Using your Controller

There is a wide range of control devices fitted to kilns; from the simple to the complex. For many reasons an owner may lack instructions for their operation.

Many quite sophisticated devices are distributed worldwide for a multiplicity of uses, so have factory embedded default settings which are suitable for a wide range of users. Some of these values may need changing to allow the unit to best perform a particular task.
These changes are made by the installer and are often better understood by them than by the device maker or reseller; so that requests to them may not always help a kiln owner.

Sometimes the kiln builder has moved, has changed ownership, is located in another country, or has ceased trading, so that it can be difficult to get information.
To ensure that situation does not arise for future owners of Riley Glass Kilns products, provided here are instructions for use of the more recent devices used on those kilns.

Builders of other kilns wishing to insert user friendly instructions for the devices they use can contact the web manager via “Contact”.  Similarly for kiln owners who have exhausted the normal avenues of getting information, make contact in the same way and we will endeavour to source and publish the information.

General instructions

• It is good practice to always plan and write down the data for each step of a firing pattern before entering it in a controller. This can often save much angst and confusion.

• Initially one can have difficulty in reading alpha/ numerical characters on instrument displays. Some will be perfectly clear but others may call for some imagination. T may have the left half of the cross bar removed. M  may be more like a H with another horizontal bar at the top. 

• There are numerous ways of entering a step time in a pattern. This has been chosen by the instrument maker and cannot be changed by the kiln builder or user. For more on this go to Inserting data

Shinko PCD-33A controller

This instrument stores nine patterns each of nine steps; numbered from 1 to 9.
Used in recent Riley GS, FS and Custom kilns, and in Miley pottery kilns, it has been configured so that it will wait at the end of each step until the kiln catches up. There are slight differences in programming when the instrument is used in Education Queensland schools. See below for more.

Description of operation.

Standby mode

In standby mode the controller will display a pattern (PTN) number and the temperature inside the kiln (PV). All other displays will be unlit. If any other displays are lit the unit can be placed in Standby mode by pressing the STOP button for longer than 1 second.

From Standby mode the controller can be placed in either Run mode or programming mode.

In Standby, any one of the pattern numbers can be selected by using the PTN button to cycle continuously through them.

Run Mode

When in Standby mode the selected pattern can be run by pressing the RUN button.

• The SV display will be lit and will rapidly step up to approximately the same value as the PV and then step up at whatever rate is called for by the pattern selected.
• The numeral 1 will appear in the STEP window.
• The small RUN light will be lit and will remain lit as long as the controller is in Run mode.
  
• The small OUT light will flash either continuously or intermittently indicating that an output trigger signal is being sent to the power switching circuits.

NOTE. In Miley pottery kilns in EQ schools with ventilation interconnection, when the RUN light is lit the EVT (event) light will also be lit and will remain lit until the end of pattern (end of step 9) is reached. It is this output which triggers the ventilation system.

As the firing progresses the step numerals will increase with the OUT light switching ON and OFF in accordance with the power required.

Programming mode

Procedure for entering a pattern

Ensure the controller is in standby mode. If unsure, press STOP button for one second.
The controller is in Standby mode when only the PV (kiln temperature) and pattern number are shown.

• Use the PTN button to select the desired pattern number. The number will cycle continuously through numbers 1 to 9.

• Press the MODE button. Controller enters programme setting mode.

Step 1 will be displayed
Stylised TEMP will be shown in PV display
Enter the desired temperature for step 1 in SV display using ▲ or ▼ arrows.

• Press the MODE button again. Stylised TIME will be shown in PV display.

 You can then enter the desired time for step 1 in SV display using ▲ or ▼ arrows. The time entered is the total time for the step, entered in hours and minutes. Thus, if you wish to heat to 500ºC at a rate of 5º per minute, the time for the step is 100 minutes and is entered as 1.40 (1 hour 40 minutes)

• Continue to press the MODE button and enter temperature and time for as many of the steps as you wish to use in this particular pattern

• Continue to press the MODE button through each of the remaining steps, making sure that each temperature value is default value or is lower than the last step in the pattern; and that all times are zero.Default value is zero degrees. 
• After step 9 time a further pressing of the MODE button will return the controller to standby mode.

You can then press the RUN button to start the firing.
You can halt the firing at any time by pressing the STOP button for one second.

If the PV is lagging SV when the controller reaches the end of a step then the Step Number display will flash until the kiln catches up and the controller advances to the next step.

Should you wish to advance to the next step before the present step time has expired, press RUN for one second. This is convenient when monitoring deep slumps or similar firings where timing is crucial. Enter a long soak time, monitor movement of the glass and press RUN for one second when the glass gets to where you want it.

For more information, email sales@fastron.com.au  or go to Shinko Technos

Procedure for altering a pattern.

This is for situations such as when a minor alteration in temperature or time may be required in one or more steps in an existing pattern.

• Ensure the controller is in standby mode. If unsure, press STOP button for one second.

The controller is in Standby mode when only the PV (kiln temperature) and pattern number are shown. 

• Use the PTN button to select the desired pattern number. The number will cycle continuously through numbers 1 to 9.

• Press the MODE button. Enters programme setting mode

• Continue to press MODE button until the step number and temperature or time requiring alteration appears. Make the desired changes in that and any other succeeding values using ▲ or ▼ arrows.
• Press RST (reset) button to return to standby mode.

Press RUN button to commence firing.

Changes can also be made to a pattern whilst it is running; either to the step which is running or to any other step.

At any time during the firing simply press the MODE button and the controller will appear to go into programming mode. The stored pattern will continue to run in the background. Press the MODE button as described above to select the data area to be changed, make any change necessary and then press MODE again. The change will be immediately applied to the running pattern. Press RST to return to run mode.

It is important to understand that if the change is made to the step which is running then it will affect the entire step and not just the remaining part of the step. Thus, if the change is to the time for a step then a new momentary set value will be calculated. If the time was shortened then the new value will be higher than previously and full power will be applied in an effort to have the kiln catch up. If the reverse is the case then power will be turned off until the SV reaches the PV.

Shinko PCD-13A

This is the model previous to the PCD-33A above. It differs in that it stored only four patters each of seven steps. Instead of the Pattern number display it had four separate lights indicating the pattern number, only one of which could be lit at any time. It's operation is the same as for the PCD-33A in all other respects.  

BTC 9090 Ramp & Soak controller.

This is a multi purpose unit which can be configured by the user to perform a multitude of functions. There may be updated versions but their operation will be similar.When used in glass and pottery kilns this unit is generally configured as a "Soak and Ramp Controller". It has no "Wait" capability. For more on this see 53. Simple kiln controls

Fig 2. To come.

The following description applies to the unit when fitted to Riley GS kilns and to some of their special units. Other kiln builders may configure it to work in a similar way.

It is important to remember that this instrument has no wait capability. Thus, it goes through the timed procedure without paying any attention to what the kiln is doing. If a rate of rise beyond the capability of the kiln is entered then the controller will reach soak temperature before the kiln and will immediately commence timing out the delay or soak time. In extreme cases it can turn off the power before the kiln has actually reached soak.

The SCROLL KEY allows you to cycle continuously through three settings:

• SETPOINT VALUE. This is the desired soak temperature.

• ASP1. Stands for Alarm Set Point 1. Can be loosely called Soak time but is actually the time delay in minutes after the controller reaches soak temperature before the power to the elements is switched off.

• Lower case  rr.  Rate of rise.  Set in ºC per minute.

When numbers appear in both displays, the top display (PV) is showing the temperature inside the kiln whilst the other (SV) shows the desired soak temperature.
When you press the ‘scroll’ key the top display shows the selected setting (ASP1 or rate of rise) whilst the lower will show the delay time in minutes or the rate of rise in ºC per minute. 

• To alter SETPOINT VALUE display. (Desired soak temperature.)

    Adjust Setpoint Value up or down by pressing UP or DOWN keys.
    Press Scroll key as many times as necessary to return to the altered display to ensure that the changed value has been retained in memory.

• To alter RATE OF RISE.   

    Press Scroll Key until ‘rr’ (lower case R) appears on the top display.  Alter Rate of Rise by pressing UP or DOWN keys.
    Press Scroll key as many times as necessary to return to the altered display to ensure that the changed value has been retained in memory.

• To alter ALARM SETTING (soak time).

        Press Scroll key until ‘ASP1’ appears on the top display.  Alter setting by pressing UP or DOWN keys.
    Press Scroll key as many times as necessary to return to the altered display to ensure that the changed value has been retained in memory.

Do not enter 00:00 time in this instrument as that means infinity. It will not switch off power. A minimum time of 00:01 (one minute) should be entered..

The 9090 controller commences ramping up as soon as it is switched on. If there is a long delay between switching on the instrument and power being able to go to the elements, you are advised to return the instrument to the start condition by turning the POWER switch OFF and then ON again.

• This device is also used on some GeGe pottery kilns. For info go to GeGe kilns

• Manufacturers literature for this device can be obtained from  ECEFAST  Australia or to Brainchild Taiwan but this will not give the detailed configuration made by the kiln builder.