6441 SE Johnson Creek Blvd., Portland, OR 97206 Phone (503) 774-6000 Fax (503) 774-7833
www.skutt.com
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SERVICE TRAINING MANUAL
14.1 REV 11/19/04
REP
AIRS
(continued)
KilnMaster Relay Replacement
FOR MODELS: KM1027 / KM1227 1-PHASE 208/240 VOLT
This relay replacement kit is intended to replace three relays and all the necessary relay wir-
ing in your kiln. It is absolutely necessary to install the entire kit including all relays and wiring
for proper performance. Do not re-use any of the original black wiring.
Your new relay replacement kit consists of the following items:
1. Three relays with all of the necessary harness and control wires attached
2. One relay adapter plate.
The tool necessary to install the relay replacement kit is a #2 Phillips screwdriver
STEP-BY-STEP INSTRUCTIONS:
Before beginning the actual replacement, it is strongly recommended to read through these
instructions to familiarize yourself with the following procedures.
RELAY AND WIRING REMOVAL
1. Unplug your kiln. Remove your control box from the kiln. Place
the control box, face down on a flat surface. Protect the touchpad
of your control box with a soft cloth or towel.
2. Remove the fiberglass lined heat baffle by removing the six sheet
metal screws holding it in place. Carefully lift the heat baffle out
of the control box, taking care not to stretch the attached wires on
the underside.
3. Using the Phillips screwdriver, remove the six black wires at-
tached to the heat baffle terminal strip. Save your screws. If you
want to get the heat baffle entirely out of the way, remove the
remaining red and yellow thermocouple wires.
4. Begin removal of the three old relays from the control box by
removing the six sheet metal screws holding the relays in place.
Save your screws. ALL wires, both black and red, connected to
the relays will be removed. With the relays loosened, remove the
two large screws on the terminal block holding the black relay
wiring in place. The wires at this point should be crimped into
two large silver connectors that also will contain one red wire
each. Follow each red wire and remove the push-on connectors
from the fuse holder and the transformer bottom tab. Use a gentle
side to side rocking and pulling motion to remove these connec-
tors. Be especially careful when removing the connector from
the transformer to avoid damaging it. Remove the red connector
from the top-center transformer tab also. Remove the top red
wire connected to the circuit board labeled output 2. Remove the
double red wire on the circuit board labeled center tap. Carefully
pull the relays and all attached wires out of the control box.
5. Refer to photo #1 to ensure that all of the relays and proper wiring have been re-
moved.
PHOTO #1
