Olympic Kiln Sitter P K Manual.

Olympic Kiln Sitter P K Manual.
OPERATING
MANUAL
MODELS P & K
CAUTION
The KILN-SITTER control is a valuable tool to help
you achieve consistent result when firing your kiln. It is
engineered to give you years of trouble-free
performance when it is kept in proper adjustment and
maintained as described in the KILN-SITTER
Operating Manual.
The KILN-SITTER control is NOT intended to
perform as a fail-safe shut-off device and your kiln
should NOT be left unattended beyond the estimated
firing time. An uncontrollable accident, such as
greenware falling against the end of the KILNSITTER tube, might cause an over-firing which could
damage your kiln. In this event, the operator should be
in attendance to shut off the kiln manually.
WARNING
DO NOT FIRE YOUR KILN OVER OR NEAR FLAMMABLE
MATERIAL (i.e. wood floor, carpeting, etc.) SEE KILN
SITTER Limited Warranty.
KILN-SITTER
OPERATING MANUAL
Thank you for choosing the KILN-SITTER control on your ceramic kiln. You, like
ceramists the world over, can now enjoy your hobby more because the KILN-SITTER
is "watching" your kiln while you do other things. Years of trouble free firing are yours to
enjoy if you will take the time to carefully read the kiln operating instructions and KILNSITTER manual.
The KILN-SITTER is a mechanical control that fires your kiln by the TIME and
TEMPERATURE method of heat treatment using a small cone or bar. The cone or bar,
after being exposed to the proper time and temperature, softens and bends to a predetermined angle, shutting off the kiln. Your choice of cone or bar, proper KILNSITTER adjustment and tube position determine when the kiln will shut off.
The KILN-SITTER requires very little attention but may need an occasional
adjustment check and replacement of critical parts such as the tube assembly, cone
supports or sensing rod. Frequency of replacement depends on the type of firing being
done, type of clay used, venting and the moisture content of the pieces being fired.
To insure that your KILN-SITTER is properly adjusted, we suggest
you follow the instructions on the following pages and test fire your
empty kiln with the KILN-SITTER before you do anything else.
1
2
Adjustments
Even if your KILN-SITTER was adjusted at the factory, it could have been jarred out of
adjustment during shipment or delivery. Let's first be sure the KILN-SITTER is in
proper adjustment before using.
Here are some simple adjustment checks for you to make before firing your kiln. We
urge you to make them carefully and repeat this check every 30 firings during its
lifetime.
1. TURN ALL SWITCHES OFF
2. INSTALL FIRING GUAGE
Normally the firing gauge is in position
when your kiln is shipped from the factory
(held by a rubber band at the end of the
KILN-SITTER tube.) If it has been
removed, it should now be replaced over
the sensing rod and cone supports, as
shown in Figure .
CAUTION : Remove firing gauge before
operating kiln.
3. CHECK POSITION OF RELEASE CLAW AND WEIGHT TRIGGER
a. With the firing gauge in position, swing the weight up against the guide plate. Pull
the claw forward (against the slight play in the swivel/pivot assembly) and check for
a 1/16th-inch clearance between the inside tip of the claw and the face of the trigger
as shown in Figure 2. The set screw on top of the claw may be loosened if the
adjustment of the claw position is necessary. Retighten the set screw firmly.
3
b. When the weight swings
forward, the trigger should
just clear the tip of the claw,
as shown in Figure 3. The
setscrew in front of the
weight may be loosened to
raise or lower the trigger, as
shown in Figure 4. The
setscrew must be firmly
tightened or the force of
repeated falling of the
weight may cause the
trigger to creep out of
adjustment.
Check your kiln with a level to make sure it is not standing on an uneven floor. If this
should occur, your weight may not fall when released.
WARNING: Do not fire your kiln over or near FLAMMABLE material (i.e. wood floor,
carpeting, etc.)
4. CHECK THE TRAVEL OF THE SENSING ROD
THE FIRING GUAGE SHOULD NOW BE REMOVED BUT KEPT FOR FUTURE
PERIODIC ADJUSTMENTS. The sensing rod is now free to travel vertically within
the tube cavity. It should travel freely in the center of the cavity without touching
the sides at any point, as shown in Figures 5 and 6.
If necessary, the sensing rod may
be centered by loosening the two
guide plate screws in front of the
KILN-SITTER and moving the
guide plate right or left as required,
as shown in Figure 7. Be sure the
guide plate screws are firmly
tightened.
When these adjustments have been made, you are ready to test fire.
4
TEST FIRING
Firing tests are made with the kiln empty. Two small size cones, which mature at a
relatively low temperature, are provided with the KILN-SITTER for test firing. This
allows you to complete the test firing in the shortest possible time. Additional cones are
available from your dealer.
1. FIRING GAUGE HAS BEEN RMOVED.
2. APPLY KILN WASH
(A small nail polish bottle with brush is ideal for this purpose.) Mix Hi-Fire kiln wash
with water to a creamy solution. Apply a THIN coat to the cone supports and the
sensing rod where they will come in contact with the cone. Do not apply kiln wash
to the cone or to the end of the porcelain tube. Allow wash to dry thoroughly. Do
not allow kiln wash to accumulate.
3. RAISE WEIGHT UP AGAINST GUIDE PLATE.
4. PRESS CLAW DOWN LIGHTLY UNTIL IT ENGAGES TRIGGER.
5. INSERT CONE (SEE PAGE 7, Item 7.)
While holding the claw down over the trigger, carefully place one of the test cones
flat on the cone supports with the inside edge of the number circle even with the
outside edge of the cone support. See Figure 8. The cone should be back against
the metal step of the cone support with the center of the cone parallel with the end
of the tube.
CAUTION: Since the softening and bending of the cone shuts off your kiln, its
correct positioning is important for proper firing. IF THE CONE IS DISLODGED BY
ACCIDENT OR ALLOWED TO COME IN CONTACT WITH THE PORCELAIN
TUBE, AND 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 the test fire.
5
6. TURN ALL SWITCHES OFF.
7. INSERT A FINBER INTO THE HOLE IN THE WEIGHT AND PUSH FIRMLY IN ON
THE PLUNGER UNTIL IT LOCKS.
8. FIRE THE KILN BY USING THE REGULAR KILN SWITCHES, AS INSTRUCTED
BY THE KILN MANUFACTURER. (For purposes of test firing, when the kiln is
empty, the highest temperature setting may be used.)
In approximately one hour the KILN-SITTER weight will drop, shutting off the kiln.
When the kiln is cool enough to handle you may open it and inspect the cone. If all
adjustments have been made correctly, the cone on the KILN-SITTER will be bent to
an approximate 90-degree angle shape similar to the illustration in Figure 9. However, if
it is bent similar to the "over-fired" illustration, reduce the kiln switch settings. This will
increase the firing time, reduce the rate of climb and allow the cone to mature properly.
The best way to verify that your load is reaching a certain firing treatment is by using
witness cones. These are valuable and inexpensive instruments that reliably measure
actual firing performance. Witness cones are optional but we recommend their use
during test firing and also periodically during normal operations, as a check for
consistent firing performance, For information on witness cones, refer to page 9.
You are now ready to begin normal firing operations.
6
NORMAL OPERATION
It is the responsibility of the KILN-SITTER user to become familiar with the proper
operation and adjustment of the KILN-SITTER. If the simple steps and precautions,
outlined in this manual, are followed with care, it will serve you as a valuable and
reliable instrument for greater success and enjoyment in your ceramic firing.
When you have assured that the KILN-SITTER is in proper adjustment by test firing,
as described in that section, you are ready for normal firing operation.
1. CHECK THE SENSING ROD
Before each firing check the sensing rod for free and
centered travel. See Figure 10. In spite of
precautions, the swivel/pivot of the tube
assembly can become corroded or contaminated
and alter the normal shut off. If the sensing rod
moves sluggishly, does not fall freely or you have
inconsistent firings, immediately replace the tube
assembly. Refer to pages 12 through 14.
2. TURN ALL KILN SWITCHES OFF
The life of the KILN-SITTER switch will be increased if kiln switches are off
before engaging the KILN-SITTER
3. APPLY KILN WASH
Apply a THIN coat of Hi-Fire kiln wash to the cone supports and sensing rod where
they will come in contact with the cone. Allow the kiln wash to dry thoroughly. We
suggest two pair of supports be available. This allows you to prepare a clean pair
while the other pair is being used in the firing. Refer to page 11; Care of Cone
Supports.
4. STACK WARE IN THE KILN
When loading your kiln, care should be taken to keep the KILN-SITTER tube,
cone supports, and cone or bar visible from above at all times. If the tube is
covered from view, the cone or bar could accidentally be dislodged from its proper
position without being noticed and cause a malfunction of the KILN-SITTER shutoff. Shelves and ware should be positioned at least an inch above or below the
KILN-SITTER tube so that the normal shut-off function will not be obstructed.
5. RAISE THE WEIGHT UP AGAINST THE GUIDE PLATE
6. PRESS THE CLAW DOWN LIGHTLY UNTIL IT ENGAGES THE TRIGGER
7
7. INSERT THE CONE (Small size cones or bars are used on KILN-SITTER)
While holding the claw down over the trigger, carefully place the cone or bar,
selected for your firing, flat on the metal cone supports with the inside edge of the
number circle even with the outside edge of the cone supports. See Figure 8. The
cone or bar should be against the metal step with the center of the cone or bar
parallel with the end of the tube.
Consistent placement of the cone or bar in this manner will lead to consistent firing
control.
The cone or bar now holds the claw engages so that the weight is supported and your
hands are free.
8. CHECK THE POSITION OF THE CONE OR BAR
As a last step before closing the kiln, always check to see that the cone or bar is in
its proper position and free of obstructions. AN IMPROPERLY PLACED CONE OR
BAR COULD CAUSE AN OVERFIRING AND DAMAGE YOUR KILN AND WARE.
9. CLOSE THE KILN All switches are off at this point.
10. REMOVE THE TOP PEEP HOLE PLUG
Venting of the kiln for the entire firing period will add years of life to your KILNSITTER tube assembly. (On large kilns also remove the bottom peephole plug.)
11. INSERT A FINGER INTO THE HOLE IN THE WEIGHT AND PUSH FIRMLY IN ON
THE PLUNGER UNTIL IT LOCKS.
12. WEIGHT CLEARANCE
The area outside the kiln should be clear of obstructions so the free fall of the
weight is not impeded.
13. FIRE THE KILN BY USING THE REGULAR KILN SWITCHES, AS INSTRUCTED
BY THE KILN MANUFACTURER.
DO NOT LEAVE THE KILN UNATTENDED BEYOND THE ESTIMATED FIRING
TIME. An uncontrollable accident, such as greenware falling against the end of the
KILN-SITTER tube may cause an over-firing, which could damage your kiln.
Should this occur, the operatorWITNESS
should be inCONES
attendance to shut of the kiln manually.
8
A pyrometric cone is a slender pyramid composed of materials compounded in selected
combinations to make a cone that will react to time and temperature in the same way as
the ware you place in your kiln. Because different clays and glazes require different heat
treatments to mature properly, pyrometric cones are made in a series of cone numbers
so that one is available to properly control the firing of the clay or glaze you are using.
Even though small cones are always used on the KILN-SITTER, large size cones are
recommended as witness cones when test firing your kiln and KILN-SITTER, and
periodically during normal firing. This will help you determine whether firing shut-off is
just right … too soon (temperature too low) … or too late (temperature too high.) During
the test firing you will also learn your kiln's "personality" or its heat distribution.
For this test firing you will need a plaque,
which is a porous clay base designed to
hold three large size cones at an angle of
8-degrees from vertical. See Figure 12.
(Note: self-supporting cones are also
available.)
A cone, one number cooler than the firing
cone, is place on one side. This is called
the GUIDE CONE. It matures at a
temperature approximately 30-degrees
lower than the firing cone. When it bends,
it serves warning that shut-off time is near.
See Figure 13.
The cone number we wish to fire to is
placed in the middle. It is called the
FIRING CONE. It is the same cone
number as the cone on your KILNSITTER. When it bends over with the tip
close to, but not quite touching, the base,
you know that the desired heat treatment
has been reached. See Figure 14.
9
On the other side is a cone that is one number hotter than the firing cone, It is called the
GUARD CONE. If it bends at all, you know that the kiln has fired beyond the
preselected point.
The plaque of three cones should be placed on a shelf close to the level of the KILNSITTER tube. However, because a shelf supported by stilts is not completely stable,
the height of the shelf should be one inch above or one inch below the tube. This will
prevent a possible jamming of the normal KILN-SITTER shut-off function should the
shelf expand or tilt in the direction of the tube.
After test firing, during normal operations, you may wish to place a plaque on EACH
shelf level, since temperatures vary at different levels within a kiln. When setting your
kiln shelves, follow the kiln manufacturer's instructions. The spacing between shelves
will depend upon the objects you wish to fire. This spacing, as well as the size and
weight of your ware, has an affect on heat distribution.
After firing is completed, you will see some differences in the appearance of the test
plaques. If for example your firing was made with two or more shelves, the lower shelf
will usually show less bending of the cones than the plaque located on a shelf near the
top of the kiln. This range of heat treatment normally will be within the range
recommended for your materials.
The shelf locations, and amount of material placed on each shelf, and the switching
sequence, will have some affect upon the heat distribution in your kiln. But as long as
each plaque of cones show cone values within the range recommended for your
material, you can be sure it is receiving proper heat treatment.
Now fire the kiln in the manner recommended by the kiln manufacturer. Use the proper
switch sequence and follow venting procedures for necessary air circulation.
If witness cones, after the first test fire, appear similar to those illustrated in Figure 14,
you will know that the KILN-SITTER is in proper adjustment. But make a second test
firing exactly as you did before. This will serve as a double check and indicate the
consistency of firing performance.
If the witness FIRING cone is UNBENT, then test fire a second time using a hotter cone
on the KILN-SITTER (one number higher.)
If a second test fire, as recommended above, does not cause proper maturing of the
witness cones, as illustrated in Figure 14, then it is recommended that you recheck all
adjustments, as described in that section and repeat the two test fires.
10
MAINTENANCE OF YOUR KILN-SITTER
Your KILN-SITTER is manufactured from the finest materials available … selected for
strength, durability and resistance to heat and corrosion. However, during the firing
operation, moisture and corrosive gasses are created which can, in time, alter the
normal shut off function. Below are maintenance procedures and operating
recommendations which will keep your KILN-SITTER doing its job. Careful attention to
these instructions will reward you with trouble free firing
NEVER USE LUBRICANTS OF ANY KIND ON THE KILN-SITTER
PERIODIC ADJUSTMENTS
The KILN-SITTER may get out of adjustment during use and we suggest you repeat
an adjustment check every 30 firings as described on Page 3 under "ADJUSTMENTS".
VENTING THE KILN
The top peephole should be left open for the entire firing period. This venting will reduce
deterioration of the kiln's metal parts and increase the life of the tube assembly. (Larger
kilns may need both top and bottom plugs removed.)
CARE OF CONE SUPPORTS
It is important that excess kiln wash not be allowed to accumulate on the supports. We
recommend they be cleaned after every firing with a small wire brush. In the event the
kiln wash or cone glaze cannot be removed, rotate the supports to the clean side or
replace them. We suggest two pair of supports be available. This allows you to prepare
a clean pair while the other pair is being used in the firing.
CARE OF THE SWIVEL/PIVOT (Tube Assembly)
The swivel/pivot of the tube assembly is the most sensitive part of the KILN-SITTER
and can become corroded and contaminated during normal firing. This can cause
sluggish movement of the sensing rod and alter the shut off of the KILN-SITTER. We
recommend, as good insurance against a mishap, that the guide plate be removed and
the swivel/pivot of the tube assembly be examined every 6 to 12 months. The frequency
of inspection depends on the type of firing, clay composition and moisture content, and
humidity in the area. Evidence of contamination or sluggish movement would indicate
immediate replacement of the tube assembly
SENSING ROD
Continued operation at high-fire temperatures will eventually cause the end of the rod to
deteriorate or bend. This will, in turn, affect the adjustment of the trigger and claw. If this
occurs, the rod must be replaced.
OPERATIONAL TEMPERATURE
The KILN-SITTER is engineered to withstand kiln temperature up to and including
Cone 8. Temperatures higher than this limit will reduce the normal lifetime of the cone
supports and sensing rod.
11
REPLACEMENT OF TUBE ~ MODEL P
Should it become necessary to replace the tube in the Model P KILN-SITTER, the
following instructions should be followed
CAUTION: BE SURE POWER IS OFF BEFORE PROCEEDING!
1. Refer to PARTS IDENTIFICATION, Model P, on Page 2 for an exploded illustration
of Model P and the names of its parts.
2. Remove the box from the baffle plate by unscrewing the 1/4-inch machine screws on
the right and left sides (4 screws.)
3. Remove the baffle plate from the kiln by unscrewing the four 3/8-inch metal screws.
The baffle plate with tube assembly attached is now free to be withdrawn from the
opening in the kiln wall.
4. Disassemble the old tube from the baffle plate by removing the large nut and
washer.
5. Remove the nut and washer from the new
tube assembly. Insert the nipple and tube
through the hole in the baffle plate, as shown
in Figure 15. Replace the washer and nut, but
before tightening be sure that the spline
protruding from the baffle plate engages in
the notch at the top of the tube metal jacket. When the nut is tightened, the end of
the nipple threads should be flush with the outer surface of the nut. If necessary, the
nipple can be threaded in or out of the jacket to achieve this adjustment. When these
things are done, tighten the nut firmly.
6. As shown in Figure 16, the rear end of the sensing rod
should be even with or slightly behind the ends of the cone
supports. The setscrew in the swivel assembly may be
loosened if adjustment is necessary. Be sure the setscrew
is firmly tightened.
7. Place the spring wire retainer over the tube and onto the
metal jacket, then the washer. After replacing the baffle
12
plate onto the kiln wall, push the washer and spring wire retainer forward against the
kiln wall.
8. Counterweights are on all tube assemblies except the 2-1/2 inch, 3-inch and K-long
or short tube assemblies. These weights provide a counterbalance that controls the
weight of the sensing rod as it bears on the cone during firing. In this way, firing
performance is equalized between sensing rods of differing lengths.
The counterweight must be positioned up tight against the swivel nipple, held inplace
by the sliding spring grip. See Figure 17.
9. Replace the box assembly. Adjust and test fire the newly installed tube, as described
in the front part of the manual.
13
REPLACEMENT OF TUBE - MODEL K
Should it become necessary to replace the tube in the Model K KILN-SITTER, the
following instructions should be followed.
CAUTION: BE SURE POWER IS OFF BEFORE PROCEEDING!
1. Refer to PARTS IDENTIFICATION, Model K on Page 2 for an exploded illustration
of Model K and the names of its parts.
2. The tube is attached to the front plate by two flat-headed screws that are hidden
behind the metal guide plate. It is therefore necessary to first remove the guide plate
by removing its two screws.
3. Remove the two flat-headed screws, which were hidden behind the guide plate. This
frees the tube from the front plate.
4. Free the front plate from the kiln wiring box by removing its four screws … top and
bottom.
5. The plate can now be pulled forward as far as the wiring will allow. Usually this will
provide enough room to remove the old tube and install its replacement. If the wiring
does not provide sufficient clearance for the tube, it may be necessary to remove the
entire wiring gutter from the kiln.
6. Attach the new replacement tube, Refer to the exploded diagram on the inside back
cover of this booklet for proper positioning of the tube.
7. Replace the front plate onto the kiln wiring box.
8. Counterweights are not needed for the short and long tube assemblies.
9. Adjust and test fire the newly installed tube as described in the front part of the
manual.
14
KILN-SITTER PARTS LIST
MODELS P and K
Part No
1.
2.
3.
4.
5.
6.
6a.
6b.
8.
9.
9a.
15.
16a.
16b.
18.
19.
24.
26.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
40.
42.
43.
44.
45.
46.
47.
48.
68.
70.
70a.
71.
72.
75.
75a.
76.
78.
80.
81.
93.
94.
95.
95a.
95b.
96.
97.
98.
99.
100.
101.
102.
103.
310.
Description
Gauge, Firing
Cone Supports (pair)
Sensing Rod (advise model and kiln wall thickness)
Tube Assy (advise model and kiln wall thickness)
2-1/2 inch
5-inch
3-inch
5-1/2 inch
4-inch
6-inch
4-1/2 inch
7-inch
Washer
Brass Nipple (nipple only)
Brass Nipple with Swivel (short)
Brass Nipple with Swivel (long)
Washer, Tube Nut
Nut, Tube (nut only)
Nut Tube, with Swivel
Plunger Assembly
Claw and Set Screw
Guide Plate (plate only)
Screw, 6-32 x 1/4
Set Screw, 6-32 x 1/8
Paper Washer Center Post
Spring, Center Post
Set Screw, 8-32 x 3/8
Pivot Pin
Lock
Spring, Lock
Retainer, Lock Spring
Screw, 4-40 x 1/4
Retainer, Locking Cam or Lock
Screw, Lock Spring 4-40 x 1/8
Screw, #6 x 3/8 Self-Tapping
Screw, #8 x 3/8 Self-Tapping
Box, Large Opening (LT-3-P)
Heat Baffle, Off Center Hole (LT-3-P)
Retainer, Spring Ring
Counterweight, Tube (P and LT-3) 4-Inch
Counterweight, Tube (P and LT-3) 5-Inch
Counterweight, Tube (P and LT-3) 4-1/2 and 5-1/2 Inch
Counterweight, Tube (P and LT-3) 6-Inch
Counterweight, Tube (P and LT-3) 7-Inch
Spring Grip
Tube Assy, Short K & LT-3K (6" from end of porcelain to end of bracket)
Tube Assy, Short K & LT-3K (7" from end of porcelain to end of bracket)
Screw, Center Post 6-32 x 5/16
Lock Washer, Center Post Screw
Center Post
Center Post Assy (Items 24, 26, 71, 72 and 75)
Nut, Switch Mounting 4-40 Radio
Stand-Off Bushing, Switch Mounting
Screw, Flat Head 6-32 x 5/16
Screw, Switch Mounting 4-40 x 1-1/2 Oval Head
Nylon Washer, Switch Mounting
Switch Block (block only)
Switch Block, with Contacts, less Center Post and Spring
Switch Block Assy, with Contacts, Center Post and Spring
Switch Block Assy, #95a with Item 15 Plunger Assembly
Rear Contact, Modified
Nylon Washer, Contact
Nut, Contact
Screw, 10-32 x 3/8
Front Plate Assy, P (Items 29, 30, 102, 103, less 16a and 16b)
Front Plate Assy, K (Items 29, 30, 102, 103, less 16a and 16b)
Trigger, 1/16 x 3/4 x 1-1/8
Weight, 1/16 x 3/4 Cavity (weight only)
Bracket, Tube
15
U.S. Patent Nos. 2,675,600, 3,287,530
& 4,464,548

Cone
No.
022
021
020
019
018
017
016
015
014
013
011
010
09
08
08
07
Large Cones
108°F*
270°F*
1069°F 1086°F
1116
1137
1157
1175
1234
1261
1285
1323
1341
1377
1407
1458
1454
1479
1533
1540
1596
1566
1591
1623
1627
1641
1629
1641
1679
1693
1733
1751
1783
1803
Cone
No.
06
05
04
03
02
01
1
2
3
4
5
6
7
8
9
10
Large Cones
108°F*
270°F*
1816°F
1830°F
1888
1915
1922
1940
1987
2014
2014
2048
2043
2079
2077
2109
2088
2124
2106
2134
2134
2185
2151
2285
2194
2232
2219
2264
2257
2305
2300
2336
2345
2381
*Rate of Heating (Example: 108°F rise per hour)
Notes:
1) The rates of heating shown at the head of each column of
temperature equivalents were maintained during the last several
hundred degrees of temperature rise.
2) The temperature equivalents are not necessarily those at which
cones will deform under firing conditions different from those under
which the calibrating determinations were made. For more detailed
technical data, please write the Orton Foundation.
W.P. DAWSON, INC.
399 Thor Place
Brea, California 92821-4133
Tel: (714) 529-2813
FAX: (714) 529-3254
email: [email protected]
Internet: www.kilnsitter.com
CONE CHART REPRODUCED BY PERMISSION OF THE EDWARD ORTON JR CERMIC FOUNDATION
 Booklet Copyright 2000 ~ W.P. Dawson Inc.
TEMPERATURE EQUIVALENTS FOR
ORTON STANDARD PYROMETRIC CONES
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