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AMACO® EXCEL® kilns

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1. TH r I f 2 YN d t pU foo Y op Ly P C FL 38 1 a S d i Current Sensor Terminal Strip 700 Board QTY per kiln Stock No 24278K 24322P 24332C 28071F 243245 22134W 24296H 24251R 24245 28068C 24246K 28782C 243045 24249N 24274F 28071F 24275G 24266V p a GI G0 G1 Go Bo E53 CJ I l Transformer L1 L2 L3 ep Grnd green ENT QTY Description per kiln Transformer 1 Harness wire set 1 Current sensor kit 1 Connectors terminal lugs 12 Terminal block three phase 1 Fuse holder 1 Terminal strip 1 Manual Style Sitter Timer Models Brick grooved for tube assembly 1 Switch box with shield 2 Infinite control switch 6 Switch box upper 1 Kiln Sitter limit timer model LT 3K 1 Tube assembly only 1 Pilot light assembly 1 Master switch box 1 Connectors NPW terminal Lugs 12 Master switch box shield 1 Switch box shield lower 1 Wiring Diagram Parts List EX 365 EX 365SF Single Phase 3 x CO RS m e 4 3 Current f Sensor J oH Wa i jH r a i H V e rc Elements Top Ring Transformer Terminal Strip Pu Front Back n k Em u AN i m nal E3 a Relay CJ L1 i L2 700 Board GR Grnd green Stock No Description said Stock No Description PEU 5 All Models 24278K Transformer 1 24267W Brick for lid with band no hardware 1 24322P Harness wire set 1 24262P Lid supp
2. e Wire not shown Fuse Power Cord Power Cord Quality Components That Make EXCEL Kilns a Smart Choice Select Fire Controller if equipped At the heart of your new kiln is the Select Fire con troller This unit allows you much greater control over your kiln than ever before It is essentially two controllers in one You can fire by cone numbers or specify your own firing profile with multiple ramps and holds nacO Gelect Fire DE The wall mounted Select Fire is an option that functions in the same manner as the builti in version with the exception that it can be moved from one kiln to another While the wall mounted version cannot fire more than one kiln at a time it can control any number of kilns a studio operates provided they have the same cord plug and receptacle configuration Brick EXCEL kilns are constructed of the finest insulating firebrick available today offering strength cleanliness and long life All bricks are precision cut and grooved to assure tight fit perfect element support and ease of replacement Because of their porous composition insulating firebrick are fragile Always handle your kiln and its brick with care The brick in your kiln may begin to show some fine cracks after the first few firings especially after Cone 10 high firings This is normal and does not harm the structural integrity of the kiln or impair its functioning Elements The highest
3. opening and closing the kiln lid effortless In addition to making the lid lighter it makes your kiln safer by reducing the risk of sudden lid drops that can cause injury Lid Brace The lid brace holds the lid securely open for loading and unloading the kiln As you open the lid allow the lid brace to follow over the anchor pad and screw that is attached to the side of the kiln Simply allow the notched end of the brace to engage the anchor pad and screw allowing the lid to rest in a full upright position Periodically test the thumbscrew for tightness If loose tighten Easy to Change Element Connectors EXCEL kilns use corrosion resistant element lug con nectors which allow for easy replacement of ele ments without having to cut wires and solder back together All you need is a screwdriver to remove the element and re connect the new one Keno Safety Information Safety Information Tens of thousands of kilns are used safely in homes schools and professional studios throughout the world With a good understanding of your kiln and a little com mon sense you can avoid any accidents Please observe the following safety recommendations Operation e The stainless steel jacket and some of the other fixtures surrounding the kiln will get hot enough to burn your skin when the kiln is heated Therefore it is important to be extremely careful when working close to the kiln We recommends posting warn
4. 2 700 Board G Grnd green e e e Wiring Diagram EX 1850SF Three Phase Terminal Strip Front Back AE eo Elements Top Ring L1 LS 700 Board amp Gmd green Call AMACO Technical Support for replacemant parts 800 374 1600 61 seyd day aseud PUIS 4S0S8 1L Xj sweJbeig buutM American Art Clay Co Inc 6060 Guion Road Indianapolis Indiana 46254 www amaco com e 800 374 1600 Email technicalsupport amaco com
5. Pyrometric Cones Pyrometric cones should be used during every firing whether or not your kiln is equipped with a pyrometer or automatic cutoff They deform progressively under advancing heat and serve as accurate indicators of firing cham ber temperatures rate of firing atmospheric condi tions etc Each pyramidal shaped cone is numbered and will melt or deform at a given temperature For general use the tempera Before Firing Y Guide Cone A Guard Cone C Firing Cone B ture ranges from Cone 022 1094 F 590 C to Cone 10 2381 F 1305 C are sufficient Cones are selected in relation to the maturing tempera ture of the clay or glaze you are firing Usually three cones are used for each firing a guide cone to deform at one cone number cooler than the target temperature A a firing cone to deform at the cone number for the exact maturing tempera ture of the clay or glaze B and a guard cone to deform at one cone After Firing V d Guide Cone A Guard Cone C Firing Cone B 31 SJOJe2Ipu 9Jn3e19duuo uonededo ujry enuey Temperature Indicators number higher C The guide cone A bends first and warns that the maturing temperature approaches When the firing cone B bends halfway down the kiln should be turned off If the guard cone C bends the kiln is too hot and the pieces in the kiln could be overfired A cone support for holding the cones is s
6. 41 uoneuuojJu Hull Ceramic Defects Ceramic Defects Their Causes and How to Avoid Them The first and most important aspect of troubleshooting defects is to be familiar with the clays glazes and kilns used in the studio Completely understanding how each works the parameters of the materials and what the norm for the studio is will help figure out what went wrong when pieces do not look as expected There are many different defects that can be caused by numerous things This section will discuss some of the most com mon glaze flaws and some simple inexpensive things that can be done to help reduce the occurrence of defects General Concepts 1 Most defects are not seen until the piece comes out of the kiln so knowing that the kiln performed as expected is important Even if the kiln is computer controlled plac ing cone packs or self supporting cones will allow the user to accurately know if the kiln completed the firing as programmed Unlike pyrometers that only measure heat cones measure both heat and time at heat which is key to how the glaze and clay will look Knowing that the kiln fired properly is just as valuable as knowing it didn t when you are troubleshooting 2 Know how long your kiln cycle actually takes If the kiln cycle normally takes 6 hours to fire and now it is tak ing 87 this is a sign that perhaps elements are wearing out or possibly one or more have burned out 3 Know how the weather whe
7. Check thermocouple to make sure it is connected properly Do thermocouple bypass test If temperature read ing is still negative the board has been damaged and needs service Check relay Check element Check cone used in Kiln Sitter Press 1 to clear the dis play and restart the kiln Press 1 to clear the display If firing was in progress it will continue Recheck the selected program and reprogram if necessary A hardware error has been detected by the con The controller must be Hardware error i troller software returned for service The kiln or one of the zones in a zone control kiln is more than 100 F 37 C above the travel ling set point Invalid program variable Key was held too long or was stuck Controller is reading a board temperature above 160 F 71 C Firing has stopped Analog to digital converter did not pass the self Room temperature is too hot Check relay Reprogram If problem persists have board sent in for service If problem persists after releasing key have key pad replaced Lower room temperature below 100 F 37 C Board will need to be serviced check diagnostic test on reset Steady display indicates thermocouple has failed FAIL If flashing thermocouple s of a zone control kiln Change thermocouple m oo has failed N 8 Select Fire FAQ s How can I correct a value that s been incorrectly typed b
8. The controller is plugged into a wall receptacle which provides three phase voltage You will no longer need to use the three phase contractor box However an electri cian may need to wire a receptacle for the controller if a three phase contractor box was used previously You may need to make other changes to the supply for kilns not made by AMACO Other manufacturers may not use pilot cords Please discuss this with your distributor Thermocouple Installation EXCEL kilns have a hole stamped in the stainless band where the thermocouple flange is to be installed It is located to the right of the red switch boxes The firebrick is visible through this hole The thermocouple flange is a metal tube approximately s 1 59 cm diameter and 1 5 in 3 81 cm long attached to a metal washer Remove the thumbscrew from the flange Align the thermocouple flange so that it is exactly over the hole in the stainless band Position the flange so the thumb screw is on the top Attach the flange to the kiln using the two Phillips self tapping screws provided NOTE To start the screws lightly hit each screw with a hammer until the point has pierced the stainless steel band Insert a 5 in 0 64 cm twist drill or carpenter s bit through the flange holder Slowly drill through the kiln wall brick into the kiln chamber Insert the thermocou ple into the kiln so that 1 25 in 3 18 cm to 1 5 in 3 81 cm of the tip protrudes into the kiln cham
9. Tightening the Stainless Steel Bands This operation should be done while the kiln is cool and at room temperature Step 1 Grasp adjusting screws in one hand with chan nel locks or a pair of vise grips Step 2 With other hand Use a large flat screwdriver to tighten adjusting screws To make bands extra tight heat metal bands with a propane torch Be sure to only heat the metal bands and not the firebrick Once the band is heated retighten screws Troubleshooting Your Kiln Warranty Work All EXCEL Kilns come with a Two Year Warranty which covers parts and labor All warranty claims must be ap proved and serviced by an Authorized EXCEL Distribu tor If there is not an Authorized EXCEL Representative in your area contact AMACO directly for authorization however labor costs will not be covered Non Warranty Work Once the warranty has expired many EXCEL owners prefer to work on their own kilns to save money We still recommend that you work closely with an AMACO representative to insure the diagnosis and repair are correct and done safely There are a number of resources available to help you troubleshoot the problem efficiently and effectively 26 Your Local EXCEL Distributor Your local EXCEL Distributor should have a kiln repair technician on staff and replacement parts in stock This is the best place to start since the call is local and you can often pick up parts the same day The AMACO Fa
10. 9 Thread the coil around the kiln pushing it carefully into the groove and push the second terminal through the outer hole in the wall Make sure the coil is resting securely in the groove and replace the element pins 10 Cut off excess terminal wire outside of the wall leav ing sufficient wire to replace the terminal lug 11 It is sometimes useful to strip back the insulation on the jumper wire so that it may be doubled back against itself before insertion into the lug This will provide for a greater contact surface with the element terminal in the connection Note The need to establish an absolutely tight connection cannot be over emphasized 12 Before fastening switch box to kiln carefully push wires into the front corners of the switch box Avoid con tact between wires and kiln 13 Replace element staples in corners of bricks CAUTION Elements become very brittle after a few firings so if straightening is necessary heat the element 38 electrically to visible redness unplug the kiln from the wall and immediately push the element back into posi tion with a wooden implement reheating whenever stiff ening is detected Place your hanging pins in a straight row and the element will serve the rest of its normal life Replacing Thermocouple EXCEL Kilns with Select Fire Only Kiln Mount Model 1 Remove the screws that secure the control panel to the kiln 2 Swing the box open 3 The thermocouple has
11. age load density and temperature range will all affect the kilns ability to heat Conversely the kiln s insulation will influence its ability to cool A rate must be entered for each segment Step 5 Temperature F or C This prompt is asking you to enter a temperature to go to When it gets to that temperature it will either hold at that temperature or switch to a new rate and aim for a new temperature If you are programming in Celsius it will read C instead of F The controller will allow you to program temperatures between 32 F 0 C and 2400 F 1315 C A temperature should not be entered which exceeds the kiln s temperature rating Step 6 Hold Time HOLd A HOLD time is generally entered to allow the kiln time to balance out and all of the pieces in the kiln to reach the input temperature before the kiln moves to the next segment You may enter hold times of 00 00 to 99 99 A Hold at peak temperature can be used for this reason or to gain additional heatwork to fine tune cone bends or to fire in between cones Remember that everything to the left of the decimal point on the display is Hours and everything to the right is Minutes Excessive Hold times may cause over fires Step 7 Repeat Continue to enter a rate a temperature and a hold time for all the segments When the last segment has been entered the display will prompt you to enter an Alarm temperature The default is 9999 for no alarm Input an Al
12. 1 phase 40 0 9 5 6 gauge 60 6 50 208 1 phase 39 4 8 3 6 gauge 60 6 50 EX 399 240 1 phase 48 0 11 5 6 gauge 60 6 50 240 3 phase 29 3 11 5 8 gauge 40 15 50 208 1 phase 48 0 10 0 6 gauge 60 6 50 208 3 phase 317 11 0 8 gauge 40 15 50 EX 1099 240 1 phase 60 0 14 3 4 gauge 80 6 50 240 3 phase 40 0 14 3 8 gauge 50 15 50 208 1 phase 69 0 14 3 3 gauge 90 6 50 208 3 phase 46 7 14 3 8 gauge 60 15 50 EX 1850 240 3 phase 66 0 23 6 3 gauge 90 15 50 208 3 phase 76 0 23 6 3 gauge 100 15 50 EX 1266 240 1 phase 48 0 11 5 6 gauge 60 6 50 208 1 phase 48 0 10 0 6 gauge 60 6 50 GSF 670 240 1 phase 34 7 8 3 6 gauge 50 6 50 240 3 phase 20 0 8 3 10 gauge 30 15 50 208 1 phase 40 0 8 3 6 gauge 60 6 50 208 3 phase 23 1 8 3 10 gauge 30 15 50 For runs longer than 50 feet use heavier wire numerically two numbers lower For example instead of 8 gauge wire use 6 gauge Three Phase Installation Three phase Models EX 270SF EX 365SF EX 399SF and EX 1099SF can be plugged directly into a 3 phase 15 50R wall receptacle with the exception of the EX 1099SF which is direct wired 208 Versus 240 Supplies As you can see from the chart on the previous page most EXCEL models are available in either 208 or 220 240 volt versions The 120 208V supply is increasingly encountered in schools and newly built communities because it s more efficient for heavy 120V loads This affects all EXCEL models because their elements receive the full 208 or 240 applied vol
13. 21 u a cae HHT Htt ue 1000 500 Switch r OFF 06 BISQUE HEAVY PIECES Vent lid for first hour then close Hours 0 12 13 14 15 16 17 18 19 20 21 2500 i 2000 1500 1000 500 Switch LOW T OFF 06 GLAZE FAST FIRE When firing 05 06 red glazes or other bright colors it is suggested to leave the peephole plugs out Hours 0 1 2 3 4 5 6 7 8 g 10 11 12 13 14 15 16 17 18 19 20 21 2500 T 2000 1500 1000 500 Switch 2 4 6 HI OFF Peephole plugs may be placed into peepholes when the kiln begins to glow a dark red approximately 1000 F 34 6 GLAZE SLOW FIRE When firing 05 06 red glazes or other bright colors it is suggested fo leave the peephole plugs out Hours 0 1 2 3 4 z 6 D 8 g 10 11 12 13 14 15 16 17 18 19 20 21 2500 Switch 2 3 6 OFF 9 10 GLAZE Hours 0 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2500 2000 1500 1000 LL Switch OFF OVERGLAZES Vent lid Fio for entire zs DO NOT put in agro d Hours 0 10 11 15 17 18 19 20 21 2500 Switch 6 HI OFF Peephole plugs may be placed into peepholes when the kiln begins to glow a dark red approximately 1000 F 35 se npeu s buuiJ pe1sebbng Troubleshooting Guide for Manually Operated Kilns Troubleshooting Guide for Manually Operated Kilns Your EXCEL kiln is put under heavy load as it heats and cools Like any elect
14. Cone Value entered Step 3 Input a CONE VALUE Press ENTER Display will read Spd alternately with the last Speed entered Step 4 Press a SPEED SLOW MED or FAST Press ENTER Display will read HOLD alternately with a Hold time value Step 5 Input a HOLD TIME if one is desired Press ENTER Display will flash CPL then will return to Idle Mode At this point the program is loaded and ready to start Before pressing START it is a good idea to press REVIEW to make sure the program was input correctly Also verify that the lid latch is engaged if your kiln is equipped with a lid lifter and check to see the area is clear of all combustible materials Step 6 Press START Display will read ON briefly and then display the current temperature of the kiln If a delay start has been entered the display will begin counting down the time entered When the firing is complete the display will read CPLT alternately with the current temperature of the kiln and the time it took to complete the program To clear this data and return to Idle Mode press ENTER Decription Step 1 Cone Fire The Cone Fire Mode runs a factory installed multi seg ment program which is selected based on the Cone Value Speed and Hold time you choose Below is an example of a program which is run if you choose a Cone Value of 04 a Speed of Medium and Hold time of 5 minutes One of the greatest features of Cone Fire Mode is Cone Correlation It automati
15. F 65 C output 4 will turn off When a RAMP HOLD program is inputted it will ask whether you want the fan or other accessory on for each segment you program After you Input the hold time for each segment the display will show FAN along with the number of the segment you are programming Alternately it will flash the current setting either OFF or ON To change the setting toggle it with the 1 key and press ENTER to select that setting 23 soinjea4 NU W Menu Features OP b Option B During a CONE FIRE program Output 4 will turn on when START is pressed It will then turn off at 1450 F 788 C It will turn back on when the kiln is cooling and the tem perature drops below 1000 F 538 C It will then turn off when the kiln cools to 150 F 65 C When a RAMP HOLD program is inputted it will ask whether you want the fan or other accessory on for each segment you program After you Input the hold time for each segment the display will show FAN along with the number of the segment you are programming Alternately it will flash the current setting either OFF or ON To change the setting toggle it with the 1 key and press ENTER to select that setting OP C Option C When Option C is selected Output 4 does not come on during any portion of a CONE FIRE Mode program When a RAMP HOLD program is inputted it will ask whether you want the fan or other accessory on for each segment you program After
16. The first method allows the user to program custom Cone Fire programs The second involves controlling the rate in which the kiln cools down Writing Custom Cone Fire Programs This new feature on the 700 Board allows you to utilize the cone correlation benefits of Cone Fire Mode coupled with the flexibility of RAMP HOLD Mode To use Cone Correla tion to calculate your final temperature during a RAMP HOLD program press CONE TABLE instead of entering a temperature for your final heating segment Input the Cone Value you would like to correlate and Press ENTER Slow Cooling Cone Fire Controlled Cooling COOL is a feature that allows you to add a 1 segment cooling program to the end of a Cone Fire program When COOL is toggled ON it will prompt you to enter a Rate Temperature and Hold Time after you finish entering the Hold Time for a Cone Fire program This is helpful when trying to achieve certain glaze effects Programming the Ramp Hold Mode Programming Steps Step 1 From Idle Mode press RAMP HOLD Display will show PROG alternating with a number between 1 and 6 Step 2 Input the PROG Number of the Program you wish to create or run This is a number between 1 and 6 that you assign to a program which will be stored in permanent memory until it is replaced Press ENTER Display will show SEGS Step 3 Input the total number of segments for your program Press ENTER Display will show RA 1 Step 4 Input
17. a feature that comes standard on the EXCEL EX 1850SF and optional on EX 365SF and EX 1099SF Zone Control is a feature that allows the control ler to independently fire sections on multiple section kilns to ensure even temperature top to bottom There are three optional setting configurations for Zone Control which can be accessed through the ZONE fea ture under the CNFG menu e NOTC Pld e SHTO NOTC Number of Thermocouples if equipped with Zone Control Your kiln should be properly programmed for the cor rect number of thermocouples before it leaves the fac tory You cannot set a kiln to fire in more than one zone unless it is configured in the factory as a Zone Control kiln If you try you will receive a FAIL error code To change the number of zones on a Zone Control kiln access the ZONE setting through the CNFG menu then use the menu key to toggle to the NOTC feature and press ENTER The controller will display the current NOTC setting Input the desired value and press ENTER PID Proportional Integral Derivative if equipped with Zone Control PID is a zone control setting that uses the center section elements to help the bottom and top sections when nec essary In most kilns the center section is usually the hot test section The PID option is designed to help speed up the firing when the top or bottom section is cooler and lagging behind the other sections When the top or bott
18. a yellow cloth wrapped lead wire attached to the terminal strip with slide on connec tors marked with positive and negative Slide the connectors off 4 Remove the two screws that hold the thermocouple terminal block onto the heat shield 5 Gently pull the thermocouple assembly out of the brick 6 Loosen the two screws that hold the thermocouple ele ment in place and remove it from the thermocouple block 7 Insert the new thermocouple in the same careful manner 8 Reattach to terminal block onto the heat shield with the two screws 9 Reconnect the thermocouple lead wire to the termi nal strip matching the positive and negative markings 10 Close the box 11 Replace the screws Wall Mount Model 1 Gently pull the thermocouple out of the kiln 2 Unplug the thermocouple from the receptacle at the end of the yellow wire 3 Plug the new thermocouple into the receptacle 4 Replace the thermocouple using the same care as when it was removed Select Fire Wall Mount Repairs The Select Fire Wall Mount controller is made of solid state parts that are not user serviceable If repairs are necessary contact EXCEL Technical Services at 800 374 1600 for instructions on how to return your unit for repair Brick Floor or Lid Repairs Please contact your EXCEL dealer or EXCEL Technical Services at 800 374 1600 for assistance with refrac tory repair Important If you ever have the need t
19. bracket and arm 1 24265T Lid handle 1 Brick grooved for peephole 4 28815L Thermocouple 1 Brick grooved straight 40 24319J Relay 2 Brick grooved terminal 3 24250P Control Panel 1 Insulator tubes 8 24278K Transformer 1 Supply cord connector 1 24322P Harness wire set 1 Power supply cord 1 24332C Current sensor kit 1 Kiln stand 12 sided 1 28071F Connectors terminal lugs 8 Heat shield supply cord 1 24325T Terminal block single phase 1 Bottom slab with band 1 243248 Terminal block three phase 1 Sash lock 2 22134W Fuse holder 1 Stainless steel body band 2 24296H Terminal strip 1 51 seyd ajbuls 4S997 L X3 S17 S 4 g We1peg Bui Wiring Diagram Parts List EX 1266SF Three Phase 52 Stock No 24277 24263R 24279L 24280M 24281N 24244H 242525 24253T 24282P 24256X 24306V 24258B 24235R Wiring Diagram Parts List EX 1266SF Three Phase Elements Top Ring WANA MAYA zo ne Bottom Ring MM Em 1 WANANAAAACAD Um MM IL Te I n AVA i M e Description Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 12 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band E RA Front Back Terminal Strip QTY per kiln 1 1 4 40 NO N O
20. electrician Power interrupted during firing kiln is still hot 1 If still in venting stages re fire as if a fresh load using original cones 2 If venting is completed and you know the load was never within one hour of shut off resume firing with the Same cones and re fire as usual except that the lid can be left closed throughout Abrupt increase in firing time 1 Check your Senior cone and shut off kiln manually if it is down Check Kiln Sitter thoroughly as outlined on pages 32 33 2 If your Senior visual cone is still standing and you re sure that it has the right number check the fuses or breakers If temperature then begins to rise complete firing as usual 3 One section not heat ing may mean an element has failed When the kiln is cool visually inspect each element for breaks See page 38 for element re placement 4 f no elements appear to be broken in a section that fails to heat contact EXCEL Technical Support 5 If all sections are operating and firing time problems persist ask your power company to perform a voltage test at your wall outlet with all elements on High Gradually increasing firing times often accompanied by increasingly uneven temperatures within the kiln 1 Circuit or wall receptacle is defective Have them checked by a qualified electrician 2 Kiln switch box connections need tightening Contact EXCEL Technical Support for instructions specific to your kiln mode
21. hand building pieces and attempt to keep the moisture level as even as possible throughout the piece 2 Avoid areas on a piece that are thick in some areas and thin in others If this must be done to achieve a certain look make sure to slow the drying process way down This can be done by loosely covering the piece with plastic This will take trial and error to determine how much time it will take and time will vary depending on your studio conditions But remember that drying it too long is always better than not enough 3 Avoid sharp interior or exterior corners Rounded cor ners are always better as exterior corners always dry faster than the interior of the piece Interior corners are natural areas where stresses can be focused and start to crack 4 Avoid sharp interior and exterior edges Same reason ing as above 5 Simple shapes like a 6 plate are much easier to dry than a 36 platter the larger the piece the slower the drying time 6 Incising may cause stresses due to variations in thickness 7 Applied decorations need good scoring good appli cation of slip and slower drying to avoid cracks 8 Be careful not to unduly flex wet shapes as clay has memory and it will tend to go back to the warped shape even if you smooth out the warps This may cause stress cracks 9 Throwing thick bases on pots can lead to S cracks on the bottom of the piece 10 In general the more complex the shape the slower the drying
22. have other rights which vary from state to state Your kiln is registered We keep a permanent record of the serial number model number and purchaser of every kiln sold With this information we can supply the necessary replacement parts for your particular kiln Keep your pa pers in a safe place You will want to refer to this instruc tion booklet special kiln instructions wiring diagram and catalog File them in a safe place for handy reference Table of Contents Contents List Kiln Features eese 2 Quality Components of EXCEL Kilns 3 Safety Information ssena 4 5 Electrical Requirements esses 6 7 Kiln Venting Why It s Important eere 7 When Your KIIN Arrives esee 8 EIT LO CAMIO NI PN TM 8 Prepar OM lien nho HARDER MS 9 i is P 9 Getting Started eese eere aaa 10 UB IH 11 L zdiINO TIDSasncsdemi nn ttn niin niin rnit 12 Select Fire Control Features eene 13 Select Fire Programming eere 14 24 General Information eene 14 15 Choosing a Program eet tia endis 16 Programming Cone Fire Mode 16 18 Advanced Cone Fire Features sss 18 Programming Ramp Hold Mode 18 19 Advanced Features eese 19 Runn
23. holder Terminal strip QTY per kiln OU os NO ee ee 59 aseud a buls 456601 X3 1S1 seg Wwesbeiq Bul Wiring Diagram Parts List EX 1099SF Three Phase 60 Wiring Diagram Parts List EX 1099SF Three Phase Terminal Strip Front Back m Elem ents Top Ring _ pA AAO Transformer AAAA 700 Board amp Grnd green Stock No Description E Stock No Description per kiln 24277 Brick for lid with band no hardware 1 24287W Hinge complete 24263R Lid support brace bracket and arm 1 24265T Lid handle 24279L Brick grooved for peephole 6 28815L Thermocouple 24280M Brick grooved straight 60 Special order Relay 24281N Brick grooved terminal 5 24250P Control panel 24244H Insulator tubes 12 24278K Transformer 242528 Supply cord connector 1 24326V Harness wire set 24253T Power supply cord 1 24332C Current sensor kit 24282P Kiln stand 12 sided 1 28071F Connectors terminal lugs 24256X Heat shield supply cord 1 24325T Terminal block single phase 24306V Bottom slab with band 1 243248 Terminal block three phase 24258B Sash lock 2 22134W Fuse holder 24235R Stainless steel body band 3 24296H Terminal strip QTY per kiln 1 1 1 3 1 1 1 1 12 1 1 1 1 Wiring Diagram EX 1850SF Single Phase Terminal Strip Front Back AD e 4 pa
24. is programmed Bad elements to decrease The temperature must stay 50 degrees Bad relay below this set temperature for 18 seconds before the error is displayed O d lid P Check elements Check relays 27 bunoouse qnoJ Troubleshooting A negative temperature is displayed This gener ally indicates the thermocouple is wired incor rectly To correct this situation ensure the red and yellow wires are connected correctly to the controller and at all junctions You can identify the red lead on an unmarked thermocouple with a magnet because a magnet will be attracted to the red lead When using the CONE FIRE mode the tempera ture is decreasing during the last ramp segment If this a Kiln Sitter Kiln using a Wall Mount Controller Kiln Sitter may have shut off the kiln Continuous PF in display A continuous Err P indicates a short term power outage has occured and the kiln has continued with the program This code indicates there was a power loss to the controller while writing a program to the non volatile memory chip Using the kiln in tempera tures below 0 F 17 C Thermocouple connected backwards red and yel low leads reversed Board has been damaged by static electricity or ESD electro static discharge Faulty relay Broken element Kiln Sitter shut off kiln Indicates a long term power outage and the kiln has been shut down Power outage Power surge Power loss Error ses
25. items to allow them to breathe Using half shelves with a 1 4 space gap in the middle will also help increase the flow of oxygen within the kiln chamber especially when used in combination with a vent system Allow for Proper Clearances Kilns lose most of their heat from the lid and the slab Ideally there should be at least two inches of space between the lid and the closest piece The first shelf should be posted up one inch from the bottom slab Nothing Directly Under the Kiln Vent Holes Holes drilled in the lids of the kiln that have AMACO kiln vents allow air to be drawn into the kiln chamber If a piece of ware is sitting directly under one of these holes it could leave a spot in the glaze If it is not possible to cap the load with a shelf leave a five inch radius on the shelf directly below each hole DO NOT Rush Take the time to properly load and fire the kiln Check each piece to insure that too much glaze or unsteady placement will not cause disaster during the firing A few extra minutes can save you a lot of frustration DO NOT Load Damp Ware into Your Kiln Make sure all ware is bone dry before loading into the kiln It should feel like room temperature If it doesn t water is still evaporating from it Load Slowly Dropped ware on shelves may damage the inside of your kiln DO NOT Set Pieces Directly on Kiln Floor The first shelf should be 1 off the floor of the kiln For best results ware should
26. kiln wash the walls or lid of your kiln Test Firing The test fire is very important and should not be skipped It ensures the kiln is operating correctly and nothing was damaged in shipping It burns off element oils and develops an oxide coating which will help prolong the life of the elements Loading This first firing should be done with only kiln shelves Place the first shelf layer on one inch 2 5 cm posts above the slab When loading ware in the kiln it is important to load it evenly to ensure proper ventilation For a full description on loading see page 12 Place Witness Cones A Cone 04 1945 F 1063 C is recommended for proper pre oxidation of a new element For more about cones see Heat Work Cones on page 43 If your kiln is equipped with a lid lifter be sure to latch the lid shut Test Fire The Kiln Follow the Cone Fire Mode programming instructions found in the Programming section of this manual to run a Cone 04 Medium Speed program with No Hold time and No Preheat After the kiln has cooled to room tem perature unload the kiln and inspect the cones If the cones are satisfactory you are ready to begin using the kiln If there is a problem with the cones see the section on fine tuning your kiln on page 15 Dul 159 uonejedaJjg Getting Started Getting Started This page is a memory aid not a substitute to reading and understanding the manual Activate the power source by plugging in the kiln o
27. may cause that area to read colder than the rest of the kiln load See Troubleshoot ing Guide p 36 for additional solutions Under fired Ware Bubbles in Fired Glaze Pinholes Blisters Pinholes L 5 LI Blisters It is ALWAYS a good idea to have a set of pyrometric cones in every kiln firing They cost only a few pennies each and can be critical in determining if a kiln load is under fired Under fired ware can be caused by kiln issues like weak elements or non functional elements A kiln load that is over filled may cause areas of the kiln to be under fired Usually simply re firing the pieces to the correct tem perature can correct the problem Some potters like to apply a thin coat of glaze to the piece before re firing simply to make the glaze a little more reactive and to help it melt easier The causes of these issues can be many but the most likely cause is off gassing of material in the clay body that cause air bubbles to either pop on the surface of the glaze or become trapped inside the glaze when it solidi fies The key is to have the gases escape from the body before the glaze melts enough to seal off the escape route of the gases This is not always an easy thing to do because the actual cause will depend on the system 45 S129Ja Dwele Ceramic Defects the potter is using Sometimes firing the load faster can solve the problem sometimes a slower firing will work and sometimes simply putting a t
28. not be placed within 1 of the elements Large flat pieces like plates that demand the full width of the kiln should have their rims positioned between two elements DO NOT Crowd the Kiln Sitter or Thermocouple Keep shelves at least 14 from the sensing rod and ware at least 2 away If your load should shift during firing there will be less danger of jamming the Kiln Sitter or having ware resting against the thermocouple causing inaccurate temperature readings or damage to the ware Select Fire Control Features if equipped Digital Readout Shows prompts messages and temperature throughout firing and cool down Touchpad Menu Lets you access menu diagnostics feature Smooth surface pads are easy to clean and have no moving parts Delay Option Action Controls Lets you delay start of firing Lets you start or stop kiln operation Ramp Hold Mode Lets you select up to eight segments of temperature change and hold Alarm You can set alarm to sound at any temperature Cone Fire Mode View Current Segment Lets you fire by simply entering the desired Cone number Shows you what Ramp Hold segment the kiln is currently in Firing Speeds Cone Table Converts Cone numbers to temperature Choose from Slow Medium or Fast heating Review Reviews your current firing program 13 S9Jn1eaJ O1 UOD 129 ag Programming General Select Fire Programming Information If
29. peak temperature It can be set for a Ramp Hold or Cone Fire program You can enter any Alarm temperature between 0 and the maximum temperature rating of the kiln From Idle Mode press ALARM Input Alarm Temperature then press ENTER When START is pressed the program currently loaded will begin When the temperature of the kiln reaches the Alarm temperature entered the Alarm will sound in a se ries of beeps Press ENTER to turn off the Alarm DO NOT press STOP this will stop the program The Alarm tem perature will stay in memory until it is cleared To clear it follow the instructions for entering an Alarm and enter 9999 for the Alarm Temperature 9999 is the default for having the Alarm off Menu The Menu features are discussed in depth in the Menu Features section of the manual pages 21 24 Review The Review key allows the user to look at the current program loaded to make sure it is correct We highly suggest using this feature to check programs prior to each firing Press REVIEW and the display will step through each segment of the program for a Ramp Hold program It will also let you know if there are Alarm temperatures or Delay times entered and whether or not the Error Codes feature is ON or OFF Below is a sample Review of a Cone Fire program Sample Cone Fire Review 1 Cone 04 Cone Number 2 F 1920 Actual temperature when kiln shut off 3 SPD FAST Cone fire speed 4 HOLD 0 00 Length of hold at top tempera
30. piece to listen to the ring In severe cases the piece will split apart into several smaller sections It is always important when cooling the kiln to allow the temperature to fall slowly through this temperature range When glaze and bisque firing ware it is important to heat and cool the kiln slowly through this temperature range Listed below are some key points to remember when firing 1 The thicker the piece the slower the temperature rise or fall through the quartz inversion should be Remem ber that when heating the kiln the temperature of the pieces will lag behind the temperature of the kiln that the thermocouple is measuring When cooling the kiln the opposite holds true the piece is actually hotter than the air inside the kiln 2 With programmable kilns it is not a problem to change the firing speed You can select any temperature rate you desire by simply writing your own program 3 The more open a clay body is when it is fired the less prone to these types of issues Conversely porcelains or denser clay bodies are much more prone to having ther mal issues The Raku process takes the ware through this stage very fast which is why Raku clays are normally very open high grog content type bodies Even with this quartz inversion cracks are pretty common when firing Raku Glaze Fit Glaze fit problems are simply a matter of matching the thermal expansion of the clay body and the glaze so that the glaze is slightly lowe
31. process needs to be 11 Avoid drying pieces in direct sunlight excessively arid environments and avoid the temptation to use fans to dry pieces Many expert potters will use all of the techniques that were suggested to avoid learning to push the boundaries of what can be done with ceramics comes with experience and experimentation 12 Sometimes it is important to determine if a crack occurred during the heating of a glaze firing or during the cool down phase If a crack occurs during the heat up it is possible to closely examine the crack to see if the glaze has run into the crack very fluid glazes or has at least rounded over at the edge stiffer glazes If it is determined that the crack has occurred during heat up of a glaze firing one must consider slowing down the heating of the glaze firing slowing down the cooling of the bisque firing and even looking as far back as the forming and drying of the piece Thermal Cracks The causes of thermal cracks are simple it is the rapid heating or cooling of a piece through the quartz inversion stage The temperature at which this takes place is 1063 F 573 C Without going into great detail silica crystals go through a radical physical change at this temperature If a fired piece of pottery goes through this temperature rapidly it will not be able to adjust to the change and the piece will crack These cracks are usually very tight and are sometimes only found by tapping on the
32. quality iron aluminum chromium Kanthal type A 1 element wire is used in all EXCEL kilns All multi sided EXCEL kilns are high fire type and are designed to reach Cone 8 or 10 except EXCEL 399 208V single phase Cone 5 and EXCEL 270 208V single phase Cone 6 Elements are thoroughly tested both before and after installation for assured performance and even firing Element life will vary depending on whether the kiln is used primarily for low firing of bisque or greenware or high firing of stoneware and porcelain Elements will last for many firings if treated carefully Remember these points 1 Keep the element grooves free of debris bits of bisque glaze cones metal or high fire kiln wash will immediately fuse to an element and proceed to eat through it Elements become brittle after repeated firings so be extremely careful not to break them by scraping 2 Do not attempt to fire beyond the rating on your kiln Stainless Steel Jackets Only the finest grade stainless steel is used in EXCEL kiln jackets selected for its expansion qualities so that the bricks are never unduly stressed yet are fully sup ported during all stages of heating and cooling Stain less steel may discolor with repeated heating Stainless steel cleaner is available EZ Lift Spring Assisted Hinge Available on all 10 sided and 12 sided EXCEL kilns axi standard on EX 1266SF m EX 399 399SF and EX J 1099SF EZ Lift makes mm
33. right hand corner of the display To select a new scale press ENTER and it will automatically toggle to the alternate scale C represents Celsius and F represents Fahrenheit 16 S 16 Segment This option links the RAMP HOLD programs stored in memory positions 5 and 6 to create a 16 segment pro gram Normally a program is limited to 8 segments This feature will only display when a CONE FIRE Mode pro gram or the number 5 Ramp Hold program is loaded See page 19 for programming instructions dIAG Diagnostics dIAG or Diagnostics is where all of the diagnostic tools are located The following options are available under the dIAG menu ERTF Err Temp amp Time of Last Firing This feature will display the temperature and the point of time in the firing at which the last Error occurred Often times this information is helpful in troubleshooting the problem which created the error Once ERTF is selected it will first flash the temperature at which the error occurred and then the time into the firing it occurred The ERTF information will also appear automatically when an error alarm sounds and the program is termi nated Pressing any key will show the temperature and elapsed time at which the error occurred VOLT Voltage This feature is used to test the voltage supply to your kiln It tests the voltage first with the elements off No Load and then again with the kiln on or Full Load Select VOL
34. side Step 3 Number the feeder wires using tape so you can remember where they will be reconnected Step 4 Loosen the terminal block lugs that hold the feeder wires These arelocated on the fiberglass lined heat baffle Remove wires from the three terminal blocks Step 5 Slide the thermocouple connectors off the terminal strip Step 6 Lift the control box up and remove it Step 7 Unhook the draw pull catches and lift the sec tions using the handles provided Disassembling the EXCEL 1850SF Kiln Step 1 Refer to page 11 Removing the EZ Lift and fol low instructions to remove the EZ Lift and lid assembly Step 2 Remove the screws from the left side of the control box and swing the panel to the side Step 3 Remove the screws holding the feeder wires to the two pole blocks on the heat baffle There are three sets with two feeder wires going to each set 40 Step 4 Remove the thermocouple wires from the ter minal strip located on the baffle They are attached with slide on connectors and should be pulled straight off pulling at an angle can damage the connector Step 5 Lift the control box up and set it aside Step 6 Unhook the draw pull catches and lift the sec tions using the handles provided Heatwork Heatwork is the measurement of the effects of time and temperature In ceramics this measurement is gauged through the use of Pyrometric Cones They are composed of materials which are car
35. the first heating rate in degrees per hour Press ENTER Display will show F 1 or C 1 if using Celsius Step 5 Input the first temperature to reach Press ENTER Display will show HLD 1 Step 6 Input the amount of Hold Time in hours and min utes Press ENTER Display will show ALRM if this the last segment you are entering otherwise it will Show RA 2 Step 7 Repeat steps 4 through 6 until all segments have been completed The display will then flash ALRM Alarm alternately with the current Alarm temperature The default setting for no alarm is 9999 Enter the desired alarm setting Press ENTER Display will briefly flash CPL Step 8 Prepare Venting See description on Page 7 Step 9 The display will return to Idle mode Atthis point the program is loaded and ready to start Before pressing START it is a good idea to press REVIEW to make sure 18 the program was input correctly Be sure to check that the lid latch is secure on kilns that are equipped with lid lifters Press START and the program will begin firing Display will briefly show ON and then will show the internal temperature of the kiln chamber unless a DELAY START has been programmed in which case it will begin counting down minutes from the designated delay time Description Step 1 RAMP HOLD Ramp Hold Mode is a mode of programming that allows you to write your own firing program When you are en tering your program you will notice data alre
36. tneennnns 42 Drying Forming Cracks eese 42 Thermal Crac KS seaercsessivevet orca toda ceto me i recita 43 GAZ F MEET CTC 43 CAZIN EE T 43 SUI MIN E sae E E EOS ESdIE 44 Poor Glaze Adhesion eee 44 Glaze C raus aus RESI DIVERSOS 44 45 Over Fired Ware essere enne 45 Under Fired Ware eese 45 46 Glaze Flowing Off the Piece 46 Wiring Diagrams Parts Lists eere 47 61 1u91UO JO ajqe Contents List Kiln Features Contents List Kiln Features Contents List EXCEL Kilns should arrive fully assembled Packed with the kiln you will find the following items e Kiln Stand Instructional DVD e Operating Manual Stand Feet Extra Thermocouple unless Type S e Warranty Card e Peephole Plugs attached to the kiln stand enough to fill each peephole on your particular model Anatomy of a Kiln Lid Latch EZ Lift if equipped Control Box anco ct 1 x Lid Select Fire Keypad EE i E Section Handle Kiln Section Ring Latch t P Peephole Plug x E a Y e Kiln Stand i D Stand Feet Select Fire Models Manual Control Models Operation Firing Instructions Plate Model Serial Select Fire Model Serial Number Plate Keypad Number Plate Infinite and Safety Control Information E Mer Kiln Sitter a Basic Cut off Operation Device Thermocouple Instructions
37. witness cones you find that the kiln fired a little hot a little cold or a little uneven there are certain things you can do to fine tune the kiln before your next firing Always be sure you use self supporting 108 F 42 C witness cones Cones should be placed about 2 inches 4 8 cm from the kiln wall and or thermo couple Never place cones directly on the bottom slab Too Cool Add more Hold Time to a Cone Fire program If the target cone did not bend at all try adding 15 minutes to the Hold Time If the Cone has started to bend add time in 5 min ute increments If hold times begin exceeding 30 minutes contact AMACO or your distributor for more information Too Hot If the Cone is knuckled down on the shelf reduce the Hold Time by 15 minutes If the tip of the Cone has just started to touch the shelf reduce Hold Time in 5 minute increments If hold times are already set to zero con tact AMACO or your distributor for more information Thermocouples drift towards an over fire as they age so if the problem persists or requires excessive changes to correct it may be time to change the thermocouple Uneven Heat Distribution Kilns will tend to fire cooler on the top and the bottom EXCEL kilns compensate for this effect by putting hot ter elements in these spots If you notice a certain area consistently firing cooler load those areas a little less dense If areas are firing a little hot load them a little more dense Al
38. 1 28071F Connectors NPW terminal lugs 3 24275G Master switch box shield 1 24266V Switch box shield lower QTY per kiln Qs MN E NO Stock No 24277 24263R 24279L 24280M 24281N 24244H 242525 24253T 24282P 24256X 24306V 24258B 24235R Wiring Diagram Parts List EX 1099SF Single Phase Terminal Strip Front Back Elements J WVV YY u AAA AAA A V V WWW VAAAAAAAV Dp af Bottom Ring VVWVYSw Description Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 12 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band r COUN Ecc A Jf Current ensor QTY per kiln 1 1 700 Board A i i i _ _ es j j F f p Stock No 24287W 24265T 28815L Special order 24250P 24278K 24326V 24332C 28071F 24325T 243248 22134W 24296H T i Transformer r CIty y W PTN f f Hi A v P pi L2 e Grnd green Description Hinge complete Lid handle Thermocouple Relay Control panel Transformer Harness wire set Current sensor kit Connectors terminal lugs Terminal block single phase Terminal block three phase Fuse
39. 1945 1063 kiln will fire much hotter 03 1987 1086 than you want it to 02 2016 1102 Remember that heatwork 01 2046 1119 is the combination of time 1 2079 1137 and temperature This is 2 2088 1142 most important during the 3 21060 1152 last 200 F of the firing If the 4 2124 1162 kiln is firing very slow dur 5 2167 1186 ing this period the control 51 2 2197 1203 ler will automatically adjust 6 2232 1222 the temperature down to 7 2262 1239 ensure the ware does not 8 2280 1249 receive too much heatwork 9 2300 1260 The cone values listed in 10 2345 1285 the chart are only valid if the kiln is firing at exactly 108 F hr during the last 200 F of the firing That is why it is very important to know the capabilities of your kiln when writing Ramp Hold Programs or entering Hold times We recommend that you still use Self Supporting Witness Cones on every firing to monitor the accu racy of your kiln Place the appropriate cone on a shelf approximately 2 inches from the kiln wall and 2 inches from the tip of the thermocouple Make sure the space between the thermocouple and cone is unobstructed The Cone Measuring Template shown here can be used to determine the exact bend measured in degrees of angle A perfect bend is considered to be at 90 degrees See Cones and Firing brochure from Orton included with your kiln Ort Measuring Template Standard Pyrometric Cones 2 10 Self Supporting 20 Cones www ortonceramic com
40. 4 SW V i Bel S W version OPA Programmable T OUTS 2KEY OP C Output test 2 keys to START dTCT Current Sensor s max rating Only available when RSET Ramp Hold Program 5 is active Reset to Factory JHHUHHHHHH 20 New Features Among other changes the 700 Board in the Select Fire controller has the ability to do self diagnostics It can now show the voltage and amperage directly from the display eliminating the need for expensive test equip ment or having to hire a technician Look through the entire MENU selection to become familiar with the options available to you New Menu Layout With the exception of the new green 14 segment LED display you will notice that the board and all of the func tion keys look exactly the same All of the changes have been made in the MENU key There are now four option headings under the MENU key They are Menu Programming Tips To access the Menu Headings press MENU You can tog gle though the Menu Headings by continuing to press the MENU key When you reach the one you wish to access press ENTER This will take you to the first option in that submenu As before if you want to tog gle through the various options under the selected heading press MENU When you reach the option you wish to access press ENTER When you select an option you are asked to either Toggle the option ON OFF Input a value e Choose a value To toggle options ON OFF pres
41. 5G 24266V G Grnd green Description Transformer Harness wire set Current sensor kit Connectors terminal lugs Terminal block three phase Fuse holder Terminal strip Manual Style Sitter Timer Models Brick grooved for tube assembly Switch box with shield Infinite control switch Switch box upper Kiln Sitter limit timer model LT 3K Tube assembly only Pilot light assembly Master switch box Connectors NPW terminal lugs Master switch box shield Switch box shield lower QTY per kiln 1 1 1 8 1 1 1 Stock No 242361 24262P 24240D 24242F 24243G 24244H 242525 24253T 24254V 24256X 24295G 24258B 24259C 24286V 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 247 EX 247SF Single Phase Elements Top Ring RAARAAAAAA rt VVVVVVVVY T Description All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 10 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band Hinge complete Lid handle Select Fire Models Thermocouple Relay Control panel Current Sensor Terminal Strip Transformer Front Back v 2 QD 2 4 s Ex ls m Lhe s Di e Di L 7 HE L1 700 Board L2 Grnd green said Stock No Description 24278K Transfor
42. 5T Terminal block single phase Brick grooved terminal 3 22134W Fuse holder Insulator tubes 8 24296H Terminal strip Supply cord connector 1 Power supply cord 1 Kiln stand 10 sided 1 Manual Style Sitter Timer Models Heat shield supply cord 1 24271C Brick grooved for tube assembly Bottom slab with band 1 24245 Switch box with shield Sash lock 2 28068C Infinite control switch Stainless steel body band 2 24246K Switch box upper Hinge complete 1 28782C Kiln Sitter limit timer model LT 3K Lid handle 1 24305T Tube assembly only 24249N Pilot light assembly Select Fire Models 24274F Master switch box Thermocouple 1 28071F Connectors NPW terminal lugs Relay 2 24275G Master switch box shield Control panel 1 24266V Switch box shield lower QTY per kiln 1 1 1 8 1 1 1 Stock No 24277 24263R 24279L 24280M 24281N 24244H 242525 24253T 24282P 24256X 24306V 24258B 24235R Wiring Diagram Parts List EX 1266SF Single Phase rhe i P i J NL P4 B Current Sensor f T f i B Elements NAA E Terminal Strip Eu Front Back te eed it _e TTA ee Le od A PiS A cele ALIM 39 SEU m Tee 97 J A l f a he J ef y Lo o L1 T 2 L2 700 Board c Grnd green yel Description said n Stock No Description PEU 5 Brick for lid with band no hardware 1 24287W Hinge complete 1 Lid support brace
43. AMACO will not assume liability for injury or damages caused by variations from the instructions put forth in this manual e Kilns get hot Observe all instructions to i ensure proper clearances from flammable combustable or temperature sensitive J objects and living things i 7 e Ventilation is key to maintaining a healthy work envi ronment and proper room temperature Proper installa tion of the Master KilnVent or KilnVent Stand Version will clear potentially harmful fumes from the room To ensure proper room temperature is maintained consult a qualified HVAC professional e The proper placement of thermocouples is crucial to the proper operation of all automatically controlled kilns Check all thermocouples for damage and correct placement Thermocouples must protrude into the kiln chamber at least 2 to ensure an accurate reading Only use the stand that is provided with your particu lar kiln model Other stands may not properly support the weight of your kiln provide adequate clearance and could pose a fire hazard The power cord is sized correctly to handle the power for your particular kiln Never use an extension cord Make sure the power cord is routed in such a way as to not touch any portion of the kiln that gets hot e Be careful of pinch hazards when working on or assembling the kiln e Be sure to properly tension the springs on kilns equipped with EZ Lift Maintenance e Always unplug the
44. AMACO EXCEL amaco com EXCEL KILNS OPERATING MANUAL American Art Clay Co Inc e 6060 Guion Road Indianapolis Indiana 46254 Introduction Thank You Congratulations You ve made a great choice from the proven EXCEL kiln line Welcome You have selected your kiln after much deliberation and this booklet is planned to assist you in its installation op eration and maintenance All electric kilns sold by AMACO are safe and well built All AMACO EXCEL kilns are listed with Underwriters Laboratories Inc You can be assured that the complete unit has met their rigid standards for safety in regard to casualty and fire hazards Most schools and institutions require the UL seal on all electrical equipment AMACO EXCEL kilns are also listed with Canadian Standards Association Important Read this entire manual before operating your kiln Whether you have owned an electric kiln be fore or not please take the time to read this manual from cover to cover We think even the most experienced vet eran will learn a few new tips Limited Warranty All EXCEL kilns and Select Fire controllers are guaran teed by AMACO against defects in materials and work manship to the original purchaser for a period of two years that covers parts and labor subject to these exclusions Exclusions 1 Damage due to misuse including but not limited to over firing improper installation rough handling im proper stacki
45. Do not place anything in the kiln you are unsure of Certain items may potentially melt explode or release toxic fumes Items that may be damp i e greenware kiln shelves have the potential to crack or explode inside the kiln when the moisture trapped inside them turns to vapor when heated e Never allow your kiln to exceed the temperature rating listed on the serial plate 4 e For your safety the protection of your kiln and the protection of your ware inside the kiln we recommend that you avoid unloading the kiln when it is above 125 F 529C Installation As with all electrical products there is danger of elec trical shock Use only properly sized and rated copper wire when installing the power supply for your kiln We recommend this work is done by a licensed electrician e Kilns should always be located in a dry place to pre vent electrical shock and corrosion e Follow all instructions for installation in this manual Always observe fire building and safety codes when in stalling any AMACO product If there are fire sprinklers located in the kiln room make sure they are rated high enough so they will not be set off when the kiln is at peak temperature This should be tested with the kiln at peak temperature the ventilation system turned off and all doors and windows closed for maximum insurance We recommend having a fire extinguisher rated for electrical fires easily accessible near the kiln e
46. Kiln Bottom 1 Undo the buckles that hold the kiln slab to the kiln Lift the kiln off the slab and place on a clean flat surface Be careful not to set the kiln on anything watch the power cord that will damage the bottom row of bricks 2 Center the slab on the stand Allow a minimum of 18 of spacing from walls and other kilns 3 If the stand is not level or wobbles shim legs accordingly Do not place shims between the stand and the slab Placing the Kiln 1 With a partner pick the kiln up by the handles and rest it on top of the kiln slab floor 2 On models with slabs that buckle to the kiln reattach the buckles Place Peephole Plugs Place the white porcelain peephole plugs into the peep holes of the kiln If you are not using the Master KilnVent or KilnVent Stand Version or any other downdraft vent be sure to leave the top peephole plug out when firing Clean Vacuum the inside of the kiln to remove dust brick chips and other foreign matter from around the el ements Be sure not to get the hose too close to the touch pad Static electric ity built up in the hose can damage the electronics Kiln Wash the Shelves Brush coat one side of each shelf with AMACO Kiln Shelf Wash Apply a thin coat of kiln wash in one direction allow to dry and apply another thin coating in the opposite direction leaving a half inch 1 3 cm margin from the outside edge of the shelf Allow to dry overnight Never
47. Sitter Notes Your Kiln Sitter is now calibrated and working properly For trouble free operation just remember these points 1 Never lubricate your Kiln Sitter Oils will gum up the works 2 Keep foreign objects out of the Kiln Sitter tubes Bits of ware or debris can stop the sensing rod from dropping Check frequently 3 Keep a light coat of kiln wash on the cone support and sensing rod surfaces This will be explained under the First Firing section 4 Replace bent cone supports or sensing rods After re peated firings these may bend For best firing accuracy replace them when they look distorted 5 Use only Junior cones properly positioned as de scribed in the Test Firing section Tips from Senior cones will not work After a firing the cone should show about a 90 bend see diagram above Much more or less bend is a sign of incorrect adjustment and will cause over or under firing 33 s10 e21pu oJn3e19duuo Suggested Firing Schedules Suggested Firing Schedules The following charts are suggested firing schedules of firings the time switch adjustments made during They vary according to the amount of ware the dryness the firing and the results This will help you adjust your of ware the way the ware is stacked and the amount firing schedule of actual voltage the kiln receives Keep an accurate log 06 BISQUE Vent lid for first hour then close Hours 0 9 12 13 14 15 16 17 18 19 20
48. T from the dIAG menu and press ENTER 21 soinjea4 NU W Menu Features After the NOLd reading is displayed press ENTER to receive the FLLd reading The power to the kiln will be switched on for a brief moment when the voltage under load is checked Our technicians can use this information to help you troubleshoot voltage related problems over the phone When the voltage read ings appear on your display write them down Voltage related problems can happen only at certain times of day so try to obtain the readings at the same general time your kiln would be firing AMPS Amperes This is probably the most useful diagnostic tool avail able to you All Select Fire controllers produced after 3 20 2006 are equipped with a current sensor in the control box This allows us to test the current of each output to the kiln This is very helpful in determining if a relay or element needs replacing When you select AMPS under the dIAG menu it will give you an ampere reading for each output of the kiln except the accessory and safety output Which ele ments these outputs control will vary by model If your kiln uses only one or two outputs it will still give you three readings but the unused outputs will give a read ing of zero LEd LED Display This feature when activated lights up all of the segments in the LED display This is helpful in locating any segments in the display that may have gone bad
49. UJ 700 Board Stock No 24287W 24265T 28815L 24319 24250P 24278K 24322P 24332C 28071F 24325T 243245 22134W 24296H L3 Gb Grnd green yel Description Hinge complete Lid handle Thermocouple Relay Control panel Transformer Harness wire set Current sensor kit Connectors terminal lugs Terminal block single phase Terminal block three phase Fuse holder Terminal strip QTY per kiln 1 1 1 2 1 1 1 1 8 1 1 1 1 Wiring Diagram Parts List EX 270 EX 270SF Single Phase i an k a a han A Current Sensor Elements Top Ring Transformer Terminal Strip Front Back Middle Ring AAA AAA VTL M QAM AU 1 L n MAU if ii a m AAA AAT ee d AW AST L1 i 12 700 Board GR Grnd green Stock No Description said Stock No Description PEU 5 All Models 24278K Transformer 1 24236T Brick for lid with band no hardware 1 24322P Harness wire set 1 24262P Lid support brace bracket and arm 1 24332C Current sensor kit 1 24240D Brick grooved for peephole 6 28071F Connectors terminal lugs 12 24242F Brick grooved straight 48 24325T Terminal block single phase 1 24243G Brick grooved terminal 5 22134W Fuse holder 1 24244H Insulator tubes 12 24296H Terminal strip 1 242528 Supply cord connector 1 24253T Power supply cord 1 24254D Kiln stand 10 sided 1 Manual Style Sitter Timer Models 24256X Heat shield supply c
50. ady stored Simply write over this information If you mis enter data you may either press zeros to clear the data and re enter it or press STOP to start from the beginning Step 2 Program Number PROG You have the option of storing up to six firing programs You may recall these programs at any time for future use We recommend that you write down which number you have assigned each program so that you do not over write existing programs you have stored Step 3 Segments SEGS This step is prompting you to input the total number of segments you wish to use in your program Each seg ment consists of a heating or cooling rate a target tem perature and a hold time at that target temperature if one is desired You may program up to eight segments Two programs may be connected to achieve 16 seg ment programs See instructions below Step 4 Rate RA This step is prompting you to input a Temperature Rate The display will show RA along with the current seg ment number you are programming alternately with the previous data entered You may enter any rate be tween 1 F hr 1 C hr to 9999 F hr 9999 C hr This can be a cooling rate or a heating rate The controller distinguishes between the two by checking to see if the temperature entered in the next segment is hotter or cooler than the previous segment Just because you enter a rate does not mean the kiln is capable of achieving that rate Things such as element
51. airs Fortunately your EXCEL kiln will give you few occasions to refer to this section But if you are not mechanically inclined call an authorized service person competent small appliance repairman or other electrician Take this owner s manual along with you To transport your kiln handle sections by their outer edges and place them on a flat surface cushioned by folded blankets Removing and Replacing Elements 1 Disconnect power plug from the wall 2 Remove the screws holding the switch box on the kiln 3 With the switch box held or pushed to one side remove lug connectors Select Fire models only Switch box is hinged on the side Swing the box out away from the kiln 4 To avoid errors work with one coil at a time Carefully re move the lug connectors attached to the defective element 5 Pull the twisted terminal through the kiln wall and into the firing chamber 6 Using needle nose pliers remove the ele ment staples and care fully pull the coil out of the brick groove re moving it from the kiln 7 Inspect the element grooves brushing out all dirt Carefully chip away any molten material which can come in contact with the new element Should it be necessary to ensure that the channel is clear of foreign materials small sections of the groove may be removed without impairment to your kiln 8 To install the new EXCEL coil pass the end of the coil through the kiln wall to the outside of the kiln
52. al noise During a hold segment the temperature rises to If only one section or greater than 50 degrees above the hold tem relay remains on then it perature which was set The temperature must Stuck relay is a stuck relay Turn off stay 50 degrees above this set temperature for 18 breaker to shut off power seconds before the error is displayed to the kiln Replace relay During a hold segment the temperature is more than 50 degrees below the hold temperature which was set The temperature must stay 50 degrees below this set temperature for 18 sec onds before the error is displayed Door or lid of the kiln was opened Check relays Relay or element failed Check elements during firing Check relay The firing is in a ramp segment where the tem If E 4 occurs when perature is programmed to decrease and temper skipping a ramp phase ature is more than 50 degrees above the previous press a key to clear the hold temperature The temperature must remain Stuck relay error Allow the kiln to 50 degrees above the hold temperature for 18 Skipped step feature cool to within 50 degrees seconds before the error is displayed E 4 is the of the next hold tempera same as E 2 except that E 4 occurs during a ture Restart kiln and skip ramp phase rather than a HOLD steps until you get to the segment you want The temperature is more than 50 degrees below the local set point temperature during a ramp segment where the temperature
53. and may explain why some indicated readings are not correct bd T Board Temperature The electronics on the controller s circuit board may be damaged if the board exceeds 160 F 71 C This should not occur under normal conditions However if the kiln is located in a small enclosure with poor ventilation or in areas where the temperatures are unusually hot it is possible Using this feature will tell you if your controller temperature is approaching potentially harmful levels If you find that your board temperature is consistently over 150 F 65 C you may want to consider improving air circulation to the kiln room A box fan blowing on the controller can help considerably SW V Software Version At AMACO we are continually working on ways of im proving our products This feature will indicate the soft ware version your controller is using OUTS Output Test There are four outputs that can be used on the board There are three designated for elements and one desig nated to run an accessory This feature allows you to test each output individually to see if it is operating correctly When activated this feature will test each output begin ning with Output 1 and ending with Output 4 It will cycle each output on for approximately two minutes You can advance to the next output at any time by 22 pressing ENTER To see if the elements are cycling ON you can place a small piece of paper on each element If the pape
54. and vent them outside insuring that the gasses do not reach the work area Cool down time is also reduced by 2 4 hours often allowing firing the very next day In addition to making the kiln room more comfortable accidental burns and jarring of the ware are reduced because the lid stays closed throughout the firing Better Finished Results Down draft direct venting systems produce truer colors more uniform firings and fewer glaze flaws by 1 Reducing carbon monoxide and increasing oxygen levels which increases the brightness and intensity of reds greens golds and yellows and allows different colors to be fired at the same time 2 Circulating the hot gasses inside the firing chamber the items on the bottom of the kiln receive the same heat as items on the top 3 Increasing oxygen levels in the kiln which helps burn out carbon and organic compounds in the clay body there by reducing pinholes craters and bubbles in the glaze Installation Note While the AMACO vents are key to cre ating safe work environments and better work these sys tems will not reduce the kiln temperature or the ambient heat the kiln inputs into the room It is suggested that the kiln room area be adequately sized and exhausted to keep the space under 100 F 389 during peak temperatures and provide at least 18 inches of clearance on all sides of the kiln Sprinkler systems in kiln area should be rated so that they will not trigger when the k
55. arm temperature and press ENTER The display will briefly flash CPL for complete and then return to Idle Mode The program is now loaded Steps 8 and 9 Prepare venting and Start Before starting the program it is always a good idea to press REVIEW and make sure the data was entered cor rectly If you find an error simply press RAMP HOLD and continue to press ENTER until you find the error and are able to correct it If there is a Delay entered when you press start the kiln will begin counting down from the input time Remember to turn on your vent or prop your lid before pressing START Advanced Features 16 Segment When the 16 Segment feature is toggled ON the control ler links programs 5 and 6 Now when you run program 5 it will automatically run program 6 to continue the fir ing after program 5 has completed Due to requirements of the software the first segment of Program 6 must be increasing in temperature Here is how to use this feature Step 1 Input a 1 to 8 segment RAMP HOLD Program in PROG 5 Step 2 Input a 1 to 8 segment RAMP HOLD Program in PROG 6 Step 3 Press RAMP HOLD press 5 Press ENTER Press STOP Step 4 Press MENU The Display will show SET Press ENTER The Display will show PRHT Press MENU until the display shows 16 S then press ENTER The display will show OFF Toggle to ON using the 1 key then press ENTER Step 5 Press REVIEW Press START IMPORTANT Program 5 must be
56. at it automati cally makes adjustments to the firing profile based on your kilns performance Cone values are based on heat work and heatwork is a function of time and tempera ture Therefore if your kiln is firing slow due to a heavy load or aging elements Cone Fire Mode automatically adjusts the peak temperature down so you get the per fect amount of heatwork There are very few reasons not to use this mode of programming RAMP HOLD Mode RAMP HOLD Mode allows you to write your own pro grams when the results you want cannot be achieved through Cone Fire Mode It is a perfect tool for e Fusing and slumping glass e Annealing metal and glass e Firing Precious Metals Clay e Specialized glaze formulations and techniques Ramp Hold is generally considered an advanced form of programming It requires in depth knowledge of heat work and a good feel for how your kiln performs under a range of conditions Below is an example of a simple glass fusing Ramp Hold program SAMPLE FUSE PROGRAM PROCESS t n d T ano ML J ie PRE ANNEALING COOLING ANMEALINL TEMPERATURE PRE PROCESS HEATING TIME Programming Cone Fire Mode Programming Steps Step 1 From Idle Mode Press CONE FIRE Display will read PRHT alternately with 00 00 Step 2 Input a PREHEAT TIME IN HOURS AND MIN UTES Press ENTER See page 23 for more information on Preheat Display will read CONE alternately with the last
57. ber Tighten the thumbscrew Uncoil the yellow thermocouple wire that is hanging from the bottom of the controller enclosure Plug the thermocouple ends into the receptacle coming from the controller There is only one way the plug will engage the receptacle The controller is now ready for use Thermocouple Installation in a Kiln Not Marked for a Thermocouple Mark a 5 in 1 27 cm to s 1 58 cm diameter hole on the stainless jacket in the center of the brick next to the Kiln Sitter brick one brick to the right of the master switch box Be sure placement is accurate so that you do not drill through an element Do not drill yet Align the flange holder accurately over the mark posi tioning the thumbscrew hole on top Mark the position of the small holes on the jacket Push hard or tap out with a nail and hammer the small screw holes Drill two 32 0 23 cm holes for the smaller sheet metal screws Drill through the metal only Install the flange with the sheet metal screws provided For the remaining installation steps consult the previous section on Thermocouple Installation for an EXCEL Kiln 25 JUNOW JIEM m3114 328J9S Troubleshooting Preventative Maintenance All Kilns e Vacuum floor and element grooves regularly Carefully vacuum around thermocouple and elements Leave Select Fire kilns plugged in when you are vacuuming to ground any static charges that may occur at the noz zle tip of the vacuum Try t
58. cally measures the rate of firing during the last hour of the heating program and adjusts the final temperature based on the observed firing rate This will insure consistent results as the kiln elements be come weaker with normal wear from repeated firing As a result the shutoff temperature may vary between firings Segs Rate Temp Hold 1 200 F HR 250 F 0 2 400 F HR 1000 F 0 3 180 F HR 1150 F 0 4 300 F HR 1694 F 0 5 120 F HR 1946 F 00 05 Step 2 Preheat Preheat is used to preheat the ware inside of the kiln before the temperature goes above the point when water turns to vapor If residual water in the clay escapes as vapor too fastit can crack the ware or in extreme cases cause it to explode Large thick walled pieces are more susceptible to damage caused by residual moisture When a Preheat time is entered and the program is started the kiln will climb in temperature at a rate of 60 F 15 C per hour until it reaches 180 F 82 C It will then hold at that temperature for as long as the time entered After the hold is complete it will begin the Cone Fire program If you do not wish to preheat your ware enter 00 00 for the hold time For instructions on turning this feature off consult the Menu section of this manual Step 3 Cone Value Every clay and glaze should have a Cone Value associated with it A Cone Value is a measurement of the Heatwork needed for the clay or glaze to mature The Heatwork is
59. cation that will put the controller at least two feet from the kiln to prevent overheating the control ler To mount the controller mark the hole positions on the wall where the controller will be installed using the paper template supplied with the controller and follow these instructions Mounting the Controller on Stud or Post Use the holes marked A on the template and screw a 12 x 2 inch wood screw into the wall leaving a 25 inch gap Repeat for the second screw Mounting the Controller on Sheet Rock Using holes marked A and B on the template drill the necessary holes to properly mount the 25 inch x 2 inch molly bolts into the sheet rock Tighten the first bolt un til there is a s gap Repeat for the other three bolts Before hanging the controller on the wall loop the cord attached to the quick reference card over a screw so that it hangs below the controller when mounted Connecting to the Kiln Single phase Switching capacity 48 Amps on 208 240V To operate the wall mounted controller simply engage the kiln plug in the receptacle located on the back of the controller Then plug the controller into the existing wall receptacle Three phase Switching capacity 40 Amps on 208 240V To connect your three phase kiln plug the power cord from the kiln into the receptacle mounted on the back of the control ler Plug the pilot cord the smaller cord into the small receptacle mounted on the underside of the controller
60. ctory AMACO has a well trained staff at your disposal for technical support and information Monday through Friday from 7 00 AM to 5 30 PM EST We will be happy to assist you with installation questions and trouble shooting of technical problems Error Codes not stop the firing but they will display a code to notify Error Codes are designed to protect your kiln and the YOU of the problem ware inside your kiln if there is a problem with the fir The following tables describe the error codes their ing In most cases when an error is triggered the kiln will probable cause and recommended solutions If you run shutoff and display E followed by the Error Code that across a code that is not listed or you need help please describes the error that occurred Non critical errors will give AMACO or your local distributor a call Error 2 cs Hardware or electrical noise electrical spikes surges or arcing across the relay Recheck the selected program and reprogram if necessary Software Error Worn or old heating elements Low voltage to the kiln Check elements A broken heating element Check relays or faulty relay Use VOLT Menu feature Burned or broken wires to to check voltage the elements or relays The temperature is increasing less than 12 degrees per hour during a ramp segment where the temperature is programmed to increase This slow rate must persist for 22 5 minutes before the error is displayed Electric
61. cued prior to toggling the feature ON Once both programs have run the controller auto matically toggles OFF the 16 segment feature Skip Step Skip any segment in a Ramp Hold Program by pressing VIEW quickly followed by pressing ENTER If done quick enough you will see SKIP in the display Immediatly press ENTER again Cone Correlation The 700 Board allows you to utilize the cone correlation benefits of CONE FIRE Mode coupled with the flexibil ity of RAMP HOLD Mode To use Cone Correlation to calculate your final temperature during a RAMP HOLD program press CONE TABLE instead of entering a tem perature for your final heating segment Input the Cone Value you would like to correlate and press ENTER 19 bDuiuuuueJ60Jg Programming Menu Tree Running a Stored Ramp Hold Program Step 1 Press RAMP HOLD Step 2 Input disired stored program number Step 3 Press STOP Step 4 Press REVIEW Step 5 Press START Select Fire Menu Tree MENU SET dIAG CNFG Settings Diagnostics Configuration Hidden ERTF Err Temp amp Time for last firing PRHT Preheat ERCd TYPE Error Codes T C type K S COOL VOLT TCOS CYCL Voltage data T C Offset Output cycle time Cooling segment MAXb Max allowable Board Temp CHG FtoC AMPS Ampere data ZONE ZC options 1 4 16 S LEd Id NOTC KISS ID number Link RHM 5 6 Lightup test SHTO bd T OUT4 Board Temp Output 4 options ALR
62. current from the outputs This feature should not be modified without consulting an AMACO technician Changing this setting will alter how the board interprets the current signal and will cause the board to produce erroneous current readings RSET Reset To Factory Settings Sometimes it is difficult to diagnose a kiln problem when factory settings have been modified To reset the factory settings access the RSET setting through the CNFG menu and press ENTER The following settings will be restored Error codes on e TC offset set to zero e Cone offset set to zero Other The features contained in this menu heading are acces sible only through direct contact with an AMACO tech nician If you change from a Type S thermocouple to a Type K thermocouple or vice a versa you will need to change a feature setting in this menu section The Wall Mounted Select Fire Controller The wall mounted Select Fire gives automatic kiln control to most mod ern EXCEL or AMACO 208 240V kilns and any other brand kiln which uses NEMA 6 50 single phase or NEMA 15 50 3 phase plugs and receptacles It can be moved quickly from one kiln to another and can control virtually any kiln in a studio which has the proper cord plug and receptacle configuration Select Fire AMACUD EXEEI Once installed the Select Fire controller uses the same operating instructions as other EXCEL Automatic kilns Choose a lo
63. e controller to discharge the static uoneuu0Ju K19Jes Electrical Requirements Electrical Requirements Make sure the electrical information on the serial num ber plate matches the electrical supply If not consult an electrician Most important to the proper operation of your new kiln is to make sure it has the correct power to operate If this is done your kiln will provide many years of excellent ser vice If the correct power requirements are not met the first firing could be disappointing or even disastrous for your kiln The chart below lists the recommended elec trical specifications for each kiln model If there is uncer tainty about the existing outlets have them certified by a licensed electrician If installing new receptacles provide this information to the electrician Model Volts Amps Kilowatts Copper Wire Fuse Breaker NEMA Size Size Receptacle EX 270 240 1 phase 48 0 11 5 6 gauge 60 6 50 240 3 phase 29 3 11 5 8 gauge 40 15 50 208 1 phase 48 0 9 9 6 gauge 60 6 50 208 3 phase 31 7 11 0 8 gauge 40 15 50 EX 365 240 1 phase 48 0 11 5 6 gauge 60 6 50 240 3 phase 29 3 11 5 8 gauge 40 15 50 208 1 phase 48 0 9 9 6 gauge 60 6 50 208 3 phase 31 7 11 0 8 gauge 40 15 50 EX 226 240 1 phase 27 8 6 7 8 gauge 50 6 50 208 1 phase 26 1 5 5 8 gauge 50 6 50 EX 324 240 1 phase 27 8 6 7 8 gauge 50 6 50 208 1 phase 26 1 5 5 6 gauge 50 6 50 EX 247 240 1 phase 40 0 9 5 6 gauge 60 6 50 208 1 phase 39 4 8 3 6 gauge 60 6 50 EX 344 240
64. efore pressing Enter Clear the display by pressing all zeros then input the correct number and press ENTER When a cone value has been incorrectly entered the process is slightly different After pressing 0000 press ENTER The display will again ask for a preheat value and then a cone value How can change only one value for a RAMP HOLD firing profile without re entering the whole program Follow the instructions for entering a new program and just press ENTER for every value that will remain the same Make a change in the value that is incorrect then continue How can change the program after it has already started Press the STOP key This will stop the firing Use either the CONE FIRE MODE or RAMP HOLD mode to input the new firing profile for the remaining portion of the firing Press START to resume the firing The controller will automatically determine where to start the program based on the current internal temperature and pro ceed with the adjusted program The kiln shuts off too early The kiln can be restarted if the cones on the shelf indi cate an under fired load This should be used only if you were present when the kiln shut off The cones are no longer accurate if they have cooled much from the time of shut off To restart follow these steps e Press CONE FIRE or RAMP HOLD to view the firing just completed Press ENTER to accept any of the segments that are correct until the point where the cone nu
65. efully measured and com pressed into the shape of a tetrahe dron The cones are placed in the kiln on a shelf with your ware and when they have received the proper amount of heatwork they bend over indicating that it is time to turn off the kiln Pyrometric Cones come in a variety of shapes and sizes Each size and shape has a different temperature chart associated with it The chart below is based on a Large Self Supporting Cone and has become the standard for commercial clay bodies glazes and controller software All clay bodies and glazes Cone are designed to fire to a No F E certain cone value In a kiln 022 1087 586 with Select Fire the com 021 1112 600 puter calculates the heat 020 1159 626 work and shuts the kiln off 019 1252 678 at the proper heat and time 018 1319 715 combination This is called 017 1360 738 Cone Correlation Cone Fire Mode programs all are con trolled by Cone Correlation Ramp Hold Programs are not EXCEL Kilns are designed to fire a range of cone val ues from 022 to 10 As you can see by the chart at right the temperature associated with each cone value grad ually increases from 022 to 10 It is very important not 016 1422 7712 015 1456 791 014 1485 807 013 1539 837 012 1582 861 011 1607 875 010 1657 903 09 1688 920 08 1728 942 07 1789 976 06 1828 998 to forget to add the leading 051 2 1859 1015 zero when entering a cone 05 1888 1031 value if it is required or the 04
66. er element replacement Unpacking and Moving the EX 1099SF Kiln Follow the general instructions on kiln set up found in this manual You will probably want to separate the kiln into sections when you set it up or move it to a different location These instructions are slightly different than for standard Select Fire kilns CAUTION Before disassembling the EX 1099SF kiln be sure to turn off power to the kiln by throwing the circuit breaker or removing the fuse on its circuit Do not restore power to the kiln until it is fully reassembled Note The mercury relays in the switch box must be operated only with the switch box in a normal vertical orientation Set Up the EXCEL EX 1850SF Kiln The EX 1850SF will be packed in three separate boxes which will include L the following Box 1 EX 1850SF Kiln 1 Box 2 3 Piece Fiber Slab Insert 12 1 inch 2 54 cen timeter Posts Box 3 2 Piece Kiln Stand Lid Prop 6 Peephole Plugs Operating Manual War ranty Card 12 Plastic Stand Feet Follow the general instructions on kiln set up in the Set up section of this manual There are three main differences that should be noted when setting up the EX 1850SF e Due to the weight of the EX 1850SF you will want to separate the kiln into sections when you set it up e The EX 1850SF has two stands that fit together for greater support Place the stands flush together e The EX 1850SF includes a three piece rigid
67. es on a circuit will lower the input and cause slow heating THE BEST SOLUTION IS TO RUN A DIRECT LINE TO THE KILN Kiln Location e Locate your kiln near your present electrical outlet or where a new circuit can be installed Position the kiln to the left of your electrical outlet so the cord will have an easy run and will not place a strain on the plug or outlet e Install it in a well ventilated sheltered area such as a garage utility or hobby room Allow a MINIMUM 18 INCHES 46 cm of space between your kiln and adja cent walls other kilns shelving etc When multiple kilns will be installed in the same room make sure the control boxes on the kilns are not facing adjacent kilns Radiant heat from nearby kilns can damage the controller e For small rooms monitor the firing so room tempera ture does not exceed 105 F 41 C Do not fire if room temperatures are 32 F 0 C or less as damage to the electronic components may result At right is an exam ple of a typical room layout e Locate the kiln in a room with a bare cement floor If a bare cement floor is not available the uniform mechani cal code requires two inches of masonry below the kiln extending a minimum of 12 31 cm beyond the outside circumference of the kiln e When installing a kiln in a room with a fire control sprin kler system do not place kilns within a 10 ft 3m radius below sprinkler heads If this is not possible contact AMACO for alternative s
68. etimes certain glazes and clay bodies will simply not work together It is always important to run trials on new clays or glazes Remember that glazing a cup where almost the entire surface of the clay is covered with glaze is very different then glazing a tile which only has glaze on one surface Gases will always attempt to find the easiest path to get out of the clay The easiest areas for gases to escape are where the piece is not glazed Glaze Flowing Off the Piece All glazes are made to work the same at peak tempera ture Some glazes are formulated to flow a lot during fir ing to produce certain effects and some are formulated to move very little for a different aesthetic and not all glazes can be applied the same Understanding how much your glaze will flow move down a vertical sur face is important in determining how to glaze the piece Running test tiles that have a vertical face is critical to understanding how the glaze will flow in the kiln A stiff glaze may be glazed with an even applied thickness all the way down to just above the foot or all the way to the bottom if the piece is to be stilted A very fluid glaze presents some issues that must be trialed Glaze may need to be applied thinner near the bottom of the piece to compensate for the movement of the glaze towards the foot In extreme cases glaze may have to not be ap plied near the bottom of the piece at all If glaze flows off the piece it may cause the piece to stic
69. ety fea ture which prevents the lid from opening too far and damaging the kiln The lid brace provides additional safety and allows you to open the lid wider if needed for larger pieces The lid latch serves two purposes The first is to make sure the lid stays in the closed position while firing To latch the lid shut simply close the lid and swing the latch arm over until it pops into place Be sure to latch the lid shut prior to every firing There are two additional venting positions that the lid can be placed in if the kiln is not equipped with a downdraft vent Lift the lid up and swing the Lid Latch into the desired venting slot When the kiln reaches 1000 F 537 C close the lid and latch it shut Always wear fireproof protective gloves when working with any hot kiln 11 JET Z3 Loading Loading Tips Balance the Load When planning how to load your kiln keep in mind that the center of the kiln is generally the hottest Therefore you will want to distribute the load with the larger thicker pieces towards the middle and the smaller thinner pieces towards the top and bottom In addition if half your load consists of small heavy pieces and the other half is large thin walled pieces don t group them all in one section Mix them so there is a balance of each type throughout the kiln Allow the Kiln to Breathe Many studios work with glazes that require oxygen to develop properly Provide enough space between
70. fiber liner that fits inside the bottom section on top of the slab There are holes cast in the liner which hold the 1 inch 2 54 centimeter ceramic posts Carefully lay the fiber insert on top of the slab after the first section is placed in position and insert the posts CAUTION Before disassembling the EX 1850SF kiln be sure to turn off power to the kiln by throwing the circuit breaker or removing the fuse on its circuit Do not restore power to the kiln until it is fully reassembled 39 4S08 81 X3 4S6601 X3 1312X3 9u1 dN 19 Disassembling Kilns Disassembling Multi Section Kilns Always Unplug a Kiln before Disassembly Step 1 Remove lid by disengaging the hinge system If equipped with EZ Lift see page 11 Step 2 Remove the screws from the left side of the control box that secure the box to the kiln and swing the panel to the side Step 3 Disconnect the numbered feeder and ther mocouple wires from the terminal strip Step 4 Lift the control box up to remove it from the hinges and set it on a clean flat surface Step 5 Unbuckle the draw pull catches between each section Step 6 Lift each section using the section handles and place on a flat clean surface Disassembling the EXCEL 1099SF Kiln Step 1 Refer to page 11 Removing the EZ Lift and fol low instructions to remove the EZ Lift and lid assembly Step 2 Remove the screws from the side of the control box and swing the panel to the
71. finite control switch Switch box upper Kiln Sitter limit timer model LT 3K Tube assembly only Pilot light assembly Master switch box Connectors NPW terminal Lugs Master switch box shield Switch box shield lower Co QTY per kiln 47 aseud ejburs 4s9zc X3 9cc x3 S17 sSyueg ujejbeirq Hui Wiring Diagram Parts List EX 324 EX 324SF Single Phase 48 Wiring Diagram Parts List EX 324 EX 324SF Single Phase ox FN CN Elements Top Ring MANNA E Terminal Strip WAAAY MAY Front Back I 3 Dc Transformer WAAAY Stock No 24297 24261N 24298K 24299L 24300M 24244H 242525 24253T 24293E 24256X 24302P 24258B 24294F 24285T 24265T 28815L 24319 24250P 700 Board QTY per kiln Description All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 8 sided Heat shield supply cord Bottom slab with band Sash Lock Stainless steel body band Hinge complete Lid handle N o_o AR N N OO UO Select Fire Models Thermocouple 1 Relay 2 Control panel 1 Stock No 24278K 24320M 24332C 28071F 243245 22134W 24296H 24282D 24245 28068C 24246K 28782C 24305T 24249N 24274F 28071F 2427
72. fired 1 Turn switches off Protect hands with gloves While kiln is still hot perform 2 o clock drop test page 33 fifty times Repeat when cooled If plunger is released every time you either forgot to latch the weight up when set ting the cone or the fall was impeded by the power cord or another obstruction 2 If any cleanly made 2 o clock drop fails to release the plunger contact your EXCEL dealer Electrical Irregular clicking noises from models equipped with Infinite Control Switches Normal These switches constantly cycle on and off at all settings other than High 36 Elements hum at first later do not Normal Kanthal type elements are magnetic only up to red heat Humming then ceases Fuse blows or breaker trips more than one minute after switching to High 1 Fuse breaker and wire sizes improper for the kiln See page 6 2 Other loads on same circuit 3 Poor quality fuses or fuses loosely screwed in sockets 4 Tarnished or loose connections at a breaker or fuse socket This can increase the temperature of either device causing unwarranted interruptions Have the circuit and breaker fuse box checked by a qualified electrician Note Your kiln will not draw more power as it ages Aging elements can only draw less power Fuse blows or breaker trips almost immediately after switching to High 1 Examine cord and plug for breaks 2 Have the circuit and breaker fuse box checked by a qualified
73. gher thermal expansions and matte glazes and underglazes tend to have lower thermal expansions ALWAYS run test tiles of new glazes on your clay body or if you are changing clay bodies always test your glaze palette on it Nothing is worse than opening the kiln to find it full of crazed and shivered pieces Poor Glaze Adhesion This is a problem that most potters fail to understand fully yet it is one of the most common problems encoun tered It is important that when glazing a bisque piece or if applying an engobe or underglaze onto green ware that the bond between the clay and the glaze be strong Glazes are made with organic binders that help 44 this process by slowing the drying of the glaze to allow it to bond better to the clay and adding organic fibers to the system that helps hold the glaze to the clay If the glaze dries too fast when applying it especially the first layer the bond between the glaze and the clay will be weak and it can easily be separated during the drying of the piece or in the early part of the firing schedule The organic binders act as food for bacteria and mold and if the binder is all consumed by the bacteria the drying time will speed up and glaze popping may occur Most commercial glazes have chemicals added to keep bac teria from growing The bacteria eat this material and it kills them When the entire amount of chemical is gone the bacteria will grow One can tell that the bacteria are gro
74. glaze the more likely it is for glazes to pop off Glazes with high percentages of clay which leads to high shrinkage of the glaze when drying will tend to be more prone to this issue Poor adhesion is often the case with underglaze decorations that pop off the piece as they tend to have higher amounts of clay Many people will think that something has changed with a glaze when in fact it has simply been depleted of its organic binder Replenishing the binder will make older glazes usable again with good results Glaze Crawls Glaze crawls may be caused by many things but are usually seen as areas where the glaze has peeled back from the clay body during firing creating a clump of glaze Due to the surface tension of the glaze it will not move back over the bare spot This is a very difficult defect to repair You can attempt to grind the piled up glaze down to a level surface with the rest of the glaze fill the hole with glaze and refire to temperature again The defective area is usually visible even through the repair The more important concern is to determine why the glaze crawled There are many chemical reasons that cause glaze crawls if you formulate your own glazes Over grinding glazes may also cause crawls In commer cially prepared glazes there are a few main causes 1 Poor adhesion of the glaze to the clay body See the section above for possible solutions 2 Poorly cleaned bisque ware Glazing over dusty bisque ca
75. gnated as Output 4 and can control a number of optional accessories including vents alarms and autodialers Output 4 will cycle these accessories on and off at different times depending on the program you are running and the way you configure it under the OUT4 feature setting There are five differ ent options for OUTA Note ALR4 is the factory default setting When you access the Output 4 feature the feature options will appear in the order listed below The first option listed is not necessarily the current setting ALR4 Alarm 4 This is the factory default setting If Output 4 is not being utilized this is the setting that should be selected This feature can also control an external alarm or auto dialer to initiate if an Error Code is generated or if the internal temperature of the kiln reaches the temperature programmed for the ALARM setting of the program To deactivate the alarm press ENTER PCT Percent On Output 4 can be programmed to be on for a percent of the time output 2 is on This option is used when output 4 controls floor or lid elements To ensure out put 4 stays off at all times use this option and set the percentage to zero The percent can be set from 0 to 150 There are currently no EXCEL Kiln designs that can utilize this feature OP A Option A When option A is selected Output 4 will turn on when a CONE FIRE Mode program is started When the program has run and the kiln has cooled to 150
76. haped of moist clay with the same or higher maturing temperature than the clay or glaze which you plan to fire The bases of the cones are cut at an angle to guide you in placing them at the proper 80 angle Set them in a row so they lean toward the lowest temperature cone Embed them just enough to hold them securely yet permit the numbers to show AMACO cone plaques or self standing Orton cones are best A clay support must be thoroughly dry before placing it in the kiln Make cone supports up ahead of time to allow for drying Never use cones with broken tips Place the cones in the kiln so they can be seen easily through the peephole Also available are reusable wire cone holders and ceramic cone holders Fortunately with today s Kiln Sitter devices and Junior cones three cone firing is rarely necessary However always placing a single Senior firing cone at Kiln Sitter level is inexpensive insurance against inadvertent under firing At higher temperatures cones can be hard to see View ing through dark glasses helps As an added measure keep ware as far back from cones as possible Junior Cones and the Kiln Sitter Junior cones are not simply miniature Senior cones They are designed to bend under the weight of the Kiln Sitter sensing rod Don t expect acceptable results using a Senior Cone in the Kiln Sitter The Junior s shorter length and greater compaction make it stand longer than a Senior if placed on end bu
77. hinner layer of glaze on will work 1 Off gassing of carbonates and sulfates in stoneware bodies can be problematic if they are given off after the glaze has sealed the body over Looking at different clay bodies may be a solution where these materials are not present Changing glazes to ones that melt later may also solve the problem 2 Many times the bubbles will actually form in the glaze and float to the top surface of the molten glaze the bub bles pop and the glaze surface smoothes itself out If the glaze is applied too heavy this extra glaze thickness may cause all the bubbles to not be liberated 3 Sometimes the issue will only happen with certain clay bodies that tend to be much more reactive Examples of this might be red clay bodies or bodies with speckles that tend to react with glaze due to the iron or manga nese and cause bubbles to form Severe bubbles may look like large blisters Switching to a clay body without these elements may totally eliminate the problem 4 If the glaze surface looks like most of the bubbles have popped and many have smoothed over the solution may be a little more heat a slower approach rate to the peak temperature or a small hold at peak 5 If the glaze surface looks like most of the bubbles are still in the glaze and only a few have popped it might work to fire at a slightly lower temperature approach the peak temperature at a faster rate or eliminate any hold at peak 46 6 Som
78. iln is at peak temperature Vent Systems Available for Your EXCEL Kiln Master KilnVent 4 m Du gyno wi pma Aro Low KilnVent Stand Version Minor modifications will need to be made to your kiln for use with either of these vent systems For specific installation instructions refer to the manual supplied with the vent purchased Hulua u nyj s1ueugaJuinbay e21323 3 When Your Kiln Arrives Kiln Location When Your Kiln Arrives Be present on kiln delivery so you can inspect the carton and contents for damage due to improper handling dur ing shipping Located on the bottom corner of the box is the SHOCK WATCH sticker and directions are provided on the outside of the box for using this program The freight company is required to provide you with com plete instructions to report any damage that occurred during shipping It is important to note all damages to the kiln on arrival as the warranty will not cover damage due to shipping The bill of lading covering this shipment is our receipt from the transportation company that the shipment was complete and in good condition when it left the factory You should thoroughly inspect this shipment as soon as you receive it Shortages and or Visible Damage to Boxes A notation concerning any shortages of boxes or visible damage to the shipment should be made on both cop ies of the delivery receipt presented by the driver for the transportation company If driver wil
79. ing a Stored Ramp Hold Program 20 Select Fire Menu Tree eese 20 Menu FeatuUres eee eere eee ee eene e nete eene sene tnetnens 21 24 OWE STUN Senor iN RDUM ROI 21 Programming Instructions eere 21 24 Select Fire Wall Mount eerte 25 TFOUDISS COIN PR o 26 30 Preventative Maintenance ssesessesesesesesesesesesesesseseses 26 Troubleshooting Your Kiln 26 EH OF COUPS caaiicacsucscoter RU UT HDI DS RI UE 27 28 Select Fire FAQ S iacuit ere iei n Rede en Even UR 29 Select Fire Display Messages 30 Manual Kiln Operation eese 31 37 Preparation csccsccscsrsssssssssssceeesecsesscssceecsacenssseseeseeeceees 31 Is cc 31 Temperature Indicators esses 31 33 Suggested Firing Schedules 34 35 Troubleshooting Guide 36 37 REDAN ERN 38 Replacing Elements eese 38 Replacing Thermocouple sss 38 Set Up Instructions eese eene ente nntnnnn 39 Disassembling EXCEL Kilns esee 40 BSE VOI onerum nien HI EDIDI MN ER DU EM 41 Ceramic Defects and How to Avoid Them 42 46 General Concepts eese
80. ing signs of this potential hazard in the kiln room e Keep anyone who cannot understand warning signs such as small children and pets away from the kiln when it is firing Be careful when opening the kiln door while the kiln is heated We recommend you use fire rated gloves to pro tect your skin and make sure clothing is kept well away from any kiln opening or hot kiln surface e The elements inside the kiln chamber will cause an elec trical shock if touched Never insert metal instruments or place any part of your body into the kiln while it is firing e Always be sure to unplug the kiln before working on the electrical components If the kiln is hard wired turn off the circuit breaker Plan on being with the kiln when it is scheduled to turn off e Long term viewing inside the kiln chamber can cause damage to your eyes therefore it is recommended that you use IR and UV protective glasses when looking into the kiln for extended periods of time No 3 welders green or gray glasses will protect your eyes e Be cautious of intense heat around the peepholes when peephole plugs are removed e In the event of a severe storm unplug your kiln Expo sure to static shock or electrical surges can damage the circuit board in the controller e The kiln lids on many models are heavy Make sure the lid brace is secure before releasing the lid Make sure the hard ware that secures the lid brace is secure and not corroded e
81. iring Diagram Parts List EX 399 EX 399SF Three Phase 58 Stock No 24277 24263R 24279L 24280M 24281N 24244H 242525 24253T 24282P 24256X 24306V 24258B 24235R 24287W 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 399 EX 399SF Three Phase Elements Top Ring MINNS m j Bottom Ring KAANAA A Description All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 12 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band Hinge complete Lid handle Select Fire Models Thermocouple Relay Control panel i i TRO LON E ia kN a Current Sensor Terminal Strip Front Back LS 2 zl M L3 700 Board eb Grnd green Se Stock No Description 24278K Transformer 1 24322P Harness wire set 1 24332C Current sensor kit 6 28071F Connectors terminal lugs 60 243248 Terminal block three phase 5 22134W Fuse holder 12 24296H Terminal strip 1 1 1 Manual Style Sitter Timer Models 1 24307W Brick grooved for tube assembly 1 24245 Switch box with shield 2 28068C Infinite control switch 3 24246K Switch box upper 1 28782C Kiln Sitter limit timer model LT 3K 1 24305T Tube assembly only 24249N Pilot light assembly 24274F Master switch box
82. k to the kiln shelf which may ruin the piece and the kiln furniture Always use liberal coats of kiln wash when working with very fluid glazes just in case Wiring Diagram Parts List EX 226 EX 226SF Single Phase Elements Top Ring Stock No 24288X 24261N 24289A 24290B 24291C 24244H 242525 24253T 24293E 24256X 24295G 24258B 24294F 24285T 24265T 28815L 24319 24250P Description All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 8 sided Heat shield supply cord Bottom slab w band Sash lock Stainless steel body band Hinge complete Lid handle Select Fire Models Thermocouple Relay Control panel Terminal Strip Front Back Sensor 700 Board QTY per kiln 24278K 24320M 24332C 28071F 24325T 22134W 24296H N _ N 24292D 24245J 28068C 24246K 28782C 24304S 24249N 24274F 1 28071F 2 24275G 1 24266V N N QOO W Stock No L1 h L2 G Grnd green Description Transformer Harness wire set Current sensor kit Connectors terminal lugs Terminal block single phase Fuse holder Terminal strip Manual Style Sitter Timer Models Brick grooved for tube assembly Switch box with shield In
83. ker to ensure it has not tripped If the circuit breaker is okay check the fuse The fuse is located on the bottom of the Select Fire Wall Mount Controller and on the lower left side of the kiln mounted controller Turn the knob a quarter turn counter clockwise to remove the fuse Check the fuse wire and if broken replace the fuse If the fuse is smoky replace it After the fuse is replaced if the new fuse blows check for other possible causes A blown fuse may be caused by a short in the circuit or a power surge Some segments of the display are dimmer than others When a few segments of the LED display become dim mer than the others the problem may be the result of age indicating the circuit board may soon fail Another possible cause is exposure of the controller to high heat This situation needs attention Do not use the kiln when this problem is present Contact your EXCEL distributor The thermocouple is flaking Flaking is normal with Type K thermocouples especially when high fired Use a soft bristle toothbrush to remove the flakes and vacuum them from the kiln so they do not attach to your ware Remove the thermocouple element periodically and check it for thinning The end firing temperature is different now than when I first got my kiln and the results do not seem quite right What should I do After about 50 Cone 6 firings or 150 Cone 04 firings it is necessary to replace the thermocouple element When the te
84. key to display the elapsed firing time and the temperature when the error occurred Consult section on Error Codes for troubleshooting information F1 F2 F3 FA F5 F6 F7 or F8 The controller is in RAMP HOLD mode The user needs to input an end temperature in F or C for each segment of the firing profile FAIL The thermocouple and controller are not properly con nected Fix the connection then press ENTER to display the kiln s current temperature Press Start after the con nection is fixed The thermocouple could be damaged Check the connections if still no luck you may need a new thermocouple HOLd Indicates a holding time in hours and minutes at the end of a CONE FIRE program HLd1 HLd2 HLd3 HLd4 HLd5 HLd6 HLd7 or HLd8 The controller is in RAMP HOLD programming mode The user needs to input a period of time in hours and minutes that the controller should maintain for each segment of the firing profile ON Briefly displayed at the beginning of firing to indicate that the kiln has started 30 PROG A prompt at the beginning of a RAMP HOLD program which allows the user to select a stored program RA1 RA2 RA3 RA4 RA5 RA6 RA7 or RA8 The controller is in RAMP HOLD programming mode The user needs to input an appropriate temperature in F hr or C hr for each segment in the profile SEGS Looks like SE65 The controller is in RAMP HOLD mode The user needs to Input the number of segments in the pr
85. kiln at any point of a program It may also be used to return to Idle Mode in the middle of entering a program ENTER must be pressed after entering any time temperature or programming speed ENTER is also used to turn an Alarm off that has sounded during a firing Delay The Delay feature allows you to program the kiln to automatically start at a future time This feature is pri marily used to take advantage of better off peak elec tric rates or to time the shutoff of the kiln for a time that is convenient for you to be there It can be set fora Ramp Hold Mode or Cone Fire Mode program and can be accessed only after the program has been entered and the controller is in Idle Mode You can enter a delay time up to 99 hours and 99 minutes From Idle Mode press DELAY Input Delay time in hours and minutes then press ENTER When START is pressed to begin the program the time entered for the delay will reappear on the screen and begin counting down When it reaches 00 00 the kiln 14 Mode Firing Speed tilll l FAST M will start the program currently loaded The Delay time will stay in memory until it is cleared To clear it follow the instructions for entering a Delay and enter 00 00 for the Delay time Alarm The Alarm feature is used to sound an Alarm at a spe cific temperature in the program This feature is primar ily used to prompt the user to lower a propped lid or for glass artists to look into the kiln at
86. kiln before performing any repairs or general maintenance If your kiln is wired direct turn off the breaker e Use only EXCEL replacement parts Improperly sourced parts pose a hazard to you and your kiln and void your warranty e Never modify your kiln without first consulting AMACO Improper modifications may pose a hazard to you and your kiln and void your warranty Items such as alternative thermocouples controllers kiln coatings may ruin your kiln if improperly installed or applied Replace any electrical components that are discolored brittle or corroded e Inspect all stainless steel bands to ensure they are tight If they are loose tighten them as much as possible to prevent the band from slipping or flexing Precautions for the Select Fire Controller The controller is a temperature con l i i lt 100 F Max trol device It is not a safety device e The maximum operating temperature is 100 F 38 C and the minimum tem lt 33 F Min perature is 33 F 1 C This temperature refers to the room temperature while the kiln is firing and does not pertain to the internal tem perature of the kiln The controller contains static sensitive parts that may be damaged by static electricity Use caution to avoid creating static that may damage the equipment In areas where static electricity is common or during dry times of the year throughout the country touch the kiln lid handle before touching th
87. l 3 Power supply problems Power can fluctuate during peak hours contact your local power company or a qualified electrician Precautions and Maintenance Tips to Ensure Years of Trouble Free Service If properly cared for and fired an EXCEL kiln will last for many years with very little maintenance but there are a few tasks that should be done regularly to ensure the kiln runs safely and effectively Your kiln should only be used in well ventilated areas e Do not allow glaze or kiln wash to come in contact with heating elements Before each firing brush bottom of kiln shelves and underside of the kiln lid with a soft brush e After each bisque firing vacuum out the element grooves and bottom of the kiln to remove dust and stray pieces of bisque that may have broken during firing These pieces can get caught in the elements and cause them to overheat at that point e Periodically check your kiln shelves for cracks that run through the entire shelf When the shelves have become this damaged it is not recommended to use them Element wire will increase in length with extended use and the coils will begin to move out of the grooves The wire is brittle after the first fire and should not be moved or bumped when cold Heat kiln up until red heat elements glow orange for 10 minutes disengage the power then gently push the wire back into the grooves with a wooden tool e The more the kiln is fired the less efficient
88. l not allow notations to be made to both copies notify AMACO directly Concealed Damage or Shortage When your shipment is unpacked if any item from the order was omitted you are to contact AMACO at once If the merchandise was damaged in transit report this to the delivering carrier and request an inspection of the shipment Unless you take this action the transportation company will dispute their liability to any claim of lost or damaged merchandise If the inspection request is denied make an affidavit stating that you requested an inspec tion on a certain date and were denied an inspection This with other papers will help support the claim and should be filed immediately The responsibility for filing claims is with the person school or company paying the freight bill Save all packing materials Don t assemble or fire your kiln until your damage claim has been resolved Fax or email a copy of the signed inspection report to AMACO Inspec tion reports MUST BE DATED NO LATER THAN 15 DAYS AF TER DELIVERY OF SHIPPMENT IN ORDER FOR CLAIM TO BE VALID When this procedure is followed AMACO makes every effort to assist in obtaining reparation When your kiln is unpacked check the metal nameplate to see that the voltage shown is the same as you ordered If your electrician has not tested the power outlet to see that the specified current is available he should do so before the kiln is installed For example too many ap plianc
89. late 1 Turn switches off 2 Install the firing gauge This metal gauge fits over the sensing rod and cone supports positioning the rod as it should be when the Kiln Sitter is properly adjusted 3 Check the clear ance of the trigger and release the claw The trigger should just clear the release claw If it strikes the claw orhasmorethan a few thousandths of an inch clearance adjust the trigger height by loosening the trigger set screw Tighten firmly when you are finished because repeated falling can cause the trigger plate to jar out of adjustment 4 Check the travel of the sensing rod Remove and save your metal firing gauge Move the sensing rod up and down It should travel freely without touching the sides of its tube On the outside of the kiln the claw should move freely within the guide plate If there is interference 1 loosen the guide is plate screws and center its slot so the rod and claw move freely Tighten screws Sensing Rod Cone Supports 5 Make the 2 o clock test To be sure your falling weight causes the plunger to pop out press the plunger in raise the weight to about the 2 o clock position and drop it It should cleanly trip the plunger out Set claw i s jrom trigger Set trigger to just clear claw Underfired Incorrect Adjustment Over fired Incorrect Adjustment Correct adjustment Approximately 90 angle Additional Kiln
90. led thermocouple touch a lighted match to the welded tip The needle should register an increase in temperature If the needle moves in the op posite direction simply reverse terminal connections Kiln Sitter The Kiln Sitter is a me chanical cut off device A junior size cone mounted horizontally in the kiln bends when the matur ing temperature of the cone is attained releasing a weighted trigger which shuts off the kiln The Kiln Sitter is designed to use only Junior Cones The limit timer is simply a clock mechanism which you set for a time slightly longer than your anticipated firing By keeping an accurate record of every firing you will soon be able to estimate the length of a firing to within a half hour or less Then should anything go wrong with your Kiln Sitter the limit timer will turn off the kiln before over firing can do damage CAUTION Automatic cut off devices must be carefully checked and properly installed Report any malfunction to instrument manufacturer Since AMACO does not manufacture these instruments the company disclaims any liability for operational failure or resulting damage IMPORTANT You must adjust and test your Kiln Sitter on your new or repaired kiln As good as your Kiln Sitter is you must calibrate and test it before you trust your ware solely to its control Here s what you should do be fore the first firing and periodically to keep the Kiln Sitter in adjustment Guide P
91. ll the AMACO Brent Technical Support Department toll free 1 800 374 1600 or 317 244 6871 local b Email the AMACO Brent Technical Support Depart ment at technicalsupport amaco com 3 Provide the following information and the Technical Support Agent will provide further assistance a Model number of item b Serial number of item c Voltage and phase of item d Date purchased e From whom purchased f Nature of problem AMACO recommends that all maintenance and repairs to kilns be performed by an Authorized EXCEL Ser vice Technician however if this is not possible AMACO recommends that the owner work closely with our Tech nical Services representatives to ensure the diagnosis and repair are correct and performed safely Normally simple repairs can be made over the phone with our trained Technical Service Staff Monday Friday 7 00 am 5 30 pm EST If it is necessary to mail or ship parts to AMACO for further inspection parts must be sent prepaid For your protection insure all parts The equipment and part serial number must accompany the defective item Repair parts will be sent with a full refund on the invoice if examina tion confirms a defect in materials or workmanship If repairs must be made at the factory it will be done at no charge for parts and labor provided all shipping costs are supplied by the purchaser Do not return any mer chandise without authorization This warranty gives you specific legal rights You may
92. mber or final firing temperature is requested Program in a hotter cone or higher firing temperature You could also add a few minutes of hold time at the final firing temperature e Press START after the reprogramming is complete The kiln will begin firing based on current tempera ture and will fire to completion using the newly pro grammed data e Helpful hint If the firing is just slightly under fired pro gram five minutes of hold time at the final firing tem perature This will allow the sections of the kiln that are somewhat cooler to catch up to the hotter sections The kiln displays CPLt but the kiln won t cool off Check the elements to see if any are still glowing inside the kiln If a whole section of the kiln is glowing a relay is stuck Unplug the kiln and contact your distributor for further information At night I see a blue flash coming out of the control box when it clicks Is it serious The flash occurs when the contacts open causing a small arc This is a normal occurrence and should not be a concern programmed a RAMP HOLD profile and when I pressed Start the alarm sounded Review the program to ensure that all segments of the profile have a value entered Also check the alarm to see if a value has been entered that is lower than the room temperature The default setting for no alarm to sound is 9999 The kiln is plugged in but there is nothing on the display First check your circuit brea
93. measured through the use of Pyrometric Cones see page 41 The values of these cones used by the Select Fire controller ranges from Cone 022 through Cone 10 It will not let you enter a cone value outside of this range Remember that there is a big difference between values with 0 s in front of them and ones without 0 s Example A Cone Value of 6 is much hotter than a cone value of 06 Step 4 Speed The Firing Speed you select will determine how long the kiln will take to heat up This is important because if you heat some pieces too quickly they can crack or explode There are three available speeds to choose from Below is a description of each speed along with a graph show ing the firing profile Cone Fire Slow Slow Speed will take approximately 12 hours to com plete Slow Speed is recommended for large or thick walled pieces We recommend that most teachers use Slow Speed because it is often hard to tell how thick the walls are in a student s project If you are unsure if the piece is completely dry use this speed Cone 04 Slow Speed 2000 1800 1600 LL e 1400 3 ENS S DIT l1 c 1 2 800 4 E c3 E i a eT PT Cone Fire Medium Medium Speed will take approximately 7 5 hours to fire Medium Speed is fine for most firings When in doubt use the Slow Speed Cone 04 Medium Speed 2000 Temperature F Cone Fire Fast Fast Speed will take approximately 4 hours This speed is onl
94. mer 1 24321N Harness wire set 1 24332C Current sensor kit 4 28071F Connectors terminal lugs 32 24325T Terminal block single phase 3 22134W Fuse holder 8 24296H Terminal strip 1 1 1 Manual Style Sitter Timer Models 1 24251R Brick grooved for tube assembly 1 24245 Switch box with shield 2 28068C Infinite control switch 2 24246K Switch box upper 1 28782C Kiln Sitter limit timer model LT 3K 1 243048 Tube assembly only 24249N Pilot light assembly 24274F Master switch box 1 28071F Connectors NPW terminal lugs 2 24275G Master switch box shield 1 24266V Switch box shield lower QTY per kiln Co 49 aseud a buls JSZvz X3 Zvc X3 15r Syueg ujejbeirq Hui Wiring Diagram Parts List EX 344 EX 344SF Single Phase 50 Stock No 24267W 24262P 24268X 24269A 24270B 24244H 242525 24253T 24254V 24256X 24272D 24258B 24259C 24286V 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 344 EX 344SF Single Phase j i Li vir 73 Cun Current Sensor Elements Terminal Strip Front Back LCAC Transformer q TI a 1 E E L1 L2 amp G Grnd green Description E Stock No Description All Models 24278K Transformer Brick for lid with band no hardware 1 24321N Harness wire set Lid support brace bracket and arm 1 24332C Current sensor kit Brick grooved for peephole 4 28071F Connectors terminal lugs Brick grooved straight 32 2432
95. mperature seems to drift it is an indication that the thermocouple is becoming thinner and wearing out Another possibility is a cone correlation difference As elements age it takes longer and longer for the kiln to reach temperature Cone Fire Mode programs will auto matically lower the ending temperature to compensate for the added heat work induced by the increased time pressed a number but the new cone number is not displayed Be sure the power is on and the touchpad is active After entering new values for any step in programming it is necessary to press ENTER 29 bunoouse qnoJ Display Messages Select Fire Display Messages Messages displayed while accessing menu functions are described in the menu section of the manual They are not listed below Primary Display Messages ALRM The controller is asking for an alarm temperature to be entered between 0 and 9999 that will alert the opera tor to take action CONE The kiln is in CONE FIRE MODE and needs the operator to input an appropriate Cone value from 022 to 10 CPLt The controller has completed a firing profile The firing time in hours and minutes is displayed along with the current internal temperature of the kiln Press ENTER to return to Idle Mode dELA This is a prompt to enter a time in hours and minutes to delay the firing before starting the program Enter a time or all zeros for no delay E A software error has occurred Press any
96. n easily cause glaze crawls The dusty area will cause areas where glaze adhesion will be poor and cause crawls All bisque and for that matter greenware should be totally free from loose dust 3 Do not handle greenware or bisque with any kind of grease oil or hand lotion on your hands The net result of getting these materials on your pieces will again be poor glaze adhesion to the clay body Save hand lotions for after clean up of the area at the end of the day 4 Keeping a tidy work area and using good habits when handling greenware bisque your glazes and equipment will all help prevent crawls Over fired Ware Pyrometric cones can also be important in determining if a load has been over fired Pieces that have been over fired are usually lost Applying a thin coat of glaze and re firing can be attempted but this usually doesn t fix the problem Determining WHY the kiln over fired is impor tant so that the problem doesn t occur in the next firing 1 Make sure the kiln was programmed correctly and that the correct cone value was selected 2 Check the thermocouple to make sure it isn t old and corroded This can cause the temperature reading of the controller to be different than the actual temperature in the kiln 3 Check that the thermocouple is protruding into the kiln chamber at least 2 inches otherwise the tempera ture can be inaccurate 4 Check for broken elements A broken or weak element near the thermocouple
97. ng malfunction of cutoffs and starters 2 The KILN SITTER if equipped is separately war ranted by its manufacturer W P Dawson Inc 6441 S EJohnson Creek Blvd Portland OR 97206 503 774 6000 3 Shipping damage 4 The warranty period has expired 5 Repairor service is done by an unauthorized dealer 6 Damage or failure due to acts of God such as fire flood electrical storms etc 7 Damage due to over firing reduction or salt glazing 8 Usefor other than ceramic materials 9 Normal wear as experienced in the ceramic process 10 Units modified in any manner This warranty does not cover damage caused by failure of these instruments The buyer s sole and exclusive rem edy shall be for the repair and or replacement of defec tive parts as provided herein The buyer agrees that no other remedy including but not limited to lost profits lost sales damage to property or any other incidental or consequential loss shall be available to the buyer Warranty Repair Instructions All warranty claims must be approved and serviced by an authorized EXCEL dealer If there is not an authorized EXCEL dealer in your area contact AMACO directly for authorization however labor costs will not be covered If you exprience a problem with your equipment 1 Contact the dealer or representative from whom you made your purchase 2 f the dealer is unauthorized to perform repair or un able to correct the problem a Ca
98. nual Kiln Operation Preparation Remove any brick chips or other foreign matter from around the elements Bits of bisque and glaze will eat through elements and our warranty cannot cover such accidents We recommend that you vacuum the inside of the kiln to remove any dust that accumulated dur ing shipment Wipe all new shelves clean and apply two coats of AMACO Kiln Shelf Wash to one side of each shelf Apply a thin coating of Kiln Shelf Wash in one direction and allow to dry Apply another thin coating in the opposite direction leaving a 12 margin from the outside edge of the shelf A new coat is seldom needed just spot patch and sand off the surface evenly with coarse sandpaper wrapped around a wooden block A fresh coat may be needed before a porcelain firing if glaze has dripped onto the shelf If your kiln is fitted with a Dawson Kiln Sitter Limit Timer it has a manual cone operated shut off system and infinite control switches Test Fire Once appropriately installed the kiln is ready for the test fire Test firing is important to operation of the kiln as it will help to identify any installation errors that may have occurred burn off the protective coating on the ele ments and properly oxidize them to maximize their life 1 Remove the firing gauge on the tube assembly located inside the kiln 2 Mix a small amount of AMACO Kiln Shelf Wash and apply a thin coat to the cone rests and the sensing rod Do not ap
99. o keep the vacuum away from the touch pad area e Inspect plug and wall receptacle for any indication of excessive heat Replace both plug and receptacle if necessary Kilns with Select Fire e Inspect the thermocouple for cracks or bends which could cause failure Check and tighten thermocouple screw connections at the porcelain block The thermo couple electronic circuitry may drift out of calibration You can monitor the performance of your kiln with witness cone placed in the kiln If the controller needs adjustment to fire hotter or cooler you can program a cone fire offset adjustment on the controller e Inspect connections at the terminal strip If any feeder wire or thermocouple connections are loose you can tighten the screws that hold the tabs with the tabs in the most counter clockwise position possible If the connec tors are loose do not pinch the female connectors with pliers instead replace them Pinching can distort and minimize the electrical contact area in the connector e The EX 1099SF has screw type element connectors at the element ends that may need tightening periodically Manual Control Models e The tube assembly should be inspected and cleaned of any debris in the tube The sensing rod should move freely in the tube e The sensing rod should be replaced if the tip is worn too thin or otherwise damaged e The falling weight and claw adjustments should be checked with the gauge washer periodically
100. o ship your EXCEL Kiln call EXCEL Technical Support for packing instructions Set Up the EXCEL EX 1099SF Kiln The EXCEL EX 1099SF is a heavy duty high capacity unit designed to meet the needs of the high fire pro duction potter tile maker and light industrial user This kiln is equipped with components and wiring that will allow it to high fire extremely dense loads in a relatively short time Firing The EXCEL EX 10995F kiln features the Select Fire con troller as standard equipment so operation is identical to other EXCEL Kilns with Select Fire Even though the earlier sections of this manual do not refer specifically to the EX 1099SF you may follow all the instructions on programming and firing routines Kiln Improvements If you are an extensive kiln user you might find the EX 1099SF to be the appropriate choice for your next kiln purchase Here are some of the differences from our standard kiln line e The EX 1099SF is designed to fire full Cone 10 loads without stalling on the high end To do so itis equipped with industrial gauge wiring and three types of elements for better firing balance Because of its high rating elec trical codes require the EX 1099SF be direct wired by an electrician therefore no plug is included e Mercury displacement relays are used for longer life and quieter operation e The hinged control box is larger and compression connectors are used on the feeder wires for easi
101. ofile being programmed SKIP Short for Skip Step Can be selected during a RAMP HOLD program when one feels that adequate heatwork has been done in the current segment Immediately ad vances the program to the next segment SPd The controller is in CONE FIRE MODE The user needs to Input the appropriate speed slow medium or fast for this firing STOP Designates the intentional termination of a program while in operation WAIT Displays at the time the kiln is initially powered up Wait for the display to return to Idle Mode Miscellaneous Display Messages Flashing temperature and IdLE The kiln is in IdLE Mode The kiln is off and the display is showing the kiln s current temperature Alternating display of time and temperature The kiln is in a RAMP HOLD firing profile and is in the soak stage The display is indicating the kiln s internal tempera ture and the remaining Hold time for that segment Decreasing time The kiln is in a Delay start segment of a CONE FIRE or RAMP HOLD mode The display is showing the remain ing time before the kiln starts to heat Steady temperature The kiln is in the ramping stage of either a CONE FIRE or RAMP HOLD fire profile Decimal point between 10 s and 100 s Hours are to the left of the decimal and minutes are to the right Right hand decimal point on Kiln is operating in Celsius temperature scale To change back to Fahrenheit temperature scale consult the MENU Options Ma
102. olutions before installing All kilns are vulnerable to the highly corrosive effects of marine air If you live near salt water locate the kiln indoors and protect it from the damp air Shelving T gt Z Io 4 ua Example of Typical Installation Preparation Certain kiln models may have slightly different set up instructions See page 31 for special set up instructions for kilns with manual controls and page 25 for setting up the Select Fire wall mount Save packing material until test fire is complete The kiln comes almost completely assembled If you need to dis assemble the kiln to make it lighter or smaller to move through doorways see page 40 Load the EZ Lift Springs if equipped If your kiln is equipped with a spring assisted EZ Lift you will need to load the springs They have been deten sioned to avoid damage to the kiln during shipping See page 11 for instructions on tensioning the springs Remove and Set Up Stand 1 Open the lid and secure the lid brace in place 2 Slightly bend the stand packing cardboard to relieve the tension against the brick wall and carefully lift the stand out of the kiln being careful not to damage the brick or the thermocouple 3 Remove the cardboard and peephole plugs attached to the stand 4 Install the black plastic stand feet which are located in the plastic bag with the manual 5 Place the stand where the kiln will be located Place Slab
103. om section is on full power it is lagging behind then output 2 comes on as a percent age of output 1 or output 3 The middle section will fire hotter and help the top and or bottom section catch up The percentage can be set from O zero to 150 It is fac tory preset at 85 SHTO Shutoff if equipped with Zone Control Shut off is a Zone Control feature that attempts to make firings more consistent For 2 and 3 Zone Controllers when shutoff is OFF the controller uses the average of all three thermocouples to transition from one segment to the next or to shut off the kiln When ON the kiln turns off or transitions when any one of the thermo couples reaches temperature FOR ALL DOWN RAMPS the controller transitions from one segment to the next as if shut off SHTO were turned ON i e when any one section reaches the next segment temperature Id Control Interface System ID CIS is an optional accessory that allows you to program and monitor multiple kilns from a PC Each kiln hooked up to the CIS system needs to be identified with a unique number so the software can distinguish it from the other kilns To set the identifying CIS number for each kiln ac cess the Id setting through the CNFG menu select a number between 1 and 99 and press ENTER OUT4 Output 4 Settings There are three standard outputs one safety output and one accessory output on your Select Fire controller The accessory output is desi
104. ord 1 24251R Brick grooved for tube assembly 1 24257A Bottom slab with band 1 24245 Switch box with shield 2 24258B Sash lock 2 28068C Infinite control switch 6 24259C Stainless steel body band 3 24246K Switch box upper 1 24286V Hinge complete 1 28782C Kiln Sitter limit timer model LT 3K 1 24265T Lid handle 1 243048 Tube assembly only 1 24249N Pilot light assembly 1 Select Fire Models 24274F Master switch box 1 28815L Thermocouple 1 28071F Connectors NPW terminal lugs 12 24319 Relay 3 24275G Master switch box shield 1 24250P Control panel 1 24266V Switch box shield lower 1 53 aseud ejburs 450 z X3 07c X3 1S1 Syueg ujejbeirq Bui Wiring Diagram Parts List EX 270 EX 270SF Three Phase 54 Stock No 242361 24262P 24240D 24242F 24243G 24244H 242525 24253T 24254D 24256X 24257A 24258B 24259C 24286V 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 270 EX 270SF Three Phase Elements Top Ring Description All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 10 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band Hinge complete Lid handle Select Fire Models Thermocouple Relay Control panel RAAAAAAA A VAY Front Back AAA TET RON num e eS AA b
105. ort brace bracket and arm 1 24332C Current sensor kit 1 24268X Brick grooved for peephole 6 28071F Connectors terminal lugs 12 24269A Brick grooved straight 48 24325T Terminal block single phase 1 24270B Brick grooved terminal 5 22134W Fuse holder 1 24244H Insulator tubes 12 24296H Terminal strip 1 242528 Supply cord connector 1 24253T Power supply cord 1 24254V Kiln stand 10 sided 1 Manual Style Sitter Timer Models 24256X Heat shield supply cord 1 24271C Brick grooved for tube assembly 1 24272D Bottom slab with band 1 24245 Switch box with shield 2 24258B Sash lock 2 28068C Infinite control switch 6 24259C Stainless steel body band 3 24246K Switch box upper 1 24286V Hinge complete 1 28782C Kiln Sitter limit timer model LT 3K 1 24265T Lid handle 1 24305T Tube assembly only 1 24249N Pilot light assembly 1 Select Fire Models 24274F Master switch box 1 28815L Thermocouple 1 28071F Connectors NPW terminal lugs 12 24319 Relay 3 24275G Master switch box shield 1 24250P Control panel 1 24266V Switch box shield lower 1 55 aseUd a DUIS JSS9 X3 S9 X3 SI seg Wesbeiq Bul Wiring Diagram Parts List EX 365 EX 365SF Three Phase 56 Stock No 24267W 24262P 24268X 24269A 24270B 24244H 242525 24253T 24254V 24256X 24272D 24258B 24259C 24286V 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 365 EX 365SF Three Phase Elements Top Ring MINNS m j Bottom Ring KAANAA A Desc
106. ply wash to the end of the porcelain tube Allow the kiln wash to dry thoroughly Do not allow the kiln wash to accumulate 3 Raise the weight up against the guide plate 4 Press the claw down lightly until it engages the trigger 5 While holding the claw down carefully place a cone flat on the cone supports with the inside edge of the number circle even with the outside edge of the cone support The large part of the cone should rest against the metal step of the cone support with the center of the cone parallel with the end of the tube TOP VIEW Cone Number CAUTION Since the softening and bending of the cone shuts off the kiln correct positioning of the cone is crit ical to proper firing IF CONE IS DISLODGED BY ACCI DENT OR ALLOWED TO COME INTO CONTACT WITH THE PORCELAIN TUBE AN OVER FIRING MAY RESULT WHICH COULD CAUSE SERIOUS DAMAGE TO YOUR KILN The cone now holds the claw engaged so that the weight is supported and your hands are free You are now ready to close the kiln and begin to test fire Note In a new kiln often the first few firings may be accompanied by odors of paint components and moisture from firebrick During normal firings moisture and gasses are driven off by the heat and carry a distinct odor from the kiln In addition in natural clays there are often impu rities which may smoke or give off odors The best remedy for these odors is good ventilation in your kiln room Temperature Indicators
107. r con troller After plugging in the kiln the display will read WAIT for approximately 10 seconds while power is re stored to the kiln It will then switch to Idle Mode In Idle Mode the display will flash the kiln temperature alter nating with IdLE Begin all programming in Idle Mode Be sure the programmer is set to the right temperature scale before proceeding Fahrenheit or Celsius Cone Fire Mode Step 1 Press CONEFIRE Step 2 Input PREHEAT time Press ENTER Step 3 Input Cone number Press ENTER Step 4 Input a SPEED Press ENTER Step 5 Input HOLD time Press ENTER Step 6 Press START Ramp Hold Mode Step 1 Press RAMP HOLD Step 2 Input the PROG number Press ENTER Step 3 Input the number of segments Press ENTER Step 4 Input the first heatng rate Press ENTER Step 5 Input the first temperature to reach Press ENTER Step 6 Input HOLD time Press ENTER Step 7 Repeat steps 4 through 6 until alarm flashes Press ENTER Step 8 Press START Important To effectively use Ramp Hold mode it is imperative to understand heat work theory If you know the theory well and if you have had experience with other programmable kilns or controllers then the Getting Started instructions will be useful If not please read the complete Ramp Hold instructions beginning on page 18 The Ramp Hold Mode can be used for all firing applica tions from glass to high fire porcelain and stoneware This op
108. r in expansion than the body This puts the entire system into slight compression Thermal expansion has NOTHING to do with shrinkage All materials will expand and contract when heated and cooled Clay bodies expand when heated and contract when cooled We need only be concerned with glazes contracting when cooled as they are not a solid mass when heating them in the glaze firing If the thermal fit is good the piece will be durable and stable Crazing Crazing occurs when the glaze contracts more than the clay body The glaze attempts to contract to a smaller size than the body but the body is preventing the full contraction Stresses build up in the system and the glaze is actually split apart to relieve the stress These are the small thin cracks we have all seen in old china If the mismatch is only slight only a few large craze marks will be seen If the mismatch is severe many craze marks will be seen and they will be very close to each other It is easy to see crazing on some glazes and much harder to see on others Rubbing some India Ink onto the glaze surface will help make crazing more obvious It should be remembered that crazing may not show up when the piece is first taken from the kiln It may in fact take several days for crazing to appear This is true when the mismatch is only slightly wrong If the mismatch is severe the crazing will happen as soon as the piece is 43 spajaqg Dwele Ceramic Defects removed from
109. r is burned then the element came on Important Be sure that the control box and kiln lid are closed before you use this feature in order to avoid electrical shock CNFG Configuration Caution Be sure to consult with an AMACO technician before making any configuration setting changes Unadvised changes can cause permanent damage to your kiln and the ware inside it CNFG or Configuration is where all of the controller configuration tools are located The following options are available under the CNFG menu ERCd Error Codes ON OFF Error codes are designed to help protect you your kiln and your ware when something goes wrong with the firing There are times however where you may wish to try a new technique which would trigger an error code under normal conditions When error codes are turned off the following codes are disabled Error 1 Terminate firing when kiln temperature is increasing at a rate slower that 12 F 11 C hr Error 2 Kiln Temperature 50 F 10 C degrees above hold temperature Error 3 Kiln Temperature 50 F 10 C degrees below hold temperature Error 4 Kiln Temperature 50 F 10 C degrees above previous hold when ramping down Error 5 Kiln Temperature 50 F 10 C degrees below traveling set point when ramping down Error D Kiln Temperature 50 F 10 C degrees above traveling set point TCOS Thermocouple Offset This feature allows you to calibrate the thermocouple when i
110. re you live changes by the season These changes may be dramatic depending on locale and may affect how your clay pieces dry after forming Drying is a function of temperature humidity and air movement Anything that alters these variables can cause problems Also what works in Tampa may not work in Phoenix 4 Keep your work area clean from dust oils and any thing that may contaminate your ceramic pieces 5 Keep your glaze containers clean and sealed to pre vent bacterial growth The same goes for the brushes used to apply the glaze 6 Watch how old the glazes are and more importantly know how they apply and dry when they are new Older glazes especially ones that have been poorly cared for will tend to start to dry faster and this causes issues 7 Learn what the bisque ware pieces sound like when tapped lightly with a metal object The sound a good piece makes is distinct and knowing that you can determine the clunky dull tone of a damaged piece Everyone can see major cracks but many cracks are small or the piece may simply have weak areas that will break when glaze fired Knowing that a piece is not good at this point will avoid waste of decorating time glaze and kiln space 42 Drying Forming Cracks F E E y sfr C arf An F Ew y WE o The causes for cracking are many and can be elusive Listed here are some general tips for forming and drying pieces 1 Do not use excess water when wheel throwing or
111. ription All Models Brick for lid with band no hardware Lid support brace bracket and arm Brick grooved for peephole Brick grooved straight Brick grooved terminal Insulator tubes Supply cord connector Power supply cord Kiln stand 10 sided Heat shield supply cord Bottom slab with band Sash lock Stainless steel body band Hinge complete Lid Handle Select Fire Models Thermocouple Relay Control panel Pa E i i TRO wu LS bM rd Current Sensor Terminal Strip Front Back LS 2 z M L3 700 Board eb Grnd green SEM S Stock No Description Sen 5 24278K Transformer 1 1 24322P Harness wire set 1 1 24332C Current sensor kit 1 6 28071F Connectors terminal lugs 12 48 243248 Terminal block three phase 1 5 22134W Fuse holder 1 12 24296H Terminal strip 1 1 1 1 Manual Style Sitter Timer Models 1 24271C Brick grooved for tube assembly 1 1 24245J Switch box with shield 2 2 28068C Infinite control switch 6 3 24246K Switch box upper 1 1 28782C Kiln Sitter limit timer model LT 3K 1 1 24305T Tube assembly only 1 24249N Pilot light assembly 1 24274F Master switch box 1 1 28071F Connectors NPW terminal lugs 12 3 24275G Master switch box shield 1 1 24266V Switch box shield lower 1 Stock No 24277 24263R 24279L 24280M 24281N 24244H 242525 24253T 24282P 24256X 24306V 24258B 24235R 24287W 24265T 28815L 24319 24250P Wiring Diagram Parts List EX 399 EX 399SF Single Pha
112. ro mechanical device it may show signs of wear For most home hobbyists electrical work can be both confusing and dangerous If this listing points to internal electrical trouble we recommend you contact your EXCEL dealer Kiln Sitter Kiln Sitter consistently over or under firing com pared to a Senior check cone at Kiln Sitter level 1 Check Kiln Sitter adjustments page 32 2 Bent Junior cones from Kiln Sitter deeply cracked across lower faces indicating moisture problems Buy new cones Consistently firing too hot or too cool in one section Adjust infinite switch higher or lower on Medium and High settings to compensate Occasional over firing 1 Sensing rod not accurately centered between cone rests 2 Falling weight mounting bracket bent so weight rubs against it Adjust per pages 32 33 3 Overglaze oils or organic matter from native clays accumulated on inner face of guide plate Remove plate clean with lacquer thinner Never plug top peephole Vent lid longer if necessary Senior check cone over fired but Junior Kiln Sitter cone only normally bent 1 Use magnifying glass to double check numbers of both fired cones 2 Cone drop anomalies can happen if the kiln takes more than 11 hours to reach temperature with all switches on high Element replacement might be required contact EXCEL Technical Support Kiln found with weight fallen but pilot light and all elements still on Cones over
113. s 1 When you get to the desired setting press ENTER To Input a value such as a Delay time or an Alarm tem perature input the value and press ENTER To select a value press the MENU key until your selec tion is displayed and then press ENTER Programming Instructions e SET Settings e dIAG Diagnostics e CNFG Configurations e Other SET Settings SET is where all of the commonly used options are located The following options are available under the SET heading menu PRHT Preheat This feature allows you to toggle the Preheat feature ON or OFF The Preheat feature allows you to Input an amount of time to hold at 180 F 82 C prior to running a CONE FIRE Program This feature is recommended when firing large thick walled or potentially damp ware When the feature is toggled ON it will prompt you to input a hold time value after the CONE FIRE key is pressed COOL CONE FIRE Controlled Cooling This feature allows you to add a 1 segment cooling program to the end of a CONE FIRE program When it is toggled ON it will prompt you to input a Rate Tem perature and Hold Time after you input the Hold Time for a CONE FIRE program This is helpful when trying to achieve certain glaze effects CHG Change from Fahrenheit to Celsius Scale The controller can display temperature values in Fahren heit or Celsius If the scale is set to display in Celsius an LED dot will illuminate in the bottom
114. se 3 x CO RS m e 4 3 Current f Sensor J oH Wa i 8 r a i H V e rc Elements Top Ring Transformer Terminal Strip Pu Front Back n k Em u AN i m nal E3 rr Relay Li L1 be L2 700 Board GR Grnd green Description said Stock No Description PEU 5 All Models 24278K Transformer 1 Brick for lid with band no hardware 1 24322P Harness wire set 1 Lid support brace bracket and arm 1 24332C Current sensor kit 1 Brick grooved for peephole 6 28071F Connectors terminal lugs 12 Brick grooved straight 60 24325T Terminal block single phase 1 Brick grooved terminal 5 22134W Fuse holder 1 Insulator tubes 12 24296H Terminal strip 1 Supply cord connector 1 Power supply cord 1 Kiln stand 12 sided 1 Manual Style Sitter Timer Models Heat shield supply cord 1 24307W Brick grooved for tube assembly 1 Bottom slab with band 1 24245 Switch box with shield 2 Sash lock 2 28068C Infinite control switch 6 Stainless steel body band 3 24246K Switch box upper 1 Hinge complete 1 28782C Kiln Sitter limit timer model LT 3K 1 Lid handle 1 24305T Tube assembly only 1 24249N Pilot light assembly 1 Select Fire Models 24274F Master switch box 1 Thermocouple 1 28071F Connectors NPW terminal lugs 12 Relay 3 24275G Master switch box shield 1 Control panel 1 24266V Switch box shield lower 1 57 seyd ejbuts 4566 X3 66 X3 15r Syueg ujejbeirq buutM W
115. son Note it is common to see smoke come out of your kiln on the first firing This is normal the elements are burn ing off a coating After the Firing e When completed the display will show CPLt alternately with the firing time in hours and minutes and the current temperature of the kiln Press ENTER to return to Idle Mode e When a Cone Fire Mode program or a Ramp Hold program which uses the Cone Correlation feature is run the controller may alter the peak temperature of the program based on the kilns ability to achieve the final temperature rate This is done to insure the heatwork re mains constant If you are interested in knowing if that temperature changed press REVIEW after the program is complete This temperature value will only appear in a review once after the firing so be sure to pay attention e Allow the kiln to cool naturally Never unplug addi tional peepholes or post the lid until the ware is cool enough for barehanded unloading about 130 F 54 C e When unloading be sure to examine the self supporting cones on the shelf to determine if the kiln is firing correctly e It is not necessary to unplug the kiln when not in use unless severe storms are expected Continuous plug ging and unplugging may cause components in the plug and receptacle to loosen up over time Loose com ponents in electrical connections create heat and can pose a fire hazard Fine Tuning Your Kiln If after inspecting your
116. t is reading consistently and predictably incorrect It is extremely important to consult with an AMACO technician before making thermocouple offset adjust ments Incorrect adjustments to the thermocouple offset can cause permanent damage to your kiln Adjustments made to the thermocouple offset will affect all RAMP HOLD and CONE FIRE programs If you are experiencing problems with CONE FIRE Mode check to see if the ending temperature and hold time of the programs you are running have not been signifi cantly altered from the factory programs before making thermocouple offset adjustments Access the TCOS setting through the CNFG menu The display will flash FOS alternately with the current off set setting FOS represents degrees Fahrenheit Offset If the controller was programed to display in Celsius the F would be replaced by a C If there is currently an offset input this could be the problem To be safe make adjustments in small increments and then run a test fire with self supporting cones To Make The Kiln Fire Cooler Input 00 followed by the number of degrees you wish to offset the thermocouple Press ENTER Example 0010 makes the kiln fire 10 degrees cooler To Make The Kiln Fire Hotter Input 90 followed by the number of degrees you wish to offset the thermocouple Press ENTER Example 9010 makes the kiln fire 10 degrees hotter ZONE Zone Control Options if equipped Zone control is
117. t when used horizontally in Kiln Sitter the Junior will bend at approximately the same time as a Senior standing Because electrical power and kiln location vary keep a complete record of every firing You may find that you get better results with a Junior cone one step hotter than your Senior cone that is a Cone 6 firing may come out better with a Junior 7 If you keep accurate records you can modify your technique to give the best results Pyrometers A properly installed pyrometer indicates the firing chamber tempera tures on a dial It is not set at zero but reads approxi mately room temperature Legible markings appear every 50 on the tempera ture scale making it easy to check the firing speed Also a pyrometer warns that the maturing temperature approaches so you can check the pyrometric cones in the firing chamber and thus prevent over firing 32 Check a pyrometer occasionally with cones to see if it is indicating properly After lengthy use if the pyrometer fails to indicate temperatures examine the thermocou ple If a break is found in the wires a new thermocouple must be installed To install a thermocouple connect the red lead wire to the negative terminal and the other wire to the positive terminal of the pyrometer Adjustments can be made on most models by the small screw on the lower face of the instrument dial Be sure the pyrometer reads the same as room temperature To test a newly instal
118. the elements in the kiln will become Elements in your kiln are a wear able part and will need to be replaced over time If one element has burned out from age it is a good indica tion that the others will soon follow When this happens replace all elements in the kiln e Small cracks will appear in the soft brick of the kiln walls over time This is to be expected and will not affect the operation of the kiln e If it is a manual style kiln equipped with Kiln Sitter Limit Timer scrape the kiln wash off the sensing rod and the cone supports and reapply every three to four firings to keep the cone from sticking to the sensing rod and over firing e Check that all electrical connections are tight and remove any oxidation that has formed on the wires or connectors e If itis necessary to lean over kiln while loading be care ful not to place pressure on the top inside edge of the brick The brick is extremely fragile due to its insulating ability and can be cracked or broken easily if one s body weight is pressed against it e Approximately once a month spin all switches seven times counterclockwise and seven times clockwise This will help to keep switch contacts clean and operating properly e You may wish to place a kiln shelf on the base of the kiln supported by 1 posts to protect the base 37 SUu IM pa1eJedo Ajjenueyy JO epinc 6unoouse qnojJ Repairs Elements Thermocouple Select Fire Wall Mount Refractory Rep
119. the kiln and it may in fact have started to craze while still in the kiln Crazing never occurs because the piece was removed from the kiln too soon it is just more apparent because the craz ing is accelerated as the piece contracts Crazing can have a delayed reaction and not show in a piece for years Shivering Shivering is the exact opposite of crazing During shiv ering the glaze is actually put into compression as it is supposed to be but it is put into too much compression This is because the glaze wants to contract less than the clay body but the clay body is preventing this Stresses build up in the system until the glaze is in so much com pression that it is forced to pop from the clay body to relieve the stress If the shivering is only slight this will cause small very sharp places where part of the glaze is forced up and protrudes higher than the rest of the glaze surface If the shivering is severe small pieces of glaze will actually be pushed totally from the clay piece Note See below for more information This should not be confused with poor adhesion of the glaze to the clay When using commercially made products the best way to remedy these issues is to switch clay bodies If you have crazing you will need a clay body with a higher thermal expansion If you have shivering you need a body with a lower thermal expansion As a general rule but certainly not always true high gloss glazes tend to have hi
120. tion allows you to create your own profiles with up to six ramp and hold segments A segment has three components heating rate temperature and hold It is easy to program Be sure to see page 41 for information on heat work EZ Lift Tensioning the EZ Lift The EZ Lift if equipped is shipped with the hinge springs de tensioned in order to protect the lid during shipping Please follow the instructions for tensioning the lid carefully to ensure success and avoid injury Step 1 Remove the cot ter pin and washer from the lid brace pad and remove the lid brace Step 2 Remove the cotter pins on one side of Rod A and Rod C and with the lid closed slide out the rods Step 3 With lid closed insert rod A with the springs in the position pictured below Replace cotter pin Step 4 Open lid all the way Lid will be heavy since it is not tensioned yet Insert rod C as pictured below Replace cotter pin Lid is now tensioned Close lid and replace lid brace De tensioning and Removing The Lid To remove the lid it will be neccesary to detension it first Start by removing the lid brace and raising the lid as far as it will open Next remove Rod C and close the lid Be careful when lowering the lid since it is now detensioned To remove the lid remove Rod B and lift the lid straight up off the kiln Using the EZ Lift The lid brace has been designed with a two position setting and a stop post The stop post is a saf
121. ts The 240V versions of these kilns will usually low fire satisfactorily when moved to a 208V area But the 208V versions should never be fired on a 240V supply without first installing a full set of 240V elements Otherwise all components will be seriously overtaxed NEMA Receptacle Guide 15 50 6 50 UL and CSA Listed All EXCEL kilns are listed with Underwriters Laborato ries Inc UL and or the Canadian Standards Association CSA These seals are your assurance that the complete unit not just the switches and certain parts has met their rigid standards of safety with regard to casualty and fire hazards The CUL is given to products listed with UL that meet the safety requirements of both Underwriters Laboratories and the Canadian Standards Association All EXCEL kilns are re examined regularly part by part by both of these well known testing laboratories w wW amp Kiln Venting Why it is Important Safer Work Areas Successful firings and safe healthy work environments depend on clean circulated air in the kiln room as well as the firing chamber Testing has shown that gasses generated by the use of unvented kilns exceed OSHA levels for carbon monoxide and should be removed from the kiln room It is recommended that all EXCEL kilns use a direct down draft venting system like the Master KilnVent or the KilnVent Stand Version These systems take the hot gasses from the kiln chamber mix them with room air
122. ture 5 PRHT 0 00 Preheattime Will only be displayed if preheat is set to ON 6 DELA 0 00 DelayTime 7 ALRM 9999 Alarm Temperature 8 ERCD ON _ Error Codes ON or OFF View The View key allows you to determine what segment of a Ramp Hold program the controller is currently running While a Ramp Hold program is firing press VIEW The display will show the current segment the traveling set point and the circuit board temperature The segment number is prefixed by either RA Rate or HLd to indi cate whether the kiln is heating or cooling or holding temperature The traveling set point indicates the target temperature of that segment Cone Table The Cone Table key allows the user to look up the tem perature equivalent of Cone values To use simply press ConeTable from Idle Mode enter a cone value and press ENTER This key may also be used to insert a Cone Value for the peak temperature of a Ramp Hold program This Cone Value will be automatically adjusted Cone Corre lation based on the performance of the kiln To use this feature press Cone Table when prompted to enter the peak temperature of your program enter a Cone value and press ENTER During the Firing You will see the internal temperature of the kiln dis played as the temperature increases The options avail able during the firing are e Review program at any time e View Current Segment of RAMP HOLD Program e Press STOP to interrupt a firing for any rea
123. ways be sure to post the first shelf at least 1 2 5 cm above the slab and if you have a small load concentrate the mass towards the center of the kiln Venting systems such as the AMACO Master KilnVent or KilnVent Stand Version help with uneven heating by mixing the air within the kiln chamber 15 bDuiuuueJ60Jg Programming Choosing a Program The first step in programming your kiln is to decide which Programming Mode to use Before making this decision it helps to have a good understanding of Firing Programs A Firing Program consists of a series of pro gram segments Each segment consists of a Rate a Tem perature and a Hold Time These segments determine the rate at which the kiln will heat up or cool down and how much Heatwork the pieces in the kiln will receive For more information on Heatwork see page 41 Cone Fire Mode With Cone Fire Mode the programs are written for you You simply give the controller some key information regarding the pieces you are firing and it accesses a pro gram which best suites your project This is the most commonly used mode of programming The programs were created by Ceramic Engineers and are designed to minimize problems that can occur during critical stages in the firing process Cone Fire Mode is incredibly easy to use however the software itself is extremely advanced Cone Fire Mode uses complex algorithms to simulate the heatwork of a Pyrometric Cone What is impressive is th
124. wing by seeing it in the glaze or the glaze starts to have a bad smell to it Keeping the lid on your glazes when not in use only using clean brushes using glaze in a timely manner etc will keep glazes working longer Users of glazes should mentally keep track of how their glazes dry It will take several seconds for the glaze to lose its sheen after application If the glazes starts to dry faster this is a sign that problems may be ahead AMACO Gum Solution is a combination of binders and bactericide designed to add more organic binder into the system to replace what has been lost and bacteri cide to prevent future rotting Gum solution may be added in the quantity needed to bring the glazes drying properties back to its original condition It is impossible to recommend an amount to add to a glaze because it depends on how bad the drying properties of the glaze have gotten Adding too much gum solution can cause the glaze to dry so slowly that it becomes an issue Always add this material in small amounts until you get the glaze where you need it to be After using it a few times you will develop a good feel for how much to add Remember that when adding gum solution or water to a glaze you are reducing the amount of solids you are applying to your artwork so you may want to add a little extra glaze thickness to your piece The issue of poor glaze adhesion can happen to any type of glaze The thicker the application of glaze or under
125. y recommended for items such as lusters and decals which can handle the fast increase in temperature Cone 04 Fast Speed 2000 Temperature F Note Firing profiles are approximate and will vary depending on load volume density and placement of ware and placement of kiln shelves Step 5 Hold Time HOLD is another important feature of CONE FIRE MODE Once the kiln has achieved its peak firing temperature HOLD can maintain that temperature for a set amount of 17 Duuruuue460Jgd Programming time This allows the user to make fine tune adjustments to the firing process by introducing more heatwork which can help witness cones reach maturity Addition ally a HOLD permits the kiln to equalize temperature allowing for even firings and firings that fall between cone temperatures for example Cone 05 5 CAUTION Excessive hold time can result in over firings A common mistake is to enter ten hours when a ten minute hold is desired 00 10 equals ten minutes 10 00 equals ten hours Step 6 Start Start initiates the CONE FIRE MODE firing program If a Delay is entered the kiln will start a countdown from the amount of entered delay time Before pressing START ver ify that the lid latch is engaged and that all combustible materials are moved out of the vicinity Advanced Cone Fire Menu Features In Cone Fire Mode the operator has the ability to modify the firing program They can do this in one of two ways
126. you Input the hold time for each segment the display will show FAN along with the number of the segment you are programming Alternately it will flash the current setting either OFF or ON To change the setting toggle it with the 1 key and press ENTER to select that setting MAX Maximum Programmable Temperature The Maximum Programmable Temperature setting is a great feature to use when other people may be pro gramming the kiln It helps protect against an over fire by not allowing the programmer to input any value over the designated limit To set your firing limit access the MAX setting through the CNFG menu Input your de sired limit and press ENTER 2KEY 2 Keys to Start Kiln The 2KEY feature allows you to set the controller so it 24 takes two key presses to start the kiln This helps protect against accidentally starting the kiln When activated it will be necessary to press START then ENTER to start the program To activate this feature access the 2KEY setting through the CNFG menu use the 1 key to toggle the setting to ON and press ENTER Now when you press START to begin the program you will see on the display At this point press ENTER to begin the program dTCT Detect Current Sensor Rating This feature indicates the maximum amperage rating for the current sensor installed in your kiln The current sen sor is the hardware installed in your kiln which allows the controller to read the
127. your kiln has manual controls and Dawson Kiln Sitter with Limit Timer see page 31 The LED Display The display shows 4 characters and 14 segments per character This is not always enough to exactly represent the message presented If you find you do not under stand a message consult the Display Messages section of this manual The controller may be programmed in either Celsius or Fahrenheit It is very important to know which tempera ture scale it is using If there is a LED illuminated in the lower right hand corner of the display the temperature scale is set to Celsius Refer to the MENU section of this manual to change scales if necessary When prompted to enter time values there will be an LED illuminated in the lower center portion of the dis play We refer to this as a decimal point Everything to the left of the decimal will be hours and everything to the right will be minutes Idle Mode When the kiln is flashing IdLE alternately with the cur rent temperature of the kiln chamber we refer to the controller as being in Idle Mode This simply means that the kiln is ready to be programmed To return to Idle mode you may press STOP at any time If controller is programmed for Zone Control the display will also show current thermocouple being read Start Stop Enter The START key begins the program which is currently loaded in memory It may only be accessed when the kiln is in Idle Mode The STOP key will turn off the

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