a cone to adjust the firing temperature from 38 F to 20 F Kiln Temperature Threshold Alarm can be set to audibly notify you when a temperature is reached Recovery from a power interruption occurs when proper to do so Select either Fahrenheit F or Centigrade C Units Audible Alarms and error codes indicate when the controller or the kiln is not firing correctly Program and monitor up to 16 kilns from a Personal Computer AutoFire Kiln Controller User s Guide Firing Your Kiln The purpose of firing your ware is to develop long lasting durable valuable and useful products When fired properly good looking results are obtained If improperly fired the value of the ware is greatly reduced disappointment occurs and in some cases the object is discarded When this happens your effort and anticipation leading up to the firing is wasted Understanding and controlling what occurs during firing will minimize problems and increase your ability to get consistently good results The firing after all is usually the final process in creating your masterpiece The AutoFire Kiln Controller contains 3 preset programs Lo Fire Mid Fire and Hi Fire These programs were designed for the firing of normal loads of hobby ceramics As a rule the firing in the kiln needs to be slowed down in certain temperature ranges to allow for
29. carbon burnout and to improve temperature uniformity The preset programs are designed with this in mind however when a kiln is more heavily loaded or thrown ware with thicker walls are used additional care is needed during the firing because the ramps for the preset programs may be too fast Experiment to determine the best firing conditions It is also important that the kiln be vented properly Orton recommends the use of a downdraft venting system such as an Orton KilnVent When firing to a cone number the AutoFire kiln controller constantly monitors the actual heating rate of the kiln If the kiln does not fire as rapidly as programmed the controller firmware recalculates and adjusts the top firing temperature to compensate for the slower firing rate This process more accurately fires to the cone number selected At slower heating rates cones deform at slightly lower temperatures At faster heating rates cones deform at slightly higher temperatures This ability to recalculate and compensate to fire to a cone value is a unique patented feature of all Orton Electronic Kiln Control Products The AutoFire Kiln Controller provides three preprogrammed firing cycle programs for preset cone firing These preprogrammed firing cycle programs and the corresponding preset cone fire programs follow Program Purpose Typical Cone Value Cone Range Lo Fire Decal Luster and China Firings Cone 019 022 011 Mid Fire Glaze Firings Cone 06 010 01
30. ds and the fast settings for light loads Speed is applied only to increasing ramps and not to dwells soaks Speed does not apply to the last ramp of a cone firing Firing Speed can only be modified during program setup not during an active firing cycle The Firing Speed choices are given below Display Description Std Standard cone firing program S10 Slow increase firing time by 10 decrease firing rate by 10 S 20 Slow increase firing time by 20 decrease firing rate by 20 S 30 Slow increase firing time by 30 decrease firing rate by 30 S 40 Slow increase firing time by 40 decrease firing rate by 40 F 10 Fast decrease firing time by 10 increase firing rate by 10 F 20 Fast decrease firing time by 20 increase firing rate by 20 F 30 Fast decrease firing time by 30 increase firing rate by 30 F 40 Fast decrease firing time by 40 increase firing rate by 40 NOTE The Firing Speed adjustment is a permanent change to be applied to all future firings unless reset by user This setting does not automatically reset itself This feature is different from the earlier versions prior to 0030 where Firing Speed Adjustments were reset to Standard after each firing ProG Program Review The ProG feature enables the user to review the current firing cycle of a preset cone program or a user program The user cannot change the program while in this option When selected the option defaults to the current program segment For
31. e buzzer once every 10 seconds The display alternates with the actual kiln temperature This alarm can be turned off by placing all zeros in display rEL Specify Number of Relays Default Setting 3 UniTemp Model Only The rEL feature allows the user to specify the number of relays that will be used with AutoFire UniTemp Models The controller uses this information to control up to 3 independent heating zones The specified value is saved in memory Uniformity control is disabled when only 1 relay is selected rHEo A Unitemp controller provides the capability to adjust the cycling of the middle heating elements This option can be useful if the middle portion of the kiln runs slightly hotter than the top or bottom A number from 0 to 200 in increments of 5 can be selected The default value for rHEo is 100 Values less than 100 will reduce the power to the middle heating elements while values higher than 100 will increase the power 0 1 Display Temperature of Both Thermocouples UniTemp Model Only The 0 1 feature is used to display the temperature of the top thermocouple tC 0 and the bottom thermocouple tC 1 when two thermocouples are used with UniTemp Models This feature allows temperature uniformity to be evaluated during a firing tC0 and tC1 alternate with one another and will default back to current firing temperature in approximately 20 seconds AlnG Diagnostic Tool Factory Use Only tCnt Diagnost
32. e very distinct colors and finish Fired properties such as hardness no water absorption uniform color and density require detailed attention to the firing process Normally the maturing range is very small and may be less than half of a cone Typical porcelain bodies are formulated from kaolin feldspars silica and ball clays The weight loss during firing can be around 10 to 12 percent and shrinkage can approach 20 To obtain the desired fired properties the firing must be controlled to properly burn out all organic materials If this is not done imperfections can occur or show up in later firings This normally requires slowing up the heating rate for proper burn out of binders release of chemically combined water and to burn out carbon Sufficient oxygen is mandatory to accomplish this so venting is important Cracking can also occur if a rapid heating or cooling occurs around 1063 F Porcelain bodies require very good temperature uniformity at their final firing temperature If a slight over fire occurs the body will normally warp or blister On maturing the body becomes its own glaze Some hold time is usually desirable for best results The preset firing program for Hi Fire is shown below The standard firing time is 8 hours 40 minutes 360 F hour 200 C hr for 2 hours 40 minutes 180 F hour 100 C hr for 50 minutes 216 F hour 120 C hr for 3 hours 10 minutes 108 F hour 60 C hr for 2 hours The firing s
33. emp Proprietary Algorithm Minimizes Temperature Gradients Control With 2 Type K N or S Thermocouples Power Output to Mechanical Relays for Heating Elements Control of Up to 3 Independent Heating Zones Power Output to a Mechanical Relay for Vent Fan Control option AutoFire UniTemp Solid State Relay Option Proprietary Algorithm Minimizes Temperature Gradients Control With 2 Type K N or S Thermocouples Power Output to Solid State Relays for Heating Elements Control of Up to 3 Independent Heating Zones Power Output to a Mechanical Relay for Safety Shut Off The AutoFire Plus Pro models referred to in this User s Guide are those listed above References to AutoFire UniTemp refer to both the AutoFire UniTemp and the AutoFire UniTemp Solid State Relay Option models listed above Using AutoFire with a Kiln Sitter If you have a Kiln Sitter on the kiln you may use a Cone 10 bar or cone under the sensing rod to shut off power if the kiln reaches high temperatures This bar will last many firings You can also remove the cone or bar and prop up the sensing rod with a piece of refractory material Set the Kiln Sitter timer for two hours longer than the firing AutoFire Kiln Controller User s Guide FEATURES AND BENEFITS Your new Orton AutoFire Kiln Controller has an extensive list of standard features a user friendly operator interface and a robust temperature control algorithm These combine to provide
34. firing time is at least 4 hours longer than the programmed time for the segment When this occurs the firing is aborted and FtL is shown on the display Under these conditions it is unlikely the kiln will reach its programmed temperature so the firing is stopped The Firing Too Long alarm applies to both preset cone programs and user programs Temperature Alarms ALAr FAIL tC0 tC1 Temperature Alarms apply to both preset cone programs and user programs ALAr Kiln Temperature Threshold The Kiln Temperature Threshold Alarm occurs when the kiln temperature is equal to or greater than kiln temperature threshold value that is specified When this condition is detected the controller sounds an audible alarm and alternately indicates ALAR and the current kiln temperature on the display The alarm remains active until the user acknowledges the alarm by pressing ENTER 21 AutoFire Kiln Controller User s Guide FAIL Open Thermocouple The Open Thermocouple Alarm is activated when an open thermocouple is detected When this condition is detected during an active firing cycle the controller aborts the firing cycle and indicates FAIL on the display The controller is not capable of starting a firing cycle if an open thermocouple condition exists Open Thermocouple The Open Thermocouple Alarm four dashes is activated when an open thermocouple is detected during initial power on of controller or in Idle
35. fore any work is performed All express and implied warranties for this product including the warranties of merchantability and fitness for a particular purpose are limited in duration to a period of two 2 year from the date of purchase and no other warranty whether expressed or implied will apply after this period This warranty does not apply to the thermocouple and does not apply to any damage resulting from 1 Overfiring melting of materials being fired regardless of cause of overfiring Operation beyond electrical rating including overloading or shorts in user connected equipment External sources including chemicals heat abuse and improper use Improper or inadequate maintenance by the user Parts or equipment not supplied by Orton Ceramic Foundation Unauthorized modification or misuse Operation outside environmental specifications Improper installation Units returned for service where no defect is found will be subject to a service fee If this product is not in good working order as warranted above your sole remedy shall be repair or replacement as provided above In no event will Orton Ceramic Foundation be liable for any damages including any lost profits lost savings or other incidental or consequential damages arising out of the use of or inability to use such a product even if Orton Ceramic Foundation has been advised of the possibility of such damages or for any claim by any other party The above limitat
36. hen glazes are applied to a bisque body that has already been fired the firing can made be relatively fast The ware should be thoroughly dried prior to firing The heating rate is slowed during the quartz phase change 1063 F 573 C Air is needed in the kiln to develop bright shining colors such as reds and yellows so venting is particularly important Slow firing rates can produce poor quality glazes With lead free glazes a 10 15 minute hold is beneficial Cooling too fast can produce glaze defects such as pinholes blisters and craters When earthenware or other bodies contain ball clays talc and kaolin then compounds such as water carbon and sulfur will be burned off during the firing In addition a phase change physical change in any silica present must be considered and the heating rate slowed during this reaction which occurs near 1063 F 573 C or cracking can occur This phase change occurs during both heating and cooling During the firing the material will loose about 10 percent of its weight This weight loss occurs due to e Water coming off between room temperature and 212 F Binders coming off between 300 F and 500 F Chemically combined water coming off around 900 F to 1000 F Carbon and sulfur coming off between 1100 F and 1600 F Carbon dioxide evolving from calcite and dolomite around 1700 F The preset firing program for Bisque firings is shown below The standard firing time is 7 hours 30 minute
37. ic Tool Factory Use Only nnnn Diagnostic Tool Factory Use Only 19 AutoFire Kiln Controller User s Guide ELEC Display electronics temperature Diagnostic Tool The ELEC feature displays the electronics temperature of the AutoFire Plus Pro or AutoFire UniTemp Kiln Controller This feature is useful in monitoring the electronics temperature in severe environments or if needed by factory technicians kiln manufacturers or kiln service technicians LoUn Program Lock Mode Default Setting Un off The LoUn feature allows either a user program or a preset cone fire program to be locked into memory and to disable program editing from the front panel This feature is useful when only one particular program is used over and over and multiple people may be firing the kiln When the program lock is set to Lo only a delay start can be selected all other options can only be viewed not changed This feature is best used in a school or contemporary studio where control of programming is needed Refer to Appendix G to implement this feature The information on this page can be separated from the manual if desired zodl Display Model Number Diagnostic Tool The odl feature displays the model number of the AutoFire 0000 is a Plus model 0001 is a Pro model and 0003 for a UniTemp model When provided to factory technicians kiln manufacturers or kiln service technicians this information helps answer questions about features o
38. iln manual or Orton KilnVent instruction manual If your kiln has limit switches turn all switches to the On or highest position Begin the firing refer to page 7 of this manual for using preset cone programs After the firing before opening the kiln to remove your cones make sure the kiln has cooled sufficiently Examine the fired cones Some variation in the bending of the cones may occur depending on how the kiln was loaded This includes the size of the load its distribution on the shelves and the location of the cones It is a good practice to use a witness cone in every firing This provides a permanent record of the firing conditions in the kiln and can help you identify changes in the way your kiln is firing Test fire approximately every 25 firings Test conditions should be consistent from firing to firing Save the sets of witness cones as records of the firings Review them periodically to note variations or drift in successive firings If thermocouple drift starts to occur recheck the heat distribution If one area of the kiln is much hotter or cooler than another it may indicate that one or more heating elements need replaced If there is a major change in the amount of bending of the firing cone the most likely cause is thermocouple damage or deterioration Replace the thermocouple and retest If replacing the thermocouple does not restore the performance to previous levels the controller or kiln may require additi
39. ion of liability does not apply in the event that any Orton Ceramic Foundation control product 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 Orton s liability exceed the greater of 1000 or the purchase price of the specific product that caused such damage If you are not satisfied with the performance of the controller or the conditions of this warranty return the controller in good working condition with written proof of purchase and with transportation and insurance prepaid within 30 days to THE EDWARD ORTON JR CERAMIC FOUNDATION 6991 OLD 3C HIGHWAY WESTERVILLE OH 43082 9026 USA and you will receive a full refund 32 AutoFire Kiln Controller User s Guide Appendix A User Program Charts User Program 1 USr1 Step Ramp Rate Temperature Hold Time Vent Fan rA hr F C Hd min Fn on off 1 2 3 4 5 6 7 8 9 10 User Program 2 Usr2 Step Ramp Rate Temperature Hold Time Vent Fan rA hr F C Hd min Fn on off 1 2 3 4 5 6 7 8 9 10 User Program 3 Usr3 Step Ramp Rate Temperature Hold Time Vent Fan rA hr F C Hd min Fn on off 1 2 3 4 5 6 7 8 9 10 User Pr
40. kiln during a firing rEtn Return The rEtn Return feature is used to exit the options mode and return to the IdLE or run display 17 AutoFire Kiln Controller User s Guide Level 2 Options Level 2 Options provide the user with access to many additional and useful features of the controller Most users will not use these options very often if ever Level 2 Options are accessed through the OPTIONS key either when the controller is in Idle mode or during an active firing cycle UniTemp options are only available for their respective models and will not be displayed on a Plus or Pro model Level 2 Options include the following Display Option Meaning CHG Change Temperature Units Change temperature units from F or C tC Select Thermocouple Type Select a different thermocouple type Type K N S Id Specify RS 485 Node ID Assign an number from 0 to 15 to the controller tEdE Specify Alarm Value Select temperature deviation for FtH FtC LtdE and HtdE alarms rEL Specify Number of Relays Input the number of relays for UniTemp controller rHEo Specify Middle Rheostat Adjust power to middle zone of UniTemp controller 0 1 Thermocouple Temperatures Displays top and bottom thermocouple temperatures with a UniTemp controller AlnG Diagnostic Tool Factory Use only tCnt Diagnostic Tool Factory Use only nnnn Diagnostic Tool Factory Use Only ELEC Electronics Temperature Displays temperature of the electronics
41. l to display of 15 Hold Time Selects the displayed hold time Selects options menu Selects SPd speed option default is standard Press RIGHT ARROW 2 times Scroll to display of F 20 Speed Selects 20 firing speed increase Scroll to display of rEtn or wait 20 seconds Returns to IdLE mode Starts the selected cone firing When the active firing cycle is completed The final temperature reached by the kiln will be alternately displayed with the CPLt display Acknowledges completion of the completed firing cycle and returns to ILE mode Also functions as the Abort Abrt during a firing process User s Guide Display 06 1828 6 2231 Hd 0 Hd 15 IdLE SPd Std F 20 SPd rEtn IdLE 0074 current kiln temperature The actual kiln temperature is displayed during an active firing cycle CPLt Final Temperature IdLE Abrt AutoFire Kiln Controller User s Guide USER Program using your controller for custom firing programs e The Up Arrow A increments the value 0 9 or scrolls through selections one at a time The Right Arrow shifts editing digit to the right or scrolls through selections one at a time The AutoFire family of kiln controllers feature 0 segment user programs for custom firing profiles Just follow these simple steps Step 1 Press USER PROGRAM UP RIGHT ARROWS ENTER RIGHT ARROW UP ARROW ENTER RIGHT ARROW UP ARROW
42. nding temperatures used in CONE FIRE ALAr Kiln Threshold Temperature Sets an alarm to sound when controller reaches the set point temperature and displays AlAr FAn Vent Fan Sets the Vent Fan to on or off dIFF Temperature Difference Displays the temperature difference between top and bottom thermocouples UniTemp only rEtn Return Returns to idle or run mode SS tP Skip Step Allows adjustment to next program ramp if enabled on controller and kiln wired for vent fan control To enter the Level 1 Options follow these steps Step Press Description Display 1 OPTIONS Enters the Level 1 Options mode The first SPd option is displayed 2 UP ARROW Scroll through available Level 1 options XXXX RIGHT ARROW 3 ENTER Enables editing of currently displayed option XXXX 4 UP ARROW View parameter s for selected option XXXX RIGHT ARROW 5 ENTER To exit viewing editing of current parameters XXXX Repeat steps 2 5 to continue viewing editing options Where xxxx is one of the level 1 options available or the associated parameters Controller will automatically return to IdLE or run mode after 20 seconds of inactivity IdLE 14 AutoFire Kiln Controller User s Guide SPd Firing Speed Default Setting Std The SPd feature adjusts how fast the kiln fires to compensate for the load in the kiln Adjustments are made to the normal firing programs refer to pg 25 Preset Cone Firing Programs Slow settings can be used for heavy loa
43. nt fan is off 4 If the controller is in a power recovery mode and cooling down then the vent fan is on 5 If the controller is holding at a temperature then the vent fan is off Note If it is desired to have vent fan on during the dwell portion of a cooling segment the operator can break the dwell segment into two parts The first segment can specify a zero dwell time and the second segment specify the same dwell temperature with the desired dwell time For example if the operator wants the vent fan to be on during the dwell portion of cooling segment 2 of the following User Program then the operator can divide segment 2 into segments 2 and 3 as follows Two Segment Program Ramp Dwell Dwell Vent Seg Rate Temp Time Fan 1 500 1000 30 ON 300 750 60 ON Three Segment Program 1 500 1000 30 ON 2 300 750 0 ON 3 999 750 60 ON For the two segment program the vent fan will be off during the dwell state of segment 2 even when the vent fan has been set to on in the program For the three segment program when two dwell temperatures are the same the software interprets the 999 ramp rate as a positive number so during segment 3 dwell state the vent fan will be on Irregardless of the mode of operation whenever the controller is in the abort state Abrt the vent fan is turned off The Abrt state can be a result of the operator aborting the active firing cycle or can be
44. nt temperature by the alarm value Typically this is factory set at 100 F 56 C It is changed through Options see page 17 amp 18 Terminating Alarms Display Meaning FtL Firing Too Long kiln not increasing in temperature Temperature increasing at less than 15 C hr AND the firing time is 4 hours longer than the program segment EtH Electronics Too Hot electronics temperature exceeds 85 C FAIL Open Thermocouple thermocouple s has failed opened tC01 Both Thermocouples are open in IALE mode UniTemp Models Only PLOG Diagnostic tests to determine if controller operating properly To reset PLOG error press ENTER refer to page 22 for additional details 13 AutoFire Kiln Controller User s Guide OPTIONS AVAILABLE There are two levels of options available through the OPTIONS key These enable the user to access additional firing features Level 1 contains more frequently used options These can be entered during either the idle mode indicated by display flashing IdLE or during an active firing cycle Level 2 options are not used as often these are described beginning on page 17 Not all options are available during a firing Level 1 Options Display Option Meaning Spd Speed Slows down or speeds up firing for cone programs ProG Program Review Review selected program before or during a firing oF St Cone Offset Adjusts firing temperature to match witness cones CtbL Cone Table List of cone be
45. nts T High Current ii Contactor 208V 240Vac Input 12 Volt DC User s Guide Common 12Vdc A B 7 Pin Output Power 2 Pin Serial Connector Connector R5485 AutoFire Controller Backside JPR1 mn R5485 Termination Thermocouple B Pin Input Power Input Block Connector Terminals 8 11 must be jumpered Transformer EWC A41 25 20419 or equivalent 41 To Bottom Elements or contactor AutoFire Kiln Controller User s Guide Typical Wiring For A AutoFire Plus or UniTemp Model Common 12Vdc 7 Pin Output Power 2 Pin Serial Connector Connector R5485 AutoFire Controller Backside JPR1 Es R5465 Termination 12 Volt DC h n d To Middle Elements or contactor To Top Elements or contactor Thermocouple 6 Pin Input Power Input Block 42 Volt DC Connector 12 Volt DC Relay Terminals 8 amp 11 must be jumpered Transformer EWC 44125 20419 or equivalent 208V 240Vac Input Fuse 2507 0 254 User s Guide AutoFire Kiln Controller Program Lock Unlock G endix A Please cut out these instructions if you DO NOT want readers of this manual to understand how to lock and unlock programs on your AutoFire Controller JalJO 4U09 ou SUTYDOT 2J0J93qQ ATUO aur 9U0 peeds Zunz se qons sxgyoweed SULIT tuonrppe Aue YM Suo e J9 oJ U09 2U OJUI poojuo ure18o0Jd 1epjnoried MOA DAVY o arns oq enj 9j S
46. ogram 4 Usr4 Step Ramp Rate Temperature Hold Time Vent Fan rA hr F C Hd min Fn on off 1 2 3 4 5 6 7 8 9 10 33 AutoFire Kiln Controller User s Guide Appendix B Pyrometric Cones and Their Use Using Orton Pyrometric Cones Pyrometric cones have been used since the late 1800 s to monitor kiln behavior They are useful in determining when a firing is complete if the kiln provided enough heat if there was a temperature difference in the kiln or if a problem occurred during the firing Cones are made from carefully controlled compositions Each cone bends in a repeatable manner over a relatively small temperature range less than 40 F The final bending position is an indication of how much heat was absorbed Pyrometric cones have been used to monitor ceramic firings for more than 100 years They are useful in determining when a firing is complete if the kiln provided enough heat if there was a temperature difference in the kiln or if a problem occurred during the firing Temperatures are given for three series of cones The soft series covers Cone 022 to 011 The low temperature series covers Cone 010 to 01 and the intermediate temperature series starts at Cone 1 up to 12 Cones are made to Cone 42 Temperature equivalent charts are periodically updated The temperatures shown inside represent the most accurate data available for cones shipped today It will be noted that the
47. ogram without the worry of erasing or deleting any program steps use the Program Review Mode The Program Review Mode under Level One options refer to page 14 allows for reviewing your user program without affecting the program entries Editing a Pre Programmed User Program Once a user program is stored it is easy to make a change to the program Refer to page 9 of this manual User Program using your controller for custom firing programs for details on how to enter a program NOTE You will need to go through the complete program before pressing STOP START to re save the program or you will delete part of your program In each program segment that does not need changed you simply press ENTER to advance to the next segment When you get to a segment that needs modified use the arrow keys to edit the value and then ENTER to select it and advance to the next program segment If you previously had a 4 ramp program be sure that you step through all 4 ramps again until you get to a new ramp segment rA 5 for this example before exiting by pressing STOP START It is this easy to make a change to an existing program During an active firing you can also edit the user program Use the steps explained in the previous paragraph except for pressing STOP START for finalizing and saving the user program Instead once you have made the changes in the program continue to press the ENTER through the remaining steps of the program The controller will
48. oller after a two button reset Parameter Default Possible Action RS485 Node Id 0 Set from 0 to 15 TC Type S version 31 and higher Set to K or N Temperature Units Fahrenheit F Set to C Number of Relays 3 For UniTemp Model Verify set to 3 Use Level 2 Options to check or reset these values Re enter any User Programs that might have been stored in memory prior to the two button reset The AutoFire Kiln Controller is now ready to use again If you find that 2 or 3 attempts of resetting the Plog error message does not correct the error code then contact Orton Immediate redisplay of Plog messages may indicate a component failure and unit will need to be shipped to the factory for repair NOTE UniTemp controllers with firmware earlier than 0031 need the number of relays reset to 3 If not the controller will cycle all relays at the same time and kiln will not have uniform temperature priority Refer to Level 2 Options to view version number of your controller if you are unsure 23 AutoFire Kiln Controller User s Guide POWER INTERUPTION RECOVERY The AutoFire Kiln Controller activates a Power Recovery feature when electric power to the controller has been interrupted The controller stores time and temperatures so it can determine the length of a power outage The Power Recovery feature works in the following way If the time is greater than one hour or the temperature drop is greater than 255 F the c
49. ollers Cycling occurs when the controller turns the kiln on or off and the temperature does not closely follow the program selected PID Plus minimizes the effect of cycling by anticipating how the kiln temperature will respond when power is turned on and off AutoFire controllers store programs and calibration data in memory even when powered off If during a firing the power goes out it remembers how far the firing has progressed to determine whether it can be successfully resumed when power is reapplied see page 23 Thermocouples All controllers depend on thermocouples placed in the kiln to measure temperature With time the output of most thermocouples will change this is called drift When drift occurs the thermocouple no longer measures the same temperature as it did when it was new Typically drift causes the kiln temperature to be higher than the temperature displayed by the controller Type K thermocouples drift more than Type S and these need to be replaced after 50 100 firings or when damaged Orton recommends that Type K thermocouples normally not be used at higher temperatures above 2100 F unless they are made of 8 gage wire or enclosed in a protective sheath Smaller diameter 14 gage wire are not advisable for repeat firings above 2100 F Type S can be used when firings regularly exceed 2100 F Pyrometric Cones Orton recommends using witness cones in each firing to help determine if the kiln and controller are firing
50. onal service The Cone Offset feature see page 15 can be used to adjust the temperature of a cone firing to more closely match the bending of a cone AutoFire Kiln Controller User s Guide QUICK REFERENCE SECTION This Quick Reference Section is to help familiarize you with the most often used features of your AutoFire Kiln Controller Guides to Cone Firing User Programs Display References and Alarm References are included We recommend you read the entire User s Guide to become familiar with all the exciting benefits and features of your AutoFire The Keypad Ergonomically designed 8 button Keypad High brightness 4 digit 7 segment LED display Audible feedback Washable high tech graphic panel The eight buttons on the AutoFire keypad provide the following functions ENTER load whatever is displayed into memory and to acknowledge deviation and PLOG alarms if they occur START STOP begin or end a firing to store a user s program and to acknowledge CPLt or Abort shown in the display CONE FIRE select a cone number from preset programs Page 3 USER PROGRAM input your own program Page 5 DELAY START input a time delay in minutes OPTIONS access other features Page 7 amp 8 ARROWS change the display and scroll through options e H futofire UH cm char now fet Mani en dn AN W W STOP c START 4 9 Grton a DII IE S e The AutoFire may be
51. ontroller terminates the previous firing cycle and displays an error in the display described below If the difference between the final programmed temperature and the last measured temperature is less than 100 F and the difference between the last measured temperature and the current kiln temperature is greater than 100 F then the temperature drop is considered to be too large at this stage of the firing so the controller terminates the firing cycle Otherwise the controller compares the current temperature with the last measured temperature prior to power loss and resumes the previous firing cycle as described below e A new Set point temperature is established from the current kiln temperature e If the controller is to resume program operation of a ramp the controller continues the ramp at the rate as programmed e H the controller is to resume program operation of a dwell the controller ramps the temperature at the programmed rate used to achieve that dwell temperature Dwell time is not advanced during this recovery ramp When the dwell temperature is achieved the dwell time is resumed See Flow Chart of Power Interruption Recovery on Next Page Power Loss Error Messages P1 If the difference between the previous valid temperature and the current kiln temperature is greater than 255 F 142 C then the controller terminates the firing cycle and displays the error code P1 in the display To acknowledge the error code simply press
52. or the location and condition of the thermocouple The Cone Offset or calibration feature allows the operator to specify a different temperature offset for each the three preset cone programs This may be necessary since the same offset needed for a low temperature firing may not work for a higher temperature firing The offset is applied to the appropriate preset cone programs not to user programs The user must first select the preset cone program Lo Fire Mid Fire or Hi Fire by selecting a Cone Number before assigning a Cone Offset Cone Offset is then selected from the following list Setting F Setting C Description OF 0 C No adjustment in heatwork SF 3C Increases heatwork 10 F 6 C Increases heatwork 15 F 8C Increases heatwork 20F 11 C Increases heatwork 6 F 3 C Decreases heatwork 13 F 7C Decreases heatwork 26 F 14 C Decreases heatwork 38 F 21 C Decreases heatwork The Cone Offset adjustment is a permanent change to be applied to all future firings when the preset cone program Lo Fire Mid Fire or Hi Fire is selected The value is saved in memory Each preset cone program can have its own unique Cone Offset CtbL Cone Table Default Setting 06 The CtbL Cone Table feature allows the user to determine the deformation temperature corresponding to a selected cone number Deformation temperatures are for a 60 C hour 108 F hour rate The default is cone 06 Itis changed using the arrow keys ALAr Kiln Tem
53. peed based on load size adjustment will vary the firing times from about 6 hours 20 minutes to about 10 hours 50 minutes 27 AutoFire Kiln Controller Preset Cone Fire Schedules User s Guide Low Fire Degrees F Cone Ramp 1 Setpoint 1 Ramp 2 Setpoint 2 022 540 979 108 1087 021 540 1004 108 1112 020 540 1051 108 1159 019 540 1144 108 1252 018 540 1211 108 1319 017 540 1252 108 1360 016 540 1314 108 1422 015 540 1348 108 1456 014 540 1377 108 1485 013 540 1431 108 1539 012 540 1474 108 1582 011 540 1499 108 1607 MidFire Degrees F Cone Ramp 1 Setpoint 1 Ramp 2 Setpoint 2 Ramp3 Setpoint 3 Ramp4 Setpoint 4 010 360 1031 180 1103 297 1504 108 1657 09 360 1031 180 1103 297 1535 108 1688 08 360 1031 180 1103 297 1575 108 1728 07 360 1031 180 1103 297 1636 108 1789 06 360 1031 180 1103 297 1675 108 1828 05 360 1031 180 1103 297 1735 108 1888 04 360 1031 180 1103 297 1792 108 1945 03 360 1031 180 1103 297 1834 108 1987 02 360 1031 180 1103 297 1863 108 2016 01 360 1031 180 1103 297 1893 108 2046 HiFire Degrees F Cone Ramp 1 Setpoint 1 Ramp2 Setpoint 2 Ramp3 Setpoint 3 Ramp4 Setpoint 4 1 360 1031 180 1103 216 1926 108 2079 2 360 1031 180 1103 216 1935 108 2088 3 360 1031 180 1103 216 1953 108 2106 4 360 1031 180 1103 2
54. peration or performance of your AutoFire Plus Pro or AutoFire UniTemp Kiln Controller Ser _ Display Serial Number The Ser feature displays the serial number of the AutoFire kiln controller When provided to factory technicians kiln manufacturers or kiln service technicians this information helps answer any questions about features operation or performance of your AutoFire Plus Pro or AutoFire UniTemp Kiln Controller SoFt Display Software Version Diagnostic Tool The SoFt feature displays the number of the software version of the AutoFire Plus Pro or AutoFire UniTemp Kiln Controller When provided to factory technicians kiln manufacturers or kiln service technicians this information helps answer any questions about features operation or performance of your AutoFire Plus Pro or AutoFire UniTemp Kiln Controller rEtn Return The rEtn feature allows the user to exit Level 1 or Level 2 Options and return to the IdLE or the run state To return to the IdLE or run state follow these steps Step Press Description Display 1 UP ARROW Scroll to the Return rEtn option rEtn RIGHT ARROW 2 ENTER Returns to the main display LdLE 20 AutoFire Kiln Controller User s Guide ALARM DESCRIPTIONS The AutoFire Kiln Controller Family includes a full alarm capability Temperature Deviation Alarms FtH FtC LtdE HtdE tCdE FtL Temperature Deviation Alarms apply to both preset cone programs and user
55. perature Threshold Alarm Default Setting 32 F or 0 C disabled The ALAr feature enables the user to specify a kiln temperature at which an alarm will be sounded and displayed The alarm occurs when the kiln temperature is equal to or greater than the programmed kiln threshold temperature It remains active until the user acknowledges the alarm by pressing the ENTER key The alarm is disabled when 0000 is set in the display 16 AutoFire Kiln Controller User s Guide FAn Vent Fan Operation The FAn feature is enabled by the factory and is only available when the controller has been pre wired to permit a kiln vent to be turned on or off as part of the firing cycle There are five modes of operation Off fanis always off during firing On fan is always on during the firing OptA fan is on at 100 F and off at 1450 F during heating fan on at 1000 F and off at 300 F during cooling OptB fan on when 100 F reached during heating and off when 300 F reached during cooling Fn 4 4 segment of a USER program where vent fan is set for on or off For more information on how to program and use the vent fan feature see Appendix D dIFF Temperature Differential UniTemp Model Only The dIFF feature enables the user to display the temperature difference between the top thermocouple and the bottom thermocouple used with AutoFire UniTemp Models This feature is useful in determining temperature uniformity within a
56. preset cone programs Program Review alternately displays the preset cone number and the corresponding cone deformation temperature at the 108 F hr rate 60 C hr SStP Skip Step The SStP feature allows the user to end a hold or a ramp during an active firing cycle and skip to the next program ramp This is useful if a user wants to watch the firing to visually decide when to make a change such as when glass is slumped The Skip Step applies to User programs only and not to the preset cone fire programs If the current step is a ramp then it will skip to the next ramp step and continue to ramp at the new rate If the current step is a dwell then it will skip to the next ramp step and continue to ramp to the next temperature If the current step is a ramp recovery step after power loss recovering to the prior dwell temperature then it will skip to the next dwell step and dwell at the current temperature for the remainder of the unfinished dwell time 15 AutoFire Kiln Controller User s Guide oF St Cone Offset Default Setting 0 C 0 F The oFSt feature enables the user to adjust or calibrate the preset cone programs without changing to a different cone number This is useful when the kiln does not properly bend the desired witness cone This is common when using Type K thermocouples that drift with repeated firings It is common for the kiln to be hotter than shown on the display This feature may also be useful to compensate f
57. red This is the point for which equivalent temperatures are determined Differences between a cone touching the shelf and a cone at the 4 o clock position are small usually a few C or F Temperatures shown on the inside charts were determined under controlled firing conditions in electric kilns and air atmospheres Cone bending may also be affected by reducing atmospheres or those containing sulfur oxides Orton recommends the use of Iron Free cones for all reduction firings cones 010 3 If a cone is heated too fast the cone surface fuses and binders used to make cones form gases that bloat the cone If cones are to be fired rapidly they should be calcined pre fired before use Cones should be calcined to about 850 F 455 C in an air atmosphere Temperatures are shown for specific heating rates These heating rates are for the last 90 to 120 minutes of the firing If the heating rate is different so will be the equivalent temperature The temperature will be higher for faster heating rates and lower for slower heating rates If a cone is soaked at a temperature near its equivalent temperature it will continue to mature form glass and bend The time for the cone to bend depends on several factors and Orton does not provide such data for its cones However as a general rule a 1 to 2 hour soak will be sufficient to deform the next higher cones A soak of 4 to 6 hours will be required to deform two higher hotter cones 35
58. rom the thermocouple lead wires or the electronics board When a PLOG error message is displayed the controller is inoperable The normal way to clear the PLOG error is to push the ENTER key If this does not clear the error condition then the controller requires a special two button reset Perform the Reset Parameters to Factory Default sequence explained below to clear a PLOG error message that is not be cleared by simply pressing ENTER to acknowledge the error code CAUTION Resetting all parameters to factory default setting may change current controller configurations so these will have to be reset by the user through Level 2 Options It is important to be sure that Thermocouple Type is correct especially if a Type S platinum thermocouple is being used Version 0030 and below defaults to Type K thermocouple Version 0031 and above defaults to Type S thermocouple Reset Parameters to Factory Default 1 2 Turn off power to the AutoFire Controller When turned off the controller will have no display Press Stop Start and Options simultaneously while then turning on power to the controller Keep the keys pressed until the audible beep turns off then release both keys Check to see that controller is in the Idle mode and is alternating Idle with current kiln temperature After resetting the controller some parameters may need to be reset manually to match the desired kiln configuration Here is a list of defaults of the contr
59. rs and hardware stores stock this telephone cable and connectors Communications are made using RS 485 protocol therefore a Windows compatible signal powered RS 232 to RS 485 converter is needed to connect the cable from the kilns to the RS 232 port of a computer Orton offers a converter suitable for use with ControlMaster Order Orton part number C1 25001 An introductory copy of ControlMaster LT is available free from Orton There is a 5 00 charge for shipping and handling This is a fully functional less featured version of the software package that permits programming and monitoring of AutoFire controllers from a personal computer Contact Orton for more information on this software and its use Tere renna Deg F Modted Cone D 03 07 93 nv dia Pd f era EZ oe BEH REZI Oe LSZ RR KH WR PH Fa am NUN NUM NUN NUS NUN NUN Gas Wm Sa WO WR el NUN NUN NUN 30 AutoFire Kiln Controller User s Guide TECHNICAL SPECIFICATIONS e Watchdog Timer Safety feature monitors electronics e 115 or 230 Vac 10 to 20 50 or 60 Hz Operation e Operating Temperature of 0 to 70 C 32 to 158 F e Storage Temperature of 30 to 70 C 22 to 158 F e 95 Relative Humidity e Self Test Diagnostics e Temperature Range User Program to 1820 C 3308 F Cone Fire to 1306 C 2383 F e Accepts Type K N or S thermocouples e Plus and Pro Models have 3 wire thermocouple configuration option e Relay output for vent
60. s 360 F hour 200 C hr for 2 hours 20 minutes 180 F hour 100 C hr for 1 hour 297 F hour 165 C hr for 2 hours 40 minutes 108 F hour 60 C hr for 1 hour 30 minutes The firing speed based on load size adjustment will vary the firing times from about 5 hours 40 minutes to about 9 hours 20 minutes 26 AutoFire Kiln Controller User s Guide Hi Fire The firing range of higher temperature bodies such as stoneware and porcelain varies between Cone 4 and Cone 10 These bodies are fired nearly to vitrification and can shrink up to 16 Since stoneware is formulated from materials such as ball clay feldspar silica and kaolin the firing must be controlled to permit proper burn out of organic materials and to prevent cracking As with earthenware bodies water carbon and sulfur are also potential burn out materials for stoneware Due to the types of materials used the color of the fired product is affected by the amount of oxygen present during the firing process With the presence of silica care must be taken during the silica phase change near 1063 F 573 C to prevent cracking Since the fired properties of density and porosity are critical the firing profile during the last 210 F 100 C is important for temperature uniformity and product maturity It is during this time that those critical properties develop Thick pieces of ware should be treated similar to heavy loads Porcelain bodies are formulated to produc
61. save the changes and return to the active firing at the point in the program prior to entering edit mode During the time the controller is in edit mode the relays will not cycle therefore do not take more time then needed to make your changes Included in this manual Appendix A is a reproducible User Program chart used to help record custom firing programs This chart can be used prior to entering a program into the controller to provide a visual copy of each program sequence 10 AutoFire Kiln Controller User s Guide Display Reference The following is a reference guide to the various messages that may be displayed while using your AutoFire Kiln Controller Display Meaning 0 1 Display Temperatures of both thermocouples UniTemp Models Only Abrt Active Firing Cycle Aborted AING Factory Use Only ALAr Kiln Temperature Threshold Alarm user adjustable bAdP Invalid step in User Program CHG Change Temperature Units F or C CPLt Firing Cycle Complete final temperature reached will alternately be displayed CtbL Cone Table list of Cone Numbers and their bending temperatures see Appendix B d ELA Delay mode will alternately display the remaining minutes before start of firing F Dwell Temperature F 1 10 set temperature for controller to ramp to C Dwell Temperature C 1 10 set temperature for controller to ramp to dIFF Temperature Difference between two thermocouples UniTemp Models Only
62. temperature spacing between cone numbers varies As a result some cone numbers deform closer to their neighbors than others In some cases Orton produces a half cone Cones located on a kiln shelf near the ware are referred to as witness or shelf cones Small junior cones bars are used in a KilnSitter Small cones are sometimes used as witness cones but this must be done with care because they bend at substantially higher temperatures Cones bend when sufficient glass forms and the cone becomes soft The composition of the cone and the amount of heat determine when the cone bends Kiln Sitter cones bars bend due to the weight of the sensing rod Witness cones bend due to gravity pulling the cone over Mounting heights and angle affect the bending If the cone is mounted higher than recommended or if it leans over more than 8 it will bend earlier Orton developed Self Supporting witness cones to fix mounting height and angle These provide for more repeatable performance Temperatures are given for different cone types and mounting heights all mounted 8 from the vertical 34 AutoFire Kiln Controller User s Guide Behavior of Pyrometric Cones Typically it takes 15 to 25 minutes for a cone to bend once it starts This depends on the cone number The cone bends slowly at first but once it reaches the half way point 3 o clock it bends quickly When the cone tip reaches a point level with the base it is considered properly fi
63. th other controllers It can even be programmed and the firing monitored from a personal computer using software available from Orton Contact your kiln manufacturer or Orton for more information on this feature This User s Guide will explain the features benefits options and operation of your new Orton AutoFire Kiln Controller Use the Quick start reference card for normal operation of the controller and this Guide for more detailed descriptions of controller features Before making your first firing take the time to become familiar with the features of this product With proper use and installation you will be assured many years of superior performance and service If you have any comments or questions feel free to contact the Orton Ceramic Foundation or your Orton Distributor or Reseller We would enjoy hearing from you Again thanks for choosing an Orton product For simplicity AutoFire has only 8 keys The main keys allow firing programs to be selected and the delay start feature to be used with a limited number of keystrokes The OPTIONS key provides you with access to many other features Take the time to learn the features you want to regularly use All models of the AutoFire controller use the same basic programming but not all features are available on every model AutoFire controllers use proprietary PID Plus control software that eliminates the excessive cycling associated with control schemes found with most other contr
64. what we believe to be the best temperature controller for electric kilns and furnaces on the market today The following is a list of the features we believe you will find most useful as you begin using your new AutoFire Kiln Controller Thermocouple Type Cone Firings Proper Heat Work Cone Table User Programs Accurate Control Delay Start Set Point Control Firing Speed Control Program Review Skip Step Calibrate to a Cone Temperature Alarm Power Interruption Temperature Units Diagnostics Computer Interface Choose from Type K N or S Thermocouples We recommend the use of Type K up to 2100 F Type S above 2100 F Easy firing to Cone Numbers 022 12 with hold time additional 5 to 30 minutes of hold can be added Orton s patented method of adjusting firing to ensure proper heat work Reference temperatures for each cone number 60 C hr or 108 F hr heating rates 10 to 20 Ramp Hold Segments for each program retained even when power is turned off Proprietary PID Plus temperature control algorithm assures more accurate firings This also includes Soft Start and Overshoot Control Automatically starts kiln at a later time up to 9999 minutes later Setting hold time at 9999 minutes keeps kiln at set point temperature indefinitely Speed up or slow down your firing from 40 to 40 to better match the loading of your kiln Review your firing program even while the kiln is being fired If you w

AutofirePlusUnitemp manual - Edward Orton Ceramic Foundation

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