Operating Instructions
Operating Instructions
Top Loader Top ...,
Top Loader HO ...,
Fusing Top Loader F ...
-> 04.2010
Original instructions
 Made
 in
 Germany
www.nabertherm.com
Copyright
 Copyright by
Nabertherm GmbH
Bahnhofstrasse 20
28865 Lilienthal
Federal Republic of Germany
Reg:
Rev:
M01.0029 ENGLISCH
2010-12
No responsibility is accepted for the correctness of this information. We
reserve the right to make technical alterations.
2
1 1.1 1.2 1.3 1.4 Introduction ........................................................................................................................................................... 5 Product Description ........................................................................................................................................... 6 Overview of the Complete Oven ....................................................................................................................... 7 Key to the Model Names ................................................................................................................................... 9 Scope of Delivery ............................................................................................................................................ 10 2.1 Specifications ....................................................................................................................................................... 11 Warranty and Liability .................................................................................................................................... 12 2 3 Safety .................................................................................................................................................................... 13 3.1 Explanation of the Symbols and Warnings ..................................................................................................... 13 3.2 Intended Use.................................................................................................................................................... 16 3.3 Requirements for the Oven Operator .............................................................................................................. 17 3.4 Protective Clothing.......................................................................................................................................... 17 3.5 Basic Measures During Normal Operation ..................................................................................................... 18 3.6 Basic Measures in Case of Emergency ........................................................................................................... 18 3.6.1 What to do in an Emergency ....................................................................................................................... 18 3.7 Basic Measures for Servicing and Maintenance.............................................................................................. 19 3.8 General Risks with the Oven ........................................................................................................................... 20 4 Transportation, Installation, and Commissioning ............................................................................................ 21 4.1 Delivery ........................................................................................................................................................... 21 4.2 Unpacking ....................................................................................................................................................... 22 4.3 Transportation Securing Equipment/Packaging .............................................................................................. 24 4.4 Constructional and Connection Requirements ................................................................................................ 25 4.4.1 Installation (Oven Location) ....................................................................................................................... 25 4.5 Assembly, Installation, and Connection .......................................................................................................... 26 4.5.1 Assembling the Base Extension (Accessory) .............................................................................................. 26 4.5.2 Assembling the Castors .............................................................................................................................. 27 4.5.3 Assembling the Bypass Connection ............................................................................................................ 29 4.5.4 Waste Gas System ...................................................................................................................................... 30 4.5.5 Connecting the Oven to the Power Supply ................................................................................................. 31 4.6 Commissioning ............................................................................................................................................... 33 4.7 Recommendations for Heating the Oven for the First Time ........................................................................... 33 5 Operation ............................................................................................................................................................. 34 5.1 Controller ........................................................................................................................................................ 34 5.2 Opening and Closing the Lid .......................................................................................................................... 35 5.3 Fresh Air Valve ............................................................................................................................................... 36 5.4 Loading/charging ............................................................................................................................................ 37 5.4.1 Tips for Potters ........................................................................................................................................... 37 5.4.2 Bisque Firing .............................................................................................................................................. 38 5.4.3 Glaze Firing ................................................................................................................................................ 38 5.4.4 Reduction Firing ......................................................................................................................................... 39 6 6.1 6.2 6.3 6.4 6.5 Servicing, Cleaning, and Maintenance .............................................................................................................. 39 Shutting Down the Oven for Servicing, Cleaning, and Maintenance.............................................................. 39 Regular Maintenance of the Oven ................................................................................................................... 41 Adjusting the Lid............................................................................................................................................. 42 Adjusting the Tensioning Straps ..................................................................................................................... 43 Separate the Snap-In Coupling (Plug) from the Furnace Housing .................................................................. 43 3
6.6 Cleaning Products ........................................................................................................................................... 44 7 Faults .................................................................................................................................................................... 45 8 Spare Parts/Wearing Parts ................................................................................................................................. 48 9 Electrical Connections (Circuit Diagram) ......................................................................................................... 48 10 Accessories (Options) .......................................................................................................................................... 49 11 Nabertherm Service ............................................................................................................................................ 50 12 Shut-Down, Dismantling, and Storage............................................................................................................... 51 12.1 Environmental Regulations ............................................................................................................................. 51 12.2 Transportation/Return Transportation ............................................................................................................. 52 13 Declaration of Conformity .................................................................................................................................. 53 14 For Your Notes .................................................................................................................................................... 54 4
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1
Introduction
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Dear Customer,
Thank you for choosing a quality product from Nabertherm GmbH.
You can be proud that you have chosen an oven which has been especially tailored to suit
your manufacturing and production conditions.
This product is characterized by

professional workmanship

high performance due to its high efficiency

high-quality insulation

low power consumption

low noise level

simple installation

easy to maintain

high availability of spare parts
Your Nabertherm Team
Note
These documents are intended only for buyers of our products and may not be copied or
disclosed to third parties without our written consent.
(Law governing copyright and associated protective rights, German Copyright Law from
Sept. 9, 1965)
Protective Rights
Nabertherm GmbH owns all rights to drawings, other documents and authorizations, also in
case of applications for protective rights.
Note
All the figures in the instructions have a descriptive character; in other words, they do not
represent the exact details of the oven.
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5
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1.1
Product Description
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This top loader kiln is a quality product which will give you many years of reliable service
if it is properly cared for and maintained. One basic requirement is that the kiln is used for
the purposes for which it was intended. During development and production high priority
was placed on safety, functionality and economy.
Kilns in the Top loader Top …, Top loader HO … and Fusing top loader F … series are
electrically heated kilns for ceramics, glass fusing, glass and porcelain painting. These kiln
models have an appealing design, are lightweight and produce good firing results. The right
kiln for hobby artists or small workshops.
Other features of this product are:


















Heating elements embedded in grooves, heating from all sides
Top-quality heating elements, optimum wire gauge and length for long life
Solid state relays provide for low-noise heater operation
Rapid switching cycles result in precise temperature control
Type S thermocouple
Lid interlock safety switch
Multiple layers of insulation for low power consumption and low exterior
temperatures
Models Top 60eco ff. with special high-grade, energy-saving backing insulation
Lightweight refractory bricks inside kiln chamber for clean firing results
Housing made of sheets of textured stainless steel
Lid with adjustable quick-release lock and padlock hasp
Lid heating for direct radiation of the charge (fusing top loaders F 30 – F 220)
Wear-free lid seal (brick on brick)
Powerful gas dampers make lid opening very easy
Infinitely adjustable air inlet in opening in the kiln bottom for good ventilation and
short cooling times
Exhaust air outlet on furnace side with stub for pipe of diameter 80 mm
Lockable castors for easy transport of kiln without the need for lifting
GS safety mark for certified safety, CE
Additional equipment
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6


Bottom heating for very good temperature uniformity for Top 140 and Top 190
Two-zone control of heating via P 310 controller

Raised base for Top 45/ Top 60 and F 75/F 110
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1.2
Overview of the Complete Oven
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Bypass connection (Top model only)
Adjustable lid closure
Handle
Lid
Type S thermocouple
Heating element
Power plug (up to 3600 watts)
Power plug (from 5500 watts)
Insulation
Controller
Power switch
(to switch the kiln on and off)
Supply air valve (Top model only)
Castor
Castor with locking brake
Example: Top loader model Top 60
Lid heating
(Fusing top loader F …)
Base frame (Model Top 220 /
Fusing top loader from Model F 75)
Example: Fusing top loader Model F 30
Example: Fusing top loader Model F 110
Fig. 1: Example: Top loader model Top … and Fusing top loader Model F …
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7
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Bypass connection
Lid
Handle
Type S thermocouple
Controller
Power switch
(to switch the kiln on and off)
Power plug (up to 3600 watts)
Power plug (from 5500 watts)
Adjustable lid closure
Castor
(with locking brake from Model
HO 70.. + HO 100)
Sliding air inlet plate
Heating element
Insulation
Fig. 2: Example: Hobby kiln Model HO 100
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8
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1.3
Key to the Model Names
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Example
Explanation
Top 60/Leco
Top = Top loader
HO = Hobby
F = Fusing top loader
Top 60/Leco
X
= Liters kiln chamber (volume in liters)
Top 60/Leco
L = low
LE = low energy
R = rapid
Top 60/Leco
eco = economy
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Top 60/ L eco
Top0603BN1
230 V 1/N/PE~
www.nabertherm.de
SN xxxxxx
1200 °C 2010
12.8 A 50/60 Hz 2.9 kW
Made in Germany
Fig. 3: Example: Model name (type plate)
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9
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1.4
Scope of Delivery
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The scope of delivery includes:
Kiln components
Quantity
Comment
-Kiln model Top …,
-Kiln model HO … or
-Kiln model F …
1x
Nabertherm GmbH
Power cable 1)
1x
Nabertherm GmbH
Bypass connection 1)
(only top loaders Top and HO)
1x
Nabertherm GmbH
Ceramic shelves
(691600956 – 80x80x10 mm)
3x
Nabertherm GmbH
Castors
4 to 7x 3)
Nabertherm GmbH
Open-end wrench
1x
Nabertherm GmbH
Hex key
1x
Nabertherm GmbH
Adjustable base 1)
( for kiln models Top 45/60 or F 75/F 110)
1x
Nabertherm GmbH
Shelve/s 2) for kiln models Top, HO and F
4)
Nabertherm GmbH
Props 2)
4)
Nabertherm GmbH
Other components, variable depending on the
particular kiln
---
See the shipping
documents
Document type
Quantity
Comment
Kiln operating manual
1x
Nabertherm GmbH
Controller operating manual
1x
Nabertherm GmbH
Other documents, variable depending on the
particular furnace
---
Accessories:
1)
2)
3)
4)
= in delivery scope depending on the design/kiln model
= in delivery scope as required, see shipping documents
= quantity depends on kiln model
=.quantity as required, see shipping documents
Note
Store all documents carefully. All the functions of this kiln were tested during
manufacturing and prior to shipping.
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10
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2
Specifications

Electrical specifications are on the type plate located on the side of the oven.
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Kiln model Top
Model
Tmax Inner dimensions
°C
in mm
w
d
h
Ø 290
230
1300
Top 16/R
340
1300
Ø 410
Top…45eco
340
1300
Ø 410
Top 45
460
Ø 410
Top 60/Leco 1200
460
1200
Ø 410
Top 60
460
1300
Ø 410
Top 60eco
460
1300
Ø 410
Top 60/R
460
1300
Ø 480
Top 80
570
1300
Ø 480
Top 100
460
1300
Ø 590
Top 130
570
1300
Ø 550
Top 140
570
1300
Ø 590
Top 160
690
1300
Ø 590
Top 190
Top 220
1300 930 590 460
1) = Heating only between two phases
Outer dimensions
in mm
W
D
H
440
580
580
580
580
580
580
660
660
770
730
770
770
1100
590
820
820
820
820
820
820
900
920
1040
990
1040
1040
1020
530
760
760
870
870
870
870
890
1000
920
1020
1030
1150
950
Volume
in L
Connected
load/kW
Electrical
connection
Weight
in kg
16
45
45
60
60
60
60
80
100
130
140
160
190
220
2.6
2.9
3.6
2.9
3.6
3.6
5.5
5.5
7.0
9.0
9.0
9.0
11.0
15.0
1-phase
1-phase
1-phase
1-phase
1-phase
1-phase
3-phase 1)
3-phase
3-phase
3-phase
3-phase
3-phase
3-phase
3-phase
32
62
62
72
72
72
72
100
102
110
124
130
146
150
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Kiln model F
Model
Tmax Inner dimensions
°C
in mm
w
d
h
Outer dimensions
in mm
W
D
H
Footprint
in m2
Connected
load/kW
Electrical
connection
Weight
in kg
F 30
F 75 L
F 75
F 110
F 220
950
950
950
950
950
650
950
950
1120
1120
0.13
0.33
0.33
0.47
0.47
2.0
3.6
5.5
7.5
15.0
1-phase
1-phase
3-phase
3-phase
3-phase
50
80
80
95
115
Ø
750
750
930
930
410
520
520
590
590
230
230
230
230
460
800
880
880
950
950
500
680
680
680
910
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90
90
h
Ø
H
w
65
h H
65
W
W
d D
D
Fig. 4:
Top 16 – 190 / F 30
Top 220 / F 75 – F 220
11
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Kiln model HO
Model
Tmax Inner dimensions
Outer dimensions
°C
in mm
in mm
w
d
h
W
D
H
HO 70/L
1200 440 380 420
HO 70/R
1300 440 380 420
HO 100
1300 480 430 490
HO 300
1300 920 570 610
1) = Heating only between two phases
640
640
680
320
770
770
820
1440
780
780
850
1015
Volume
in L
Connected
load/kW
Electrical
connection
Weight
in kg
70
70
100
320
3.6
5.5
5.5
15.0
1-phase
3-phase 1)
3-phase 1)
3-phase
120
120
160
430
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h
w
90
H
d
200
65
W
D
Fig. 5: Dimensions of model HO
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Voltage (V)
Electrical connection
Kiln model
Frequency:
Thermal protection class
Kilns:
Protection rating
Protection type
Ambient conditions for
electrical equipment
Weights
Kilns:
Temperature:
Humidity:
Kiln with accessories
1-phase:
3-phase:
Special voltage:
See type plate on kiln
50 or 60 Hz
according to DIN EN 60519-2
without safety controller: Class 0
(in case of fault, no protection for kiln or charge)
with safety controller:
Class 2
(in case of fault, kiln and charge protected)
1
IP20
+5 °C to +40 °C max. 80% non
condensing
Varies (see shipping documents)
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Continuous sound pressure
level:
Emissions
< 80 dB(A)
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2.1
Warranty and Liability
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§
As regards warranty and liability, the normal Nabertherm warranty terms apply,
unless individual terms and conditions have been agreed. However, the following
conditions also apply:
Warranty and liability claims for personal injury or damage to property shall be excluded if
they are attributable to one or more of the following causes:

12
Everyone involved in operation, installation, maintenance, or repair of the oven must
have read and understood the operating instructions. No liability will be accepted for
damage or disruptions to operation resulting from non-compliance with the operating
instructions.

Not using the oven as intended,

Improper installation, start-up, operation, or maintenance of the oven,

Operation of the oven with defective safety equipment or improperly installed or nonfunctioning safety and protective equipment,

Not observing the references in the operating instructions to transportation, storage,
installation, start-up, operation, maintenance, or equipping the oven,

Making unauthorized changes to the oven,

Making unauthorized changes to the operating parameters,

Making unauthorized changes to the parameterization, the settings, or the program,

Original parts and accessories are designed especially for Nabertherm ovens. Replace
parts only with original Nabertherm parts. Otherwise the warranty will be void.
Nabertherm accepts absolutely no liability for damage caused by using parts that are
not original Nabertherm parts.

Catastrophes due to third-party causes and force majeure.
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3
Safety
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3.1
Explanation of the Symbols and Warnings
Note
In the following operating instructions, specific warnings are given to draw attention to
residual risks that cannot be avoided when the oven is operating. These residual risks
include dangers for humans/products/ the oven, and the environment.
The symbols used in the operating instructions are especially intended to draw attention to
safety information.
The symbols used cannot replace the text of the safety information. Therefore, always read
the entire text.
Graphic symbols correspond to ISO 3864. In accordance with the American National
Standard Institute (ANSI) Z535.6 the following warning information and words are used in
this document:
The general hazard symbol, in combination with the words CAUTION, WARNING and
DANGER warns about the risk of serious injury. Observe the following information to
prevent injury or death.
NOTICE
CAUTION
Refers to a hazard that could damage or destroy the equipment.
Refers to a hazard with a minor or medium risk of injury.
13
WARNING
Refers to a hazard that could cause death, serious or irreversible injury.
DANGER
Refers to a hazard that could directly cause death, serious or irreversible injury.
Structure of the warning: All warnings are structured as follows
Hazard symbol
Indicates the risk of injury
Signal word
Classifies the danger
WARNING
• Type and source of the danger
• Consequences of non-compliance
• Action to prevent danger
Graphical symbols (optional)
according to ISO 3864:
Consequences, measures, and
prohibitions
Reference texts:
• Type and source of the danger
• Possible consequences of noncompliance
M
/P hibiti
or
Hazard symbol
Indicates the risk of injury
Signal word
Classifies the danger
DANGER
• Type and source of the danger
• Consequences of non-compliance
• Action to prevent danger
Graphical symbols (optional)
according to ISO 3864:
Consequences, measures, and
prohibitions
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Graphical symbols
(optional) according to ISO
3864:
Instructions or prohibitions
Reference texts:
• Type and source of the danger
• Possible consequences of noncompliance
• Measures/prohibitions
Information Symbols in the Instructions:
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Note
Below this symbol you will find instructions and particularly useful information.
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14
Rule - Rule Sign
This symbol draws attention to important rules that must be followed. Rule signs protect
people against injury and show what is to be done in certain situations.
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Rule - Important Information for Operators
This symbol draws the operator's attention to important information and operating
instructions that must be followed.
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Rule - Important Information for Maintenance Personnel
This symbol draws the maintenance personnel's attention to important operating and
maintenance instructions (service) that must be followed.
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Rule - Pull Out the Power Plug
This symbol tells the operator to pull out the power plug.
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Rule - Lift only with Several People
This symbol draws the personnel's attention to the fact that this device may only be lifted
and moved to its final destination by several people.
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Warning - Hot Surface, Do Not Touch
This symbol warns the operator that the surface is hot and should not be touched.
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Warning - Danger of Electric Shock
This symbol warns the operator that there is a risk of an electric shock if the following
warnings are not heeded.
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Warning – Danger if Heavy Loads Are Lifted
This symbol warns the operator of the potential dangers of lifting heavy loads. Ignoring this
can lead to injury.
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Warning - Fire Danger
This symbol warns operators of the danger of fire if the following information is not
followed.
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Prohibited - Important Information for Operators
This symbol warns the operator that water or cleaning products must NOT be poured over
the objects. A high-pressure cleaning device must also not be used.
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Warning Signs on the Oven:
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Warning - Hot Surface, Danger of Burning – Do Not Touch
You may not always realize that surfaces, such as oven components, oven walls, doors and
materials, and even liquids are hot. Do not touch the surface.
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Warning - Danger of Electric Shock!
Warning, dangerous electric voltage
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15
3.2
Intended Use
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Safety
This Nabertherm kiln was designed and built to comply with various carefully chosen
harmonized standards and technical specifications. Hence, it corresponds to the state of the
art and assures the greatest level of safety.
Kilns in the Top and HO series are electrically heated kilns for firing ceramics, glass
fusing, glass and porcelain painting. Kilns in the F series are for glass fusing, glass and
porcelain painting.

Any other use, such as processing of products other than those for which the kiln was
intended as well as handling hazardous materials or materials dangerous to health is
deemed IMPROPER and such uses must be approved in writing by Nabertherm.

Under certain circumstances gases or materials may be released from the materials in
the kilns that settle on the insulation or the heating elements and destroy them. If
applicable, read the labels and instructions on the packaging of materials that
you use.

Changes to the kiln require the written approval of Nabertherm. Protective
components (if applicable) must not be removed, overridden, or deactivated.

The set-up instructions and safety regulations must be followed, otherwise the kiln
will be considered improperly used, effectively cancelling any claims against
Nabertherm GmbH.

The kiln must not be opened when it is hot (above 200 °C). If it is opened above
200 °C, the kiln can be destroyed or it can lead to increased wear of the following
components: door seal, heating elements, and kiln housing
Operation with power sources, products, operating equipment, auxiliary materials, etc.,
which are listed as hazardous or which may in any way harm the health of the operator is
prohibited.
The kiln must not be filled with materials or substances that release explosive gases or
vapors. Only materials and substances whose properties are known may be used.
This kiln was designed for private and commercial use. The kiln is NOT to be used for
heating food, animals, wood, grains, etc.
The kiln must NOT be used to heat the workplace.
Do NOT use the kiln to melt ice or for similar purposes.
Do NOT use the kiln as a clothes dryer.
Note
Applicable safety instructions are contained in the individual chapters.
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16
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3.3
Requirements for the Oven Operator
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The set-up instructions and safety regulations must be followed, otherwise the kiln will be
deemed to have been used improperly, effectively cancelling any claims against
Nabertherm GmbH.
This level of safety can be achieved only if all the necessary measures have been taken. It
depends on the kiln operator's diligence in planning these measures and controlling how
they are carried out.
The operator must ensure that

This kiln is NOT used by certain persons (including children) with restricted
physical, sensorial or mental capabilities or who have insufficient experience
and/or insufficient knowledge, unless they are supervised by a person who is
responsible for their safety or are instructed in how to use the kiln. Children
should be supervised to make sure that they do not play with the kiln.

When ceramics, clay, or glaze are fired, they can emit gases and vapors that are
harmful to your health. It is therefore necessary to make sure that the "exhaust gases"
emitted from the exhaust air opening are directed outdoors in a suitable manner
(ventilate the working area). If adequate ventilation cannot be ensured at the working
area, the "exhaust gases" must be removed via a pipe (see "Exhaust Gas System").

Before placing materials in the kiln, check whether they could harm or destroy the
insulation or the heating elements. Materials that could damage the insulation include:
alkalis, alkaline earths, metal vapors, metal oxides, chlorine compounds, phosphorous
compounds, and halogens. If applicable, read the labels and instructions on the
packaging of materials that you use.

The kiln is operated only in a perfect operating condition and, in particular, that the
functions of the safety components are checked regularly.

Necessary personal protective equipment is available. Example: protective gloves,
suitable apron, etc.

This instruction manual is to be kept beside the kiln. These instructions must be
available at all times for anyone working with or on the kiln;

All the safety and operating instruction signs on the kiln can be read properly.
Damaged or unreadable signs must be replaced immediately,

Personnel are informed regularly about all issues involving occupational safety and
environmental protection and are familiar with all the operating instructions,
especially those involving safety,

If the kiln is used commercially:
Observe the safety regulations applicable in your country. In Germany, the kiln must
be checked by a qualified electrician at defined intervals in accordance with a
regulation issued by the employers' accident insurance fund.
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Note
In Germany, the general accident protection guidelines of VBG or BGZ must be observed.
The national accident prevention regulations of the country of operation apply.
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3.4
Protective Clothing
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Wear heat-resistant gloves to protect your hands.
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17
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3.5
Basic Measures During Normal Operation
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Risks during normal operation
Before switching the kiln on, check and ensure that only authorized persons are in the
working area of the kiln and that no one can be injured as a result of operating the kiln.
Each time, before starting production check and ensure that all the safety equipment
functions as intended (for example, that the contact safety switch switches the heating off
when the lid is opened).
Before starting production each time, check the kiln for obvious damage and ensure that it
is operated only in a perfect condition. Report any defects to Nabertherm Service
immediately.
Before starting production each time, remove all materials and objects that are not needed
for production from the working area.
At least once every day (see also Servicing and Maintenance) check the following:

Check the kiln for obvious external damage (visual check), for example insulation,
heating elements, power cable, exhaust gas system, if applicable.

Check that all safety equipment is functioning (for example, that the contact safety
switch switches the heating off when the lid is opened).
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3.6
Basic Measures in Case of Emergency
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3.6.1 What to do in an Emergency
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Note
The power plug is to be pulled out to stop the oven in case of an emergency. Therefore,
the power plug must be accessible at all times when the oven is operating so that it can be
pulled out quickly in case of an emergency.
A
Design
A = Grounded plug
B = CEE plug
Fig. 6: Example: Remove power plug
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18
Risks during Normal Operation!
Switch the oven off immediately in case of unexpected occurrences in the oven (e.g. a lot of
smoke or unusual smells). Wait until the oven has cooled naturally to room temperature.
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In case of fire, keep
lid closed.
Immediately remove
the power plug.
Keep doors and
windows closed. This
prevents smoke
spreading.
Immediately notify the
fire service, regardless
of the extent of the fire.
When you phone the
fire service, remain
calm and speak clearly.
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DANGER
• Danger of electric shock.
• Risk of fatal injury.
• Work on electrical
equipment may be carried out only by
qualified electricians
or by trained personnel authorized by
Nabertherm.
• Before starting work, pull out the
power plug
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3.7
Basic Measures for Servicing and Maintenance
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Maintenance work must be performed by authorized persons, following the maintenance
instructions and the accident prevention regulations. We recommend that the maintenance
and repair work be carried out by the service team of Nabertherm GmbH. Non-compliance
may cause injuries, death, or considerable damage to property.
Switch the kiln off at the power supply and pull out the plug.
The kiln must be completely empty.
When cleaning kilns, control cabinets, or electrical equipment housings, never spray them
with water.
When maintenance or repair work has been completed, before recommencing production
ensure the following:

Check that loosened screw connections/tensioning straps have been re-tightened,

Reinstall protective equipment, screens, and filters If applicable),

Remove all material, tools, and other equipment used for the maintenance or repair
work from the working area of the kiln,

Power cables may be replaced only with similar, approved cables.
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19
3.8
General Risks with the Oven
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• Bypass connection/exhaust air pipe/lid/handle all become hot when the kiln is
operating.
• Danger of burning.
• Do NOT touch the bypass connection/exhaust air pipe/lid/handle when the kiln is
operating.
• Do not insert objects into the openings in the kiln housing, the exhaust air
holes or the cooling slits of the switchgear or the kiln.
• Danger of electric shock.
• Do NOT insert any objects.
• Danger of electric shock
• Risk of fatal injury
• The kiln must NOT become wet during operation or maintenance
• Danger of explosion from materials in the kiln
• Risk of fatal injury
• Do NOT insert explosive substances into the kiln when it has reached its operating
temperature.
• NO explosive dusts or solvent-air mixtures inside the kiln.
• Do NOT operate the kiln in areas where there is a risk of explosion.
• NO explosive dusts or solvent-air mixtures in the surrounding area.
• Fire hazard if an extension cable is used
• Risk of fatal injury
With 230 V kiln models make sure that:
• The distance between the circuit breaker and the power socket that the kiln is
connected to is as short as possible.
• NO power board or extension cable is used between the power socket
and the kiln.
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Risks during normal operation
Do not place objects on top of the kiln. There is a risk of fire or explosion.
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20
4
Transportation, Installation, and Commissioning
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4.1
Delivery
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Check that everything is complete
Compare the delivered items with the delivery note and the purchase order documents.
Immediately notify the carrier and Nabertherm GmbH of any missing or damaged parts, as
complaints at a later date cannot be acknowledged.
Danger of injury
When the kiln is being lifted, parts of the kiln or the kiln itself could topple over, slip, or
fall. Before the kiln is lifted, make sure no one is in the working area. Appropriate
protective gloves must be worn.
Safety Instructions

Industrial trucks (e.g.: crane/pallet truck) must be operated only by authorized
personnel. The operator bears sole responsibility for safe operation and the load.

When the kiln is being lifted, make sure that the ends of the forks or the load do not
catch on neighboring goods. Use a crane to move tall parts, such as control cabinets.

Lifting gear must be attached only to positions that have been designated for this
purpose.

Attachments, piping, or cable conduits must never be used to affix lifting gear.

Attach transportation equipment only to positions intended for this purpose.
Note
Wear protective gloves when installing the kiln.
Risks during normal operation
Suspended loads are dangerous. Working beneath a suspended load is prohibited. There is a
risk of fatal injury.
Note
Safety and accident prevention guidelines applicable for forklift trucks must be followed.
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Transportation with a Pallet Truck
Observe the maximum permitted capacity of the pallet truck.
1.
2.
Our ovens are delivered ex works on wooden frames to facilitate unloading.
Transport the oven in its original packaging and with suitable equipment to prevent
any damage. Remove the packaging only when the oven is in its final location.
When transporting the oven, make sure it is secured against sliding, toppling over,
and damage. The oven should be transported and installed by at least two persons.
Do not store the oven in damp rooms or outdoors.
Push the pallet truck underneath the transportation frame. Make sure that the pallet
truck is completely beneath the frame. Pay attention to neighboring goods.
21
Fig. 7: Pallet truck is pushed completely beneath the transportation frame
3.
4.
5.
Lift the oven carefully and pay attention to its center of gravity. When the oven is
being lifted, make sure that the ends of the forks or the load do not catch on
neighboring goods.
Make sure that the oven is balanced safely; if not, attach securing equipment. Push
the oven carefully, slowly and with the pallet truck at its lowest position. Do not
transport the oven on inclines.
Carefully lower the oven at its final position. Pay attention to neighboring goods.
Try not to set it down too abruptly.
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CAUTION
• Device may slip or topple over.
• Damage to the device.
• Risk of injury from lifting
heavy loads.
• Transport device only in original
packaging.
• Several people must carry the device.
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4.2
Unpacking
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Note
The oven packaging prevents damage during transportation. Make sure that you remove all
packaging material (also inside the oven chamber). Keep the packaging and transportation
securing equipment in case it is needed for future transportation or storage.
At least two people are needed to carry/transport the oven, more for larger ovens.
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Wear protective
gloves
1
22
2
2
1.
2.
3.
3
Check the transportation packaging for any signs of damage.
Remove straps from the transportation packaging.
Loosen the screws and remove the wooden frame from the cardboard box (if
applicable)
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4
5
4.
5.
Carefully lift the cardboard box and remove it from the pallet. Compare the
delivered items with the delivery note and the order documents, see "Delivery".
The pallet contains a packaging unit for accessories (Example: power cable, bypass
connection, ceramic shelves, castors and tools to assemble the castors and the bypass
connection).
A
6
6.
7.
7
Remove the top protective film A from the kiln.
To carry the kiln, place your hands beneath the kiln on the side (near the feet) and
make sure that you have a good grip. Wear protective gloves when installing the
kiln. Keeping your back straight, lift the kiln from the pallet and carefully lower it at
23
the point where it is to be installed. The kiln should be transported by at least 2
people.
A
8
8.
Remove the protective film that protects the insulation between the kiln and the
lid. A Make sure that you remove all the packaging material. Keep the packaging
and transportation securing material (if applicable) in case it is needed for future
transportation or storage of the kiln.
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CAUTION
• Device may slip or topple over.
• Damage to the device.
• Risk of injury from lifting
heavy loads.
• Transport device only in original
packaging.
• Several people must carry the device.
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4.3
Transportation Securing Equipment/Packaging
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Note
No special transportation securing equipment is available for this oven
The oven packaging prevents damage during transportation. Make sure that you remove all
packaging material (also inside the oven chamber). All packaging material can be recycled.
The packaging was designed so that no special description is necessary.
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Safety information
Do not allow children to play with packaging parts. They are at risk of suffocation from
folding boxes and plastic film.
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24
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4.4
Constructional and Connection Requirements
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4.4.1 Installation (Oven Location)
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When the kiln is being installed, these safety instructions must be followed:
 The kiln must be installed in a dry room as stated in the safety instructions.
 The surface (floor or bench) where the kiln is to be installed must be level to permit
the kiln to stand upright. Place the kiln on a non flammable surface (fire safety
class A DIN 4102 – Example: concrete, tiles, glass, aluminum or steel) so that any
hot material falling from the kiln cannot ignite the surface.
 The load-bearing capacity of the bench (e.g. bench-top model Top 16/R) must be
sufficient to take the weight of the kiln and accessories.
Non-flammable surface
Bench (accessory)
Fig. 8: Example: Non flammable surface
Top 16/R
In spite of its good insulation, the kiln radiates heat from its outer surfaces. If necessary,
this heat must be dissipated (contact a ventilation engineer if necessary). Flammable
materials must be kept at least 0.5 m (safety distance S) away from the kiln. In some
cases, the distance must be greater because of specific local conditions. The minimum
distance between the kiln and non-flammable materials may be reduced to 0.2 m at the
sides. If the charge emits gases or vapors, ensure adequate ventilation at the installation site
and/or a suitable exhaust air venting system. If required, the customer must provide a
suitable vent for combustion exhaust gases.
S
S
S
Fig. 9: Minimum safety distance to flammable materials
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25
DANGER
• Fire- danger to health.
• Risk of fatal injury.
• Adequate ventilation must be ensured at the
installation location to conduct waste heat and any
exhaust gases away.
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Note
Before starting the oven for the first time, allow it to acclimatize at its installation location
for 24 hours.
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4.5
Assembly, Installation, and Connection
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4.5.1 Assembling the Base Extension (Accessory)
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Base Extension for Fusing Top Loader Model F …
Remove the base from the packaging and compare the parts with the list below.
No.
1
2
3
4
5
Quantity
2
2
4
8
1
Name
Brace, long
Brace, short
Feet with castors, two with locking brake
Collar screw M8
Open-end wrench
2
4
5
1
3
Fig. 10: Parts of the base




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26
Assemble one foot 3 with two screws 4 (with one long 1 and one short 2 brace).
Loosely tighten the screws with the supplied tool 5 .
Assemble the other feet and braces. When all the feet and braces are assembled,
tighten the screws.
Screw the castors that you removed on to the bottom of the feet (see "Assembling the
Castors").
Carefully place the kiln on to the frame. Wear protective gloves and lift the kiln only
by the base. At least two people are needed to lift the kiln, more for heavier kilns.
Base Extension Top Loader Model Top …
Remove the base from the packaging and compare the parts with the list below.
No.
3
Quantity
2
Name
Base extension Top 45/Top 60
3
2
1
4
Fig. 11: Assembling the base extension

Remove the castors 1 from the kiln feet using a suitable tool (open end-wrench SW
13) (For assembly advice regarding the castors, see "Assembling the Castors")

Carefully loosen the sleeves 2 (on the kiln feet) with a wide screwdriver and hammer
for example.

Insert the two base extensions 3 on to the kiln feet. Make sure that the base extension
sits firmly.

Screw the castors that you removed 4 on to the bottom of the feet (see
"Assembling the Castors").
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4.5.2 Assembling the Castors
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If required, the castors that are delivered can be attached to the kiln feet. We recommend
that the castors with the locking brake are attached to the front of the kiln. The number of
castors depends on the number of feet and varies depending on the kiln model. Kiln model
Top 16/R (bench-top model) is delivered without castors. Wear protective gloves when
assembling the castors or when lifting the kiln. Only lift the kiln from the base. The kiln
must NOT be placed on its side, as this will damage the insulation and heating
elements and thus destroy the kiln. Nabertherm accepts no liability for damage resulting
from assembly of the castors.

Screw the castors beneath the kiln feet using the supplied tool A .
13
A
Fig. 12: Assembling the castors
27
Assembly recommendation
Compliance with our recommendations does not release users of our products from their
personal responsibly in relation to local situations and conditions. However, several general
recommendations should be considered:

In the case of kilns up to 60 kg we recommend that you tip the kiln carefully on its
feet. Grip below the kiln 1 and carefully tip it to the side. Assemble the first castor
and then carefully release your grip on the kiln. Repeat this process for all the castors.
We recommend that a second person prevents the kiln from tipping too much, falling
over or rolling away. 3 / 4
3
1
4
2
Fig. 13: Example: Assembling castors on kilns up to 60 kg
Do NOT tip kilns above 60 kg on their feet. There is a risk of the feet "breaking off" if
you tip the kiln. To assemble the castors, we recommend that you sit the kiln on four
suitable wooden blocks. These blocks should be at least 20 cm high, so that the castors
can be screwed beneath the feet. At least two people are needed to lift the kiln, more
for heavier kilns.
min. 20 cm

Kiln base
from below
Fig. 14: Example: Assembling castors on kilns over 50 kg

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28
When the kiln is in position, lock the brakes on the castors.
When the bypass connection has been attached to and aligned on the kiln, you can
then assemble an exhaust gas system if this is required. See "Exhaust Gas System" for
more information about exhaust gas.
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4.5.3 Assembling the Bypass Connection
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The bypass connection that is part of the delivery is fixed to the side of the kiln. Kilns in the
top loader F series… have no bypass connection. Kiln model Top 16/R is delivered without
a bypass connection. This model is ventilated via a hole in the middle of the lid.

At the position where the bypass connection is fixed are two screws 1 to assemble it;
these must be removed beforehand.

Place the bypass connection 2 with the screws on to the correct position on the side
of the kiln and fix it with suitable tools.
1
2
Fig. 15: Assembling the bypass connection
When the bypass connection has been attached to and aligned on the kiln, you can then
assemble an exhaust gas system if this is required. See "Exhaust Gas System" for more
information about exhaust gas.
Assembling the exhaust air piping:
If required, see "Exhaust Gas
System"
Bypass connection
Fig. 16: Assembling the exhaust gas piping on the bypass connection
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29
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4.5.4 Waste Gas System
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When ceramics are fired, depending on the quality of the clay and/or glaze, they can emit
gases and vapors that are harmful to your health. It is therefore necessary to make sure that
the "exhaust gases" emitted from the exhaust air opening are directed outdoors in a suitable
manner (ventilate the working area). If adequate ventilation cannot be ensured at the
working area, the "exhaust gases" must be removed via a pipe. We recommend that you
connect a pipe to the kiln to remove the exhaust gases.
A suitable metal exhaust gas pipe with NW80 can be used to vent the gases. Use only metal
pipes (example: stainless steel). The pipe must be attached facing upwards and be fixed to
the wall or ceiling. Adequate room ventilation is needed to achieve the bypass effect.
Vapors may not be extracted through a fan.
Assume a maximum exhaust gas temperature of approx. 200 °C for the piping system.
There is a risk of burning at the bypass connection and the piping. Make sure that the wall
duct is made from A heatproof material.
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If the kiln is installed in a "passive house" it must be ensured that the room has an adequate
fresh air supply. Because of potential aggressive vapors, we do not recommend that it is
connected to the house ventilation system. We recommend a separate kiln room that can be
ventilated adequately.
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min. 0.5 m
A
Outside wall
min. 1 m
Install facing upward
Exhaust air piping
Bypass effect
Bypass connection
Outside wall
Kiln
Fig. 17: Example: Assembling exhaust air piping
Note
The customer is responsible for any masonry or roofing work necessary for venting the
exhaust gases. The size and design of the exhaust system must be defined by a ventilation
engineer. The accident prevention regulations applicable in the country where the kiln is
installed must be followed.
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30
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4.5.5 Connecting the Oven to the Power Supply
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The customer must ensure that the surface has adequate load-bearing capacity and that the
necessary energy (electricity) is provided.

The kiln must be installed according to its intended use. The power connection must
correspond to the values on the kiln's type plate.

The power socket must be close to the kiln and be easily accessible. The safety
requirements are not met if the kiln is not connected to a socket with a protective
ground contact.

With 230 V kiln models pay attentions that:
the distance between the circuit breaker and the power socket that the kiln is
connected to is as short as possible. NO power board or extension cable is used
between the power socket and the kiln.

The power cable must not be damaged. Do not place any objects on the power cable.
Lay the cable so that no one can stand on it or trip over it.

Power cables may be replaced only with similar, approved cables.
Note
Before connecting the power, make sure that the power switch is set to "Off" or "0".
3
click
2
1
Fig. 18: Kiln up to 3600 kW (the power cable is supplied)
1.
2.
Plug the supplied connection cable with snap-in coupling into the rear wall of the
kiln.
Then connect the power cable to the power supply. Use only a grounded socket.
31
1
Fig. 19: Kiln from 5500 kW (CEE plug)
1.
Connect the power cable to the power supply. Use only a grounded socket.
Grounding the kiln and the switchgear (acc. to VDE 0100, Part 410) is a requirement for
the heating unit's leakage current protective circuit.
Check the ground resistance (acc. to VDE 0100); see also accident prevention regulations.
Electrical systems and equipment according to BGV A3.
Note
See the enclosed circuit diagram for the wiring and electrical connections. The machine's
electrical equipment is shown in the circuit diagram.
Note
The accident prevention regulations applicable in the country where the kiln is installed
must be followed.
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NOTICE
• Danger from incorrect voltage
• Damage to the oven.
• Check voltage before connecting and
commissioning the oven.
• Compare the voltage with the details
on the type plate.
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32
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4.6
Commissioning
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Read the section on "Safety". When the kiln is put into operation, the following safety
information must also be observed to prevent serious injury, damage to the kiln, and
damage to other property.
Make sure that the instructions and information in the instruction manual and the controller
instructions are observed and followed.
Before starting the kiln for the first time, make sure that all tools, foreign parts, and
transportation securing equipment have been removed.
Before you switch on the kiln, make sure that you know what to do in case of faults or
emergencies.
Before placing materials in the kiln, check whether they could harm or destroy the
insulation or the heating elements. Materials that could damage the insulation include:
alkalis, alkaline earths, metal vapors, metal oxides, chlorine compounds, phosphorous
compounds, and halogens. If applicable, read the labels and instructions on the
packaging of materials that you use.
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Note
Before starting the oven for the first time, allow it to acclimatize at its installation location
for 24 hours.
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4.7
Recommendations for Heating the Oven for the First Time
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Heat the kiln to dry out the bricks and to get a protective oxide layer on the heating
elements. There may be some unpleasant odors while the kiln is heating. This is due to
binder being emitted from the insulation material. It is advisable to ventilate the room in
which the kiln is located well during the first heating phase.

Half open the supply air valve (see "Operation")

Close and lock the lid (see "Operation")

Switch on the kiln/controller with the power switch (see "Operation")

Heat the empty kiln, if necessary with new kiln furniture (shelves and props) to 500
°C in 6 hours, and then heat at full power; kiln models Top… and HO… to Tmax
1050 °C, kiln model F… to Tmax 950 °C and keep this temperature for one hour
before allowing the kiln to cool naturally. Read the controller instructions for how to
enter temperatures and times.
Insulation
The kiln insulation is made from high-grade fireproof material. Due to thermal expansion,
cracks in the insulation will occur after a few heating cycles. These have no influence on
the function, safety or quality of the kiln. The refractory bricks (insulation) are of a
particularly high quality. Due to the manufacturing process small holes or cavities may
occur. These are quite normal and underline the quality features of the bricks. These holes
or cavities are not a reason for complaint.
Note
New kiln furniture (e.g. shelves and props) should be heated once to dry them out (as
described above). When cold, heating elements are extremely brittle. Take great care when
packing, emptying and cleaning the kiln.
The lid lock must be locked when during firing. To release emitted gases and vapors more
quickly and to shorten the cooling phase after firing, the air inlet valve can be completely or
partially opened.
33
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Note
At high firing temperatures a slit may become visible along the edge of the lid. This is
normal and does not compromise the kiln's function or safety.
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5
Operation
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5.1
Controller
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2
3
T2
T3
T2
T1
T1
wait
time 1
time 2
time 3
wait
time 4
time 1
time 2
time 3
time 4
Made
in
Germany
1
Fig. 20: Example: Controller and power switch
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OFF/ON
1.
The control current is switched off and on with the power switch 1 . When the
control power is switched on, the controller type, version number and temperature
are shown in the controller display 2 3 .
Example:
). When the temperature is shown in the
controller display, the controller is ready for operation.
2.
The required heating and cooling programs are set on the controller 3 . See the
separate instructions for a description of the controller.
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Note
See the separate operating instructions for a description of how to enter temperatures and
times and to "start" the oven.
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34
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5.2
Opening and Closing the Lid
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Opening the Lid
Open the lid lock as shown in the figure below. Pull the handle lightly to open the lid
slightly. It is advisable to open the lid completely to pack the kiln.
Fig. 21: Opening the lid lock
Closing the Lid
Close the lid of the kiln carefully (don't slam it shut). Close the lid lock as shown in the
figure below.
When you have closed the lid, make sure that it is closed evenly all around. Check the
lock/s and, if necessary, turn the snap locks to adjust them A so that the lock can be closed
without too much effort.
A
Fig. 22: Closing the lid lock
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35
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5.3
Fresh Air Valve
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D
The volume of air fed to the kiln can be adjusted with the fresh air valve. The fresh air
valve is located on the base of the kiln. Kilns in the fusing top loader F series… have no
fresh air valve.
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Fresh air valve closed
Fresh air valve open
Fig. 23: Regulating the feed of fresh air on kiln model top loader Top
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Fresh air valve closed
Fresh air valve open
Fig. 24: Regulating the feed of fresh air on kiln model top loader HO
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36
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5.4
Loading/charging
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Packing the Kiln
Three ceramic plates are included with the delivery (691600956) to stabilize the props and
the shelves C . We recommend that you use this three-point construction for good firing
results.
Arrangement of the Shelves and Props (Accessories)
First, place three props in a triangular design on top of the delivered ceramic plates
(691600956). The ceramic plates must have been placed evenly on the floor of the kiln
beforehand A . The distance B between the props depends on the size of the shelves and
should be as large as possible to ensure stability.
Prop (accessory)
B
A
B
A
B
Fig. 25: Example: Even distribution of the props
Place the shelf C on top of the props. Now place the objects to be fired in the kiln and
distribute them as evenly as possible. If a second layer is required, place props on the shelf
to get the required distance between the shelves. These props should be situated exactly
above each other if possible to ensure stability of the shelves.
Shelf (accessory)
C
C
C
A
A
Fig. 26: Example: Several shelves in the kiln
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5.4.1 Tips for Potters
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Note
The temperature specifications given by clay and glaze producers must be observed. They
will be happy to provide you with suitable firing curves for the products.
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So that your pottery, which was made with a lot of effort and love, is not destroyed, the
following principles should be observed:

Allow pottery to dry slowly – not in a heated room or in the sun.

Dry pottery away from drafts - drafts cause uneven drying and drying cracks.

Loosely cover outstanding parts (e.g. handles) with paper or plastic film, as they dry
faster than the rest of the pot. If you don't do this, cracks may occur at the joint.
37

Allow the pottery to dry for at least one week - longer in cool basements.

Clay shrinks when it dries; in other words, the volume is reduced due to the loss of
water. Objects that stick to a surface crack when they dry - therefore, always place
your pottery on fresh, clean surfaces.

Turn your pottery often as the top dries quicker than the bottom.

Handle dry pottery carefully with both hands and don't lift it by the edges. Pottery is
very fragile in this state.
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5.4.2 Bisque Firing
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When the greenware is completely dry, it is bisque fired; that is, it is fired in the kiln at
between approx. 900 °C and 950 °C. The first firing – for unglazed pottery (terracotta) the
only firing – changes the physical and chemical properties of the clay. It becomes "bisque
ware" (like a clay brick) and is hard and cannot be dissolved in water.
During the bisque firing the pots in the kiln can touch each other. They can be stacked (also
inside each other) as long as they are not too heavy or do not prevent each other from
shrinking. Tiles or flat plates should be placed directly on the shelves to prevent distortion.
It really depends on the size of the objects whether they are stacked on several shelves or if
a few larger pieces fill the entire kiln. But the chamber should not be "overloaded" to
ensure sufficient air circulation. For the firing it is important that you know what happens
to the pottery. It loses a lot of water and shrinks. If the kiln temperature is raised too
quickly, the steam does not have enough time to escape and objects can crack and damage
the kiln. Therefore, the kiln should be heated slowly to about 650 °C at approx. 100 °C to
150 °C per hour. Chemically bound water escapes from the clay until about this
temperature. From this time you can heat the kiln to the final temperature at full power.
Nabertherm controllers handle this task fully automatically.
The controller instruction manual contains all the details.
Because of the large mass and the good insulation, it takes several hours for the kiln to
cool; be patient. You should open the lid a little only when the kiln has reached
about 100 °C.
When the kiln is completely open, many people are amazed to find that there have been
several changes to the pottery. The pieces are smaller, they are lighter in color, the clay
has a different color, the bisque ware is hard and you can now lift a pot by its handle
without fear of it breaking off.
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5.4.3 Glaze Firing
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Usually, the glaze firing is the highest temperature firing. The temperature range for
earthenware (usually red or brown clay) is about 1040 °C to 1080 °C. For stoneware
(usually white clay) the kiln has to reach at least 1200 °C. The glazes must be adapted to
suit the temperature range.
The top of the shelves should be painted with a separating agent (batt wash) before a glaze
firing. This coating should be renewed from time to time.
Check the areas where the pottery is to stand - they must be free of glaze. Pottery with a
glazed base must be placed on stilts or triangular rods for the firing. Glazed pottery should
be handled very carefully and should not be touched at the edges. The pots must not touch
in the kiln - the glaze would fuse together (there should be a few centimeters between the
pots). There must also be a gap of at least 2 cm to the heating elements.
Always use only glazes in one melting range (e.g. 1050 °C) in a firing. Heat the kiln to
about 500 °C at reduced power (approx. 180 °C per hour, see also controller instructions)
(water escapes from the glaze), and then heat to the final temperature at full power. Hold
this temperature for about 30 minutes so that the glaze melts evenly throughout the kiln.
38
Only open the lid or door when the temperature has dropped to below 50 °C. Many glaze
cracks are the result of opening the lid too soon.
You can grind any glaze drops on the bottom of the pottery or the shelves with a grinding
stone or an angle grinder - paying attention to all the safety regulations.
Do not use very runny glazes to avoid damaging the shelves, the kiln insulation or the
heating elements and the kiln itself.
You can obtain firing and glazing accessories and specialist literature from a specialist
dealer in your neighborhood. We will be happy to provide you with addresses.
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5.4.4 Reduction Firing
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In a reduction firing, oxygen in the kiln is consumed by means of a foreign substance.
However, since oxygen is needed to maintain the protective oxide layer on the heating
elements NO reduction firings should be carried out in an electrically heated kiln.
Under certain circumstances, high concentrations of gases can settle in the insulation
and destroy it.
If it is unavoidable, after each reduction firing the kiln must be fired with a normal
atmosphere to replace the protective oxide layer on the heating elements.
No warranty claims will be accepted for damage caused by reduction firings.
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6
Servicing, Cleaning, and Maintenance
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6.1
Shutting Down the Oven for Servicing, Cleaning, and Maintenance
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Risks during normal operation
Repairs and maintenance work must be performed by authorized persons, following the
maintenance instructions and the accident prevention regulations. We recommend that the
maintenance and repair work be carried out by the service team of Nabertherm GmbH.
Non-compliance may cause injuries, death, or considerable damage to property.
Operators may only rectify faults that are obviously due to operating errors.
Wait until the kiln and the connected parts have cooled to room temperature.

The kiln must be completely empty.

Switch off the main switch and pull out the power plug.
Risks during normal operation
Do not touch any objects without first checking how hot they are.
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Kilns in the top loader series Top 16/R, Top 45 and Top 60 have ceramic fiber
material in their insulation.
In the Federal Republic of Germany, active handling of these fibers (e.g. replacing the
insulation) is subject to the regulations of the German Hazardous Substances Ordinance,
Annex V No. 7 "Artificial Mineral Fibers" from June 12, 1998. In the rest of the European
Union, ceramic fibers are classified according to Commission Directive 97/69/EC from
December 5, 1997 as follows: CARC. Cat. 2; R 49; Xi R 38. Work with fiber insulation
39
should be carried out so that as little fiber dust as possible is released.
The following points should be observed when working with ceramic fiber:
- Keep dust to a minimum.
- Avoid contact with skin and eyes. The effects of
fibers in the eyes can cause mechanical irritation, which can, in turn
cause redness and itching.
- When working with large quantities of ceramic fiber, wear loose
working clothes with long sleeves, gloves, and protective eyewear.
- When working inside kilns with ceramic fiber insulation, you should also wear a
half/quarter mask with P2 filter
Commercial use:
The kiln and its equipment must be checked regularly according to the national regulations
in the country in which they are installed.
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Warning - Danger of Electric Shock!
Work on the electrical equipment may be done only by qualified, authorized electricians.
During maintenance work it must be ensured that the oven and the switching equipment
cannot be activated by mistake (pull out the power plug) and that all moving parts in the
oven are secured. Observe BGV A3 or the corresponding national regulations in the
country where the oven is installed. Wait until the oven and the connected parts have
cooled to room temperature.
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40
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6.2
Regular Maintenance of the Oven
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Item/
Maintenance Point
Measure
Maintenance Interval
Daily
Weekly
Operating
Monthly
Quarterly
Annually
Expert
Personnel
Safety inspection in
conformance with BGV
A3 or the corresponding
national regulations 1)
Compliant with
regulation
Contact safety switch
(switches the heating off
when the lid is opened)
Function check
Furnace chamber, vent
holes
and vent pipes
Clean and
check for damage,
vacuum out carefully
●
Heating elements
Visual inspection
●
Thermocouple
Visual inspection
Tensioning straps/Lid
tensioning ring
Check and adjust if
necessary before
very firin
●
x
Lid locks
heck and adjust if
necessary before
every firing
●
x
Lid fit (tight closure/fit
of the lid)
Check setting and
adjust if necessary
Symbols:
■ = clean
● = check, replace
1) = for comm rcial use
●
x
●
x
x
x
●
●
x
x
x = carried out by
Fig. 27: Maintenance table
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Warning - Danger of Electric Shock!
Work on the electrical equipment may be done only by qualified, authorized electricians.
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Note
Maintenance work must be performed by authorized personnel following the maintenance
instructions and the accident prevention regulations. We recommend that the maintenance
and repair work be carried out by the service team of Nabertherm GmbH.
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41
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6.3
Adjusting the Lid
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D
If the lid does not sit properly on the hinge side when the kiln is cold (this can be seen by a
gap between the lid and the collar insulation) the retaining plates 4 of the gas dampers
have to be adjusted. Before you make the adjustment, make sure that the lid is closed using
the lock 1 .
1
Gas damper
Fig. 28: Lock the lid
To adjust the lid, unscrew the screws 2 on each side of the switchgear cover using suitable
tools. On the hinge side, press the lid down 3 until it sits properly all the way around.
2
3
Fig. 29: Loosen retainer plate/press lid down
Press the retainer plate 4 lightly on the axis of the gas damper and tighten the screws 5
on both sides again.
4
Fig. 30: Press retainer plate down and secure
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42
5
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6.4
Adjusting the Tensioning Straps
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D
Before each firing a check must be made to ensure that the kiln casing and the lid clamp
ring retain their firm fit and that the kiln lid still closes snuggly. If either the kiln casing or
the lid clamp ring is loose, they must be retightened on the outer tensioning straps.
Tightening the straps holds the insulation in the kiln lining and the lid in place.
Tighten the screws of the kiln casing and/or lid clamp ring with the hex key that is supplied.
Secure the tensioning connections against turning with pliers, for example.
Fig. 31: Adjusting the tensioning straps
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6.5
Separate the Snap-In Coupling (Plug) from the Furnace Housing
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With a small flat blade screwdriver carefully push the locking latch 1 upward while
pulling the plug 2 out of the coupling 3 .
1
3
2
Fig. 32: Separate the snap-in coupling (plug) from the furnace housing
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43
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6.6
Cleaning Products
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Carry out the procedure to switch off the kiln (see "Operation") Then pull the power plug
out of the socket. Allow the kiln to cool naturally.
Pay attention to the labeling and information on the cleaning product packaging.
Wipe the surface with a damp, lint-free cloth. You may also use the following cleaning
products.
Component
position
and
Cleaning product
Metal surface
Stainless steel cleaner
Inside
Carefully clean with a vacuum cleaner
(be careful with the heating elements)
Insulation brick
(e.g. lid)
Carefully clean with a vacuum cleaner
(be careful with the heating elements)
Instrument field on
the controller
Wipe the surface with a damp, lint-free cloth (e.g. glass cleaner).
Fig. 33: Cleaning product
When you have finished cleaning, completely remove the cleaning product from the
surfaces with a moist, lint-free cloth.
After cleaning, check all cables and connections, insulation, heating elements for damage
and report faults immediately.
Note
The kiln, kiln chamber, and connected parts may NOT be cleaned with a high-pressure
cleaning device.
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44
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7
Faults
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Work on the electrical system may be done only by qualified, authorized electricians. Operators may only rectify faults
that are obviously due to operating errors.
Call your local electrician for faults that you cannot localize.
If you have any questions, problems, or requirements, contact Nabertherm GmbH. By mail, phone, or e-mail -> See
"Nabertherm Service".
Phone advice is free and non-binding for our customers – all you pay is the phone costs.
In case of mechanical damage, send an email containing the above information and a digital photo of the damaged part
and a photo of the complete kiln to the following address:
-> see "Nabertherm Service".
If a fault cannot be rectified with the described solutions, contact our service hotline directly.
Have the following information at hand when you phone. This makes it easier for our customer service to answer your
questions.
SN xxxxxx
www.nabertherm.de
Made in Germany
You can obtain general
controller information
by pressing the
button on the controller
Detailed fault message

Information about
stored programs
Kiln model:
Serial number:
Article number
Year of construction:
Voltage:
Operating hours:
Programmed firing sequence:
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
Pr (selected program):
_______________________________________
Pt (program runtime in min):
_______________________________________
E (power consumption in kWh):
_______________________________________
tt (total operating hours):
_______________________________________
F 1 (error memory last error):
_______________________________________
F 2 (error memory second but last error):
_______________________________________
Ht (highest program temperature):
_______________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
Time 1
T1
Time 2
T2
Tim 3
T3
Time 4
P1
P2
P3
You can find possible solutions for faults quickly and easily using the following table: Some Nabertherm controllers
display certain errors directly in the controller display (error code)
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Description
Controller does not
switch on.
or
switches on and does not
respond
Error code
controller
F 60 - F 61
F 64 - F 69
Possible
cause
Rectify
fault
No voltage.
Check power plug. Check/renew fuse(s) of the power
connection. Check switch
Check/renew controller fuse (if applicable).
Check plug-in connection of the controller
Controller defective.
Contact Nabertherm
45
Description
Error code
controller
Possible
cause
Rectify
fault
F 62
Ambient temperature too
low < - 10 °C (- 50 °F)
Heat room if necessary
F 63
Ambient temperature too
high >70°C (158°F)
Check room or ventilate gaps to walls and ceiling
F 50
Possible error in program
entry.
Check entry for heating program (see controller
instructions) under certain conditions. Lead time
programmed?
F 10
Safety switch shifted
Have an electrician check the switching path of the
safety switch and have adjusted if necessary.
Fuse(s) of the connection
defective.
Check fuse(s) of the connection and replace if
necessary. Notify Nabertherm Service if the new fuse is
triggered while you are screwing it in.
Heating element
defective.
Check for breakage. If there are no obvious breakages,
close the cold kiln. Switch kiln on for max. 5 seconds
(not longer). Remove power plug, open door/lid.
Carefully touch the heating elements to see if various
parts are hot or cold, check cold elements
Solid state relay defective
Have an electrician check the solid state relay and
replace if necessary
No heating due to low
voltage and/or open fresh
air valve at maximum kiln
temperature
Low voltage and/or open fresh air valve at maximum
kiln temperature. Close fresh air valve if possible and if
the error continues have an electrician check the power
supply "under load".
Broken/worn heating
element
Have an electrician or Nabertherm Service replace the
heating element
F 30 - F 32
Fault in thermocouple or
measurement circuit
Replace thermocouple
F 40
Thermocouple poles
reversed after replacement
Change poles
Heating element pops out
of its holding groove
Advanced wear of the
heating element
The heating element should be replaced soon. As a
temporary measure, the heating element can be pressed
back into the groove and may have to be held in place
with clamps.
Cracks in the insulation
Expansion of the
refractory bricks at high
temperatures
The kiln insulation is made from high-grade fireproof
material. Due to thermal expansion, cracks in the
insulation may occur after a few heating cycles.
These have no effect on the function or quality of the
kilns and are not a reason for complaint.
A glowing slit can be
seen between the door/lid
and the kiln.
Expansion of the
refractory bricks at high
temperatures
Heat causes the material to expand and a small slit may
appear. This slit has no influence on the functioning of
the kiln.
Dust on the ware
Expansion of the
refractory bricks at high
temperatures
Carefully vacuum out the kiln at regular intervals. We
recommend that you cover the top layer of your ware
with a ceramic plate.
Chamber does not heat
up after the program start.
or
Heating chamber heats
very slowly.
or
The selected end
temperature was not
reached.
Power failure
F 90
Power failure or
controller switched off via
main switch before the
end of the program and
program not ended via the
"stop" button on the
controller.
Check the power supply and the condition of the charge
and, if necessary, restart the kiln. In the information
menu the last temperature of the program before the
power failure can be seen under "Ht".
Kiln temperature exceed
F 70
Switching system or
Contact Nabertherm
46
Description
Error code
controller
the permitted value
"Tmax"
Possible
cause
Rectify
fault
controller defective
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If a fault message occurs, one of the following fault messages (fault codes) is displayed:
Fault code
Meaning
Comment
F 10
The furnace is not reaching the configured
temperature
E.g. heater defective, door not closed, or
door contact switch incorrectly adjusted
F 30 – 32
Fault in thermocouple or measurement circuit
Thermocouple defective
F 40
Thermocouple polarity reversed
E.g. after replacement of thermocouple –
switch polarity
F 50
Specification of temperature or time incorrect
Correct entry
F 60 – 61
Controller system fault
Controller defective
F 62
Ambient temperature too low <-10 °C (-50°F)
Heat room if necessary
F 63
Ambient temperature too high >70 °C (158°F)
Ventilate room if necessary
F 64 – 69
Controller system fault
Controller defective
F 70
Furnace temperature has exceeded the permitted
value "Tmax"
Switching system or controller defective
F 85
External fault
See furnace operating instructions
F 90
Power failure
Appears after power restored
Fault messages can be reset by turning the power switch off and back on. Leave the unit switched off for at least 5
seconds. If the fault message no longer occurs within a minute after power is turned on, the controller is ready to
operate. If there is another fault message, contact Nabertherm service. Ventilation motors (if present) remain on even in
case of a fault. The heater is always turned off
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47
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8
Spare Parts/Wearing Parts
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Ordering Spare Parts:
Our Nabertherm Service team is available to you all around the world. Due to our
considerable production depth we deliver most spare parts from the warehouse overnight or
can make them ready for delivery within short deadlines. You can order Nabertherm spare
parts easily and simply directly from the factory. If you cannot find the spare part you want
we will be glad to help you. Spare parts can be ordered in writing, by phone or on the
Internet -> see the section entitled "Nabertherm Service".
Availability of Spare Parts and Wearing Parts:
Although Nabertherm has many spare parts and wearing parts on stock, we cannot guaranty
the short-term availability of all of them. We recommend that certain parts be ordered in
advance. If you need any assistance when selecting spare parts and wearing parts, the staff
at Nabertherm will be glad to set aside time for you.
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Provide the following details from the type plate:
1 Kiln model
SN xxxxxx 2
Top 60/ L eco 1
1200 °C 2010 4
Top0603BN1 3
230 V 1/N/PE~
2 Serial number
3 Article number
4 Year of construction
12.8 A 50/60 Hz 2.9 kW
www.nabertherm.de
Made in Germany
Fig. 34: Example (type plate)
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Note
Original parts are designed especially for Nabertherm ovens. Replace parts only with
original Nabertherm parts. Otherwise the warranty will be void. Nabertherm accepts
absolutely no liability for damage caused by using parts that are not original Nabertherm
parts.
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9
Electrical Connections (Circuit Diagram)
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Note
You can obtain circuit diagrams from our Nabertherm Service Team if you need them.
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48
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10 Accessories (Options)
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Kiln Furniture/Shelves
Kiln model top loader Top …
Top 16/R
Top 45 …/Top 60
Top 80 …/Top 100
Top 130
Top 140
Top 160 …/Top 190 …
Top 220
Dimensions in mm
Ø225x10
Ø350x10
Ø420x10
Ø520x10
Ø470x10
Ø520x15
550x440x18 (R275)
Part number
691600954
691600397
691600440
691600…
691600833
691600834
691601125
Figure
Dimensions in mm
Ø350x10
550x440x18
R275x440
Part number
691600397
691604219
691601125
Figure
Dimensions in mm
340x370x13
390x400x15
490x440x17
Part number
691600181
691600182
691600184
Figure
Dimensions in mm
Ø40x50
Ø40x100
Part number
691600185
691600951

Figure
Dimensions in mm
Height 132
(without castors)
Part number
Figure


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Kiln Furniture/Shelves
Kiln model fusing top loader F ...
F 30
F 75 …
F 110/F 220



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Kiln Furniture/Shelves
Kiln model top loader HO …
HO 70
HO 100
HO 300

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Kiln Furniture/Props
Kiln models Top …, F … and HO …
Prop
Prop

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Base Extension
Kiln model top loader Top
Top 45 …
Top 60 …
401010088


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Base Extension
Kiln model fusing top loader F ...
F 75 …
F 100
Dimensions in mm
Height 132
(without castors)
Height 132
(without castors)
Part number
Figure
601402652


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49
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11 Nabertherm Service
Contact Nabertherm Service at any time for maintenance and repair.
If you have any questions, problems, or requirements, contact Nabertherm GmbH. By mail,
phone or e-mail.

Mail
Nabertherm GmbH
Bahnhofstrasse 20
28865 Lilienthal/Germany

Phone or Fax
Phone: +49 (4298) 922-0
Fax: +49 (4298) 922-129

Web or e-mail
www.nabertherm.com
contact@nabertherm.com
When you contact us, please have the type plate details of the oven or controller at
hand.
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Provide the following details from the type plate:
1 Kiln model
SN xxxxxx 2
Top 60/ L eco 1
1200 °C 2010 4
Top0603BN1 3
230 V 1/N/PE~
12.8 A 50/60 Hz 2.9 kW
www.nabertherm.de
Fig. 35: Example (type plate)
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50
Made in Germany
2 Serial number
3 Article number
4 Year of construction
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12 Shut-Down, Dismantling, and Storage
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12.1 Environmental Regulations
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When it is delivered, this oven contains no substances that make a hazardous waste
classification necessary. However, residues of process materials may accumulate in the
oven insulation during operation. These may be hazardous to health and/or the
environment.

Dismantle the electronic components and dispose of them as electric scrap.

Remove the insulation and dispose of it as hazardous waste (See Servicing, Cleaning,
and Maintenance with Ceramic Fiber Material)

Dispose of the housing as scrap metal.
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Safety information:
When the kiln is being disposed of, the lid lock should be destroyed. This stops children
being locked in and facing the risk of death.
Separate the power cable and dispose of this together with the plug.
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Note
Observe the national regulations of the country in which the kiln will be used.
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51
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12.2 Transportation/Return Transportation
If you still have the original packaging, this is the safest way to send an oven.
Otherwise:
Choose suitable, adequately sturdy packaging. During transportation, packages are often
stacked, bumped, or dropped; the packaging acts as external protection for your oven.
+45
-5°C
- Drain all piping and containers before transportation/return transportation
(e.g. cooling water). Pump off operating materials and dispose of properly.
- Do not subject the oven to extreme cold or hot temperatures (direct sunlight).
Storage temperature -5°C to 45 ° (-23°F to 113°F)
Humidity 5% to 80%, non condensing
- Place the oven on a level floor to prevent distortion.
- Packaging and transportation may be carried out only by qualified and
authorized persons
If your oven has transportation securing equipment (see "Transportation Securing
Equipment"), use this.
Otherwise, in general:
"Fix" and "secure" (adhesive tape) all moving parts and cushion and protect any projecting
parts against breakage.
Protect your electronic equipment against moisture and make sure that no loose packaging
material can get inside it.
Fill gaps in your packaging with soft but adequately firm material (e.g. foam mats) and
make sure that the equipment cannot slide around in the packaging.
If the goods are damaged during return transportation due to inadequate packaging
or some other breach of duty, the costs will be borne by the customer.
As a rule:
The oven is sent without accessories, unless the technician expressly requests them.
Enclose a detailed description of the fault along with the oven – this saves the technician
time and costs.
Don't forget to enclose the name and phone number of a contact in case there are any
questions.
Note
Return transportation may only be carried out according to the information given on the
packaging or in the transportation documents.
Note
Transportation and return transportation not covered by a warranty claim are paid for by
the customer.
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52
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13 Declaration of Conformity
Pos: 205 /EG-Erklärungen/Kopfmodul/Konformitätserklärung Niederspannungsrichtlinie 2006/95/EG @ 9\mod_1245848340236_51.doc @ 61263 @
EC Declaration of Conformity
in accordance with EC directives 2006/95/EEC and
EMC directive 2004/108/EEC
Hereby
Nabertherm GmbH
Bahnhofstr. 20, 28865 Lilienthal, Germany
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declares that the product specified below conforms to the relevant fundamental safety and health requirements of the
appropriate EU Directive both in its basic design and construction as well as in the version marketed by us. The
declaration will cease to be valid if any modifications are made to the machine without our approval.
Pos: 207 /EG-Erklärungen/Produktangaben/Modelle TOP, HO und F für die Betriebsanleitung @ 13\mod_1289805400331_51.doc @ 107827 @ 1
Electrically heated kiln
Model
Top 16/R
Top 45
Top 45eco
Top 60
Top 60/R
Top 60eco
Top 60/Leco
Top 80
Top 100
Top 130
Top 140
Top 160
Top 190
Top 220
HO 70/L
HO 70/R
HO 100
HO 300
F 30
F 75L
F 75
F 110
F 220
For all kilns with switchgear and controller
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The following harmonized standards were applied:
Pos: 208.2 /EG-Erklärungen/Mitgeltende Normen/Normen/DIN EN 60335-1 @ 14\mod_1291814199588_0.doc @ 110103 @

DIN EN 60335-1 (11.2010)
Pos: 208.3 /EG-Erklärungen/Mitgeltende Normen/Normen/DIN EN 61000-6-1, DIN EN 61000-6-3 @ 10\mod_1260454484148_0.doc @ 69791 @

DIN EN 61000-6-1 (10.2007) , DIN EN 61000-6-3 (09.2007)
Pos: 209 /EG-Erklärungen/Ort und Datum @ 0\mod_1155018513651_0.doc @ 1093 @
Lilienthal, 07.05.2010
Pos: 210 /EG-Erklärungen/Unterschriftkombinationen/Unterschriften Adamek/Bartilla mit Unterschrift @ 0\mod_1157379942170_51.doc @ 1193 @
________________________
Thomas Adamek
_______________________
Wolfgang Bartilla
Quality Management
Research and Development
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53
Pos: 212 /TD/Notizen/Für Ihre Notizen @ 0\mod_1157544056930_51.doc @ 1725 @ 1
14 For Your Notes

=== Ende der Liste für Textmarke Inhalt ===
54
55
Headquarters:
Nabertherm GmbH
.
Reg: M01.0029 ENGLISCH
Bahnhofstr. 20 . 28865 Lilienthal/Bremen, Germany . Tel +49 (4298) 922-0, Fax -129 . contact@nabertherm.de . www.nabertherm.com
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