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AF4X Kiln Controller

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Appendix F – Typical Wiring Diagram, 2 Heaters

Appendix G – Typical Wiring Diagram, 1 Heater, 1 safety relay

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Summary of Contents for AF4X

Page 1: ...ser s Guide Model AF4X Orton Ceramic Foundation The Edward Orton Jr Ceramic Foundation 6991 Old 3C Highway Westerville Ohio 43082 9026 Telephone 614 895 2663 Fax 614 895 5610 www ortonceramic com October 2018 Arrow Springs ASC 6 ...

Page 2: ...ME TO A HOLD 10 SHORTENING A HOLD 10 VENT FAN OPTIONAL 10 PROGRAMMING USER PROGRAMS 10 ERASING A USER PROGRAM 11 USER PROGRAM EXAMPLE 11 ALARMS 12 THERMOCOUPLE ALARMS 12 DEVIATION ALARMS SEE TEDE OPTION TO ADJUST DEVIATION 12 POWER INTERRUPTION ALARMS 13 DIAGNOSTIC ALARMS 13 OPTIONS MENU 13 SKIP STEP SKIP 14 HOLD TIME HLDT 14 CHANGE TEMPERATURE CHGT 14 DELAY MODE DELA 14 THERMOCOUPLE TYPE TC 14 TH...

Page 3: ...PEED PROGRAMS 19 SPEED PROGRAM EXAMPLE 20 JEWELRY PROGRAMS 21 JEWELRY PROGRAM EXAMPLE 21 PMC PROGRAMS 22 PMC PROGRAM EXAMPLE 22 CONE FIRE HOW IT WORKS 23 CONE FIRE PROGRAMS 24 CONE FIRE EXAMPLE 24 REFERENCE SECTION 26 APPENDIX A LOW FIRE CONE PROGRAMS 26 APPENDIX B MID FIRE CONE PROGRAMS 27 APPENDIX C HIGH FIRE CONE PROGRAMS 28 APPENDIX D USER PROGRAM CHARTS 29 APPENDIX E CONNECTING THERMOCOUPLES ...

Page 4: ...y device The controller operates relays to turn the kiln elements on and off It is possible for relays to fail in the ON position The controller cannot protect against relay failure To prevent over firing never leave the kiln unattended especially at the end of a firing Controller accuracy and performance depends on the condition and position of the thermocouple sensors in use Getting Started Read...

Page 5: ...to adjust for load size or thick pieces of ware Delay start Use with either mode to delay start the kiln up to 100 hours 99hr 59min Set Point Control User Program option to hold kiln at temperature indefinitely Full On Full Off User Program option to heat or cool the kiln as fast as possible Add Time Add additional hold time to firings already in progress Program edit User Program option to change...

Page 6: ...forward the display values for specific program settings Also use this button for access to the option menu This key is used to step backwards the display values for specific program settings It is also used to activate the Program Review feature When using the Increase and Decrease keys to program number values the values will change more rapidly if the key is held in In general the user interfac...

Page 7: ...ssing the Program Start key will advance you to the next option if you are setting up a program or changing settings Note If you are programming the controller options and no keys are pressed for 90 seconds the controller will exit the options menu automatically Program Review To review the current program in the controller memory before or during a firing press the Decrease Review key The entire ...

Page 8: ...re For Example 2 hours 137 2 68 5 degrees per hour Round the calculated rate to the nearest whole number and your heating rate would be 69 degrees hour If you prefer to program heating and cooling rates in degrees per minute adjust the RATE option in the options menu to MIN If you prefer to program heating and cooling rates in Hours and Minutes adjust the RATE option in the option menu to TIME RA ...

Page 9: ...able to complete the firing This may result in a FTL alarm To avoid this alarm manually stop the firing by pressing the Program Stop key or program a higher temperature to complete the firing Changing a Target Temperature During a Firing If the kiln is firing and you need to modify the current ramp target temperature use CHGT option The controller will display the current setting and allow you to ...

Page 10: ...show on the display 2 Press the Increase Option key until the display shows USER then press the Program Start key 3 Using the Increase or Decrease key select the desired program number PR01 PR25 then press the Program Start key 4 RA 1 shows in the display indicating the rate value for the first ramp step Use the Increase or Decrease keys to enter the desired heating rate Then press Program Start k...

Page 11: ...nd zero minutes 00 00 Then press the Program Start key 10 Press the Program Start key to begin the firing Erasing A User Program If you enter a zero value for a rate RA all settings beyond that point will be erased This feature can be used to erase an entire user program by entering a zero rate at RA 1 User Program Example Use Program 1 Bead Annealing To fire to 960ºF at 1500ºF hour 30 minute hold...

Page 12: ...mocouple failed during a firing firing stopped TC 2 Thermocouple failed while controller Idle TCR Thermocouple polarity reversed firing stopped LAG Thermocouple temperature is lagging firing stopped kiln not heating OTL Over Temperature Limit detected firing stopped check LIMIT option FTL Firing too Long kiln temperature has stalled firing stopped Deviation Alarms See TEDE option to adjust Deviati...

Page 13: ...rget temperature DELA Delay Change Delay start mode TC Thermocouple Type Select thermocouple type Type K N S or R ALAR Threshold Alarm Set Alarm temperature DIAG TEST Diagnostics View output amps or test outputs F C Temperature Units Change temperature units to F or C LIM Over Temperature Limit Set the maximum limit temperature COST Firing Cost View calculated firing cost EXIT Exit option menu OPT...

Page 14: ...ss the Increase Option key until CHGT appears then press Program Start to see the program temperature Use the Increase or Decrease key to edit the setting then press Program Start to exit the option menu Delay Mode DELA To program the controller to begin a firing at a later time use the Delay start feature Enter a time delay in Hours Minutes format Delay time is set during the programming sequence...

Page 15: ...xiliary output identified as AOP1 Press the Increase Option key until DIAG appears then press Program Start to see the TEST then press Program Start to start the test cycle When done the controller will exit the option menu Change Temperature Units F C The F C Option allows the temperature units to be displayed in either degrees Fahrenheit F or degrees Centigrade C Press the Increase Option key un...

Page 16: ...ss Increase Option until TCOS appears Press Program Start to see the setting Use the Increase or Decrease key to edit the setting then press Program Start to exit the option menu If you want the kiln to fire Hotter the display will show zero for offset press the Increase key to see H 1 Continue pressing until the desired thermocouple offset shows in the display e g H 15 for a 15 offset and press P...

Page 17: ...Safety Relay is enabled on output 2 Press the Increase Option key until OPT2 appears then press Program Start key Press Increase Option until AOP1 appears Press Program Start to see the setting Use the Increase or Decrease key to edit the setting then press Program Start to exit the option menu Electronics Temperature ELEC ELEC displays the controller electronics temperature This can be useful in ...

Page 18: ...e operator to set a value for the Kilowatt rating of the kiln This value is used to calculate a Kilowatt Hour usage for review on the controller display The wattage rating must be entered by the user it can usually be found on the kiln manufacturer label KWHR and COST calculations are only as accurate as the programmed KW value To view the KWHR or COST calculations see the COST option Press the In...

Page 19: ... the circuit board Door Lid switch An optional door switch can be installed and connected to the controller If not used a jumper shunt is placed at circuit board location labeled LID LID is also a display alarm that indicates when the switch connection is open The door switch acts an optional safety device to prevent the relay outputs from being energized whenever the kiln door or lid is open Comp...

Page 20: ...fire at Speed 4 1500F per hour to 960F with a 15 minute hold at temperature Follow these steps starting with the controller displaying IDLE Press Display Shows a program group SPD a Speed number SPD4 o F 1 1112 960 HD 1 00 00 00 15 STRT DELA 00 00 ON ...

Page 21: ... 10 01 30 99 59 8HR 8 Hour 300F 167C hour 101F 56C hour 349F 194C hour 301F 167C hour 300F 149C 351F 177C 1350F 732C 900F 482C 01 00 00 30 01 30 99 59 12HR 12 Hour 300F 167C hour 101F 56C hour 211F 117C hour 225F 125C hour 300F 149C 351F 177C 1350F 732C 900F 482C 01 00 00 30 03 00 99 59 The operator can adjust the final hold temperature For information on rates target temperatures and hold times s...

Page 22: ...e programs are not adjustable The 5 programs are Display code Program Rate Target Hold CLA1 PMC Fast FULL 1650 F 899 C 00 10 CLA2 PMC Slow 1500 F 833 C hour 1470 F 799 C 00 30 CLA3 PMC3 Slow 1500 F 833 C hour 1110 F 599 C 00 45 CLA4 PMC FULL 1650 F 899 C 02 00 CLA5 PMC Gold FULL 1290 F 699 C 01 30 PMC Program Example To fire PMC at a slow rate Follow these steps starting with the controller displa...

Page 23: ...ature of all Orton controllers Orton Controllers contain three preset program groups for firing to a cone number Low Fire Mid Fire and High Fire Each of the programs can be adjusted for speed hold time and cooling rate The standard programs are designed to fire normal loads of thin ware ceramics When a kiln is more heavily loaded or when thick ware is fired additional firing time is needed Experim...

Page 24: ...hen press the Program Start key 16 COOL shows in the display indicating the optional Cooling ramp at the end of the firing COOL will be alternating with a rate value use the Increase or Decrease key to set a cooling rate for the kiln to cool to 392ºF 200ºC The maximum cooling rate is limited to 180ºF 100ºC hour If no controlled cooling is needed set the rate value as zero Then press the Program St...

Page 25: ...AF4X Kiln Controller 25 CONE A cone number 06 SPD STD FAST HOLD 00 00 00 15 COOL 0 STRT DELA 00 00 ON ...

Page 26: ...et Cone Degrees hour F Degrees hour F 022 396 979 108 1087 021 396 1004 108 1112 020 396 1051 108 1159 019 396 1144 108 1252 018 396 1211 108 1319 017 396 1252 108 1360 016 396 1314 108 1422 015 396 1348 108 1456 014 396 1377 108 1485 013 396 1431 108 1539 012 396 1474 108 1582 011 396 1499 108 1607 Degrees C Low Fire Ramp 1 Target Ramp 2 Target Cone Degrees hour C Degrees hour C 022 220 526 60 58...

Page 27: ... Target Ramp 2 Target Ramp 3 Target Ramp 4 Target Cone Degrees hour F Degrees hour F Degrees hour F Degrees hour F 010 324 1022 153 1112 180 1549 108 1657 09 324 1022 153 1112 180 1580 108 1688 08 324 1022 153 1112 180 1620 108 1728 07 324 1022 153 1112 180 1681 108 1789 06 324 1022 153 1112 180 1720 108 1828 05 324 1022 153 1112 180 1780 108 1888 04 324 1022 153 1112 180 1837 108 1945 03 324 1022...

Page 28: ...complete firing schedules for Cones 1 to 12 are shown below The standard firing time is about 10 12 hours Degrees F Hi Fire Ramp 1 Target Ramp 2 Target Ramp 3 Target Ramp 4 Target Cone Degrees hour F Degrees hour F Degrees hour F Degrees hour F 1 324 1022 153 1112 162 1863 108 2079 2 324 1022 153 1112 162 1872 108 2088 3 324 1022 153 1112 162 1890 108 2106 4 324 1022 153 1112 162 1908 108 2124 5 3...

Page 29: ...7 18 19 20 User Program 2 Ramp Rate hr Temperature Hold Time Vent Fan on off 1 2 3 4 5 6 7 8 9 10 Appendix E Connecting Thermocouples For thermocouples the color coded wires should always include a red wire The red wire is the negative leg For Type K the positive leg is yellow For Type N the positive leg is orange For Type S and Type R the positive leg is black ...

Page 30: ...AF4X Kiln Controller 30 Appendix F Typical Wiring Diagram 2 Heaters Appendix G Typical Wiring Diagram 1 Heater 1 safety relay ...

Page 31: ...play will show TC Press the Increase Option key to select a thermocouple type setting Press the Program Start key the display will show F C Press the Increase Option key to select a temperature unit setting Press the Program Start key the display will show PID Press the Increase Option key to select a Kiln type BRICK or FIBER Press the Program Start key the display will show SPCL Press the Increas...

Page 32: ...warranted above Buyer s sole remedy shall be repair or replacement of the Warranted Components as provided above To the extent permitted by law ALL EXPRESS AND IMPLIED WARANTIES FOR THE WARRANTED COMPONENTS INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE TWO YEAR WARRANTY PERIOD COMMENCING ON THE DATE OF PURCHASE AND NO OTHER WARRANTY WHETHER EXP...

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