Paragon Ceramic Kiln Service Manual

Paragon Ceramic Kiln
Instruction & Service Manual
You are about to enter the magical world of custom-fired ceramics. To safely find your way around and to master your kiln, read this manual. Save for future reference.

INTRODUCTION

Thank you for purchasing a Paragon kiln. We are confident that the kiln will give you many years of relaxation and creative enjoyment. Before using yourkiln,readthe manuals that came withit. They will save you manyhours as you learn about your kiln. The more you know about your kiln, the more you will enjoy it and the longer it will last.
This manual does not cover the digital controller or the Kiln Sitter and switches. They are covered in a separate manual included in your instruction packet.
In the instruction packet for your kiln, you should find a copy of “Safe Installation of the Electric Kiln,” “Firebrick Maintenance,” and a manual that covers your kiln’s control system. Please contact the factory if you do not have copies. You can also find them at www.paragonweb.com. Select “Support” and then “Instruction Manuals” from the drop menu. The manuals are listed alphabetically.
At www.paragonweb.com select “Products,” then “Books & DVDs” from the drop menu. The books we recom mend will enhance your kiln experience. You can also email or phone us with questions. We are glad to help.
At www.paragonweb.com you will find online videos for many of the procedures shown in this manual. As you read each section, you can go online to watch an actual demonstration on your computer.
Even though your Paragon kiln may be designed to shut off automatically, check the kiln before the expected shut-off time. The warranty on your kiln does not cover damage from overfiring, regardless of the circumstances. It is the operator’s responsibility to make sure the kiln turns off when the firing is completed. Never leave your kiln unattended near the end of the firing.
Check your new kiln frequently during the first few firings and note the color change inside the kiln. After awhile you can learn to estimate, with considerable accuracy, when the kiln is about to shut off just by observing the color.
We are accustomed to using products that stay new looking for years—cars, furniture, cameras. But kilns are different. The high temperatures theyreach generate tremendous stresses. Since the insulating firebricks expand and contract with each firing, hairline cracks will appear in the bricks while the kiln is cold—even in a new kiln. Do not be con­cerned with these. They are normal. The cracks close tightly when the heated bricks expand. The cracks function as expansion jointsand will not affect the firing. Though the insulating firebrick is fragile enough to carve with a fingernail, it is a miracle of physics and when properly maintained can survive for many years.
Do not beconcerned withthe light thatappears around the edge ofthe lid ordoor. As long as thelid/door is closedall the way, there is little heat loss. Discolored paint is also inevitable and doesn’t affect firing results.
Please do not be concerned with theline of lightthat appears around the lid. It is normal.
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Do not be concerned with the clicking sound that the kiln makes during operation. Digital kilns contain relays, which send powerto the elements. Therelays click as theycycle on and off to maintainthe correct temperature.And the infinite switches of manual kilns make a clicking noise too. You will also hear the elements hum. This is only the sound of element coils vibratingin theirbrick grooves. Once you become familiar with these sounds, you may find them a reassuring indica tion that the kiln is firing normally.
If you call us about your kiln, please have the model number, part number (P/N), and voltagefromthekiln’selectricaldataplatehandy.(Theplateisonthesideofthe switch box.) Write that information here for quick reference:
P/N____________________ SN______________ Model______________ Volts____________
Thank you again for purchasing a Paragon kiln. We wish you many years of relaxation and creative enjoyment with your new purchase! You will find that owning a kiln will give you the freedom to experiment with new ideas and to fire any time you want. Owning a kiln will take your ceramic skills to a new and exciting level.
2 Monitor the kiln during operation!
©2008, by Paragon Industries, L.P. IM-104/11-08
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CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Safety Rules . . . . . . . . . . . . . . . . 4
Setting Up. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting Up The Stand . . . . . . . . . . . . . . . . . . . . . 6
Attach the Lock-In Lid Support. . . . . . . . . . . . . . 6
Where to Locate Your Kiln . . . . . . . . . . . . . . . . . 6
Seating the Elements . . . . . . . . . . . . . . . . . . . . . 7
Cleaning the Kiln. . . . . . . . . . . . . . . . . . . . . . . . . 8
The Electric Circuit . . . . . . . . . . . . . . . . . . . 8
Electrical Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . 8
Circuit Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Voltage Affects Firing Time. . . . . . . . . . . . . . . . . 9
Check the Electrical Installation . . . . . . . . . . . . . 9
Preparing The Kiln . . . . . . . . . . . . . . . . . . . . 9
Kiln Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monthly Kiln Maintenance . . . . . . . . . . . . . . . . 10
Pyrometric Cones . . . . . . . . . . . . . . . . . . . 11
Cone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Using Cones . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pyrometric Cone Charts . . . . . . . . . . . . . . . 12, 13
How to Position Cones on the Shelf . . . . . . . . 14
Using Cones in Digital Kilns . . . . . . . . . . . . . . . 15
The Bending of the Cone . . . . . . . . . . . . . . . . . 15
Firing Accessories. . . . . . . . . . . . . . . . . . . 16
Preparing To Fire The Kiln . . . . . . . . . . . . 17
Vacuuming the Kiln. . . . . . . . . . . . . . . . . . . . . . 17
Drying Greenware. . . . . . . . . . . . . . . . . . . . . . . 18
Shelf Preparation . . . . . . . . . . . . . . . . . . . . . . . 19
Loading The Kiln . . . . . . . . . . . . . . . . . . . . 21
How to Store Kiln Furniture . . . . . . . . . . . . . . . 21
Guidelines for Loading the Kiln . . . . . . . . . . . . 21
Distances Inside the Kiln . . . . . . . . . . . . . . . . . 22
Glazed Ware . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Heat Distribution Inside the Kiln . . . . . . . . . . . . 23
How to Position Posts. . . . . . . . . . . . . . . . . . . . 24
Bead Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Firing Large Ware Across Half Shelves . . . . . . 24
Tile Holders. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Firing The Kiln . . . . . . . . . . . . . . . . . . . . . . 25
The Stages of Firing . . . . . . . . . . . . . . . . . . . . . 25
When to Speed Up the Firing . . . . . . . . . . . . . . 25
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
The Basics of Firing . . . . . . . . . . . . . . . . . . . . . 28
The First Firing in Your New Kiln . . . . . . . . . . . 29
Loading and Firing Low-Fire Greenware . . . . . 30
Loading and Firing Low-Fire Glaze . . . . . . . . . 30
Loading and Firing Overglaze . . . . . . . . . . . . . 31
Loading and Firing Ceramic and Glass Decals 32
Loading and Firing Porcelain Greenware . . . . 32
Loading and Firing Porcelain Glaze . . . . . . . . . 33
Loading and Firing Stoneware
Greenware or Glaze . . . . . . . . . . . . . . . . . . . . . 33
Imperfections. . . . . . . . . . . . . . . . . . . . . . . 34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bisque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Glaze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Underglaze . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Overglaze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Porcelain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Kiln Maintenance . . . . . . . . . . . . . . . . . . . . 36
Note: Whenever you turnoff the circuitbreaker
to your kiln, tape the breaker box door shut and leave a note saying, “WORKING ON KILN. BREAKER OFF.”
How to Open the Switch Box . . . . . . . . . . . . . . 36
Preventive Maintenance
Inside the Switch Box . . . . . . . . . . . . . . . . . . . . 37
Element Maintenance . . . . . . . . . . . . . . . . . . . . 37
Firebrick Maintenance . . . . . . . . . . . . . . . . . . . 43
Tightening the Lid Band . . . . . . . . . . . . . . . . . . 45
Adding a Steel Base Plate . . . . . . . . . . . . . . . . 45
Replacing the Steel Base Plate and
Turning Over the Bottom . . . . . . . . . . . . . . . . . 45
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Index . . . . . . . . . . . . . . . . . . . . . . Back Cover
“Pottery, as you know, is frustrating. But we could not fully enjoysuccess if wedid notexperi ence failure. The whole experience is pro found.”
—Steve Burtt
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Fire only in a well ventilated area! 3
SAFETY
IMPORTANT
Read each page of this manual in detail before you install or operate your kiln. Warranty does not cover damage caused by failure to follow instructions.
Note: Experienced kiln operators keep a small
timer with them as a reminder that the kiln is fir ing. You could set the alarm on a digital wrist
­watch for the estimated firing time less 20 min
­utes. When the alarm sounds, go to the firing room to check the kiln. Do not leavethe kiln un
­attended, especially near the estimated shutoff time.
FOOD-SAFE GLAZES
Some glazes may not be designed for surfaces that will be in contact with food or drink. When you make food or drink containers, select a glaze that has been formulated, tested, and labeled as approved for surfaces that will be in contact with food or drink. Follow the glaze manufacturer's instructions exactly, without any variations. Have custom glazes tested for food safety by a lab such as Alfred Analytical Laboratory. You can learn more about glaze safety in Mastering Cone 6 Glazes, by John Hesselberth and Ron Roy.
Insurance Companies
If your insurance company ever inspects your kiln room, tell the inspector that you follow the safety and in stallation guidelinesshown next. What insurance compa nies want to see:
Fire extinguishers and smoke detectors.
An electrical shut-off near the kiln (not needed for 120 volt models).
You have removed combustibles from the kiln room.
A licensed electrician installed the circuit.
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Important Safety Rules
Following these safety pointers will add little extra time to your daily routine. There is little danger of serious burn from accidental contact if you exercise the same caution you would use with an electric iron.
Place the kiln on the stand recommended by Para
gon. When a kiln is safety tested, the lab fires the kiln
on the stand designed for it. Cinder blocks or bricks
can inhibit the flow of air under the kiln. They can
also change the kiln’s heating characteristics.
Place the kiln on a non-combustible surface.
Do not install closer than 12" from any wall or com
bustible surface.
Fire only in a well ventilated, covered, and protected
area.
Do not open the lid until kiln has cooled to room
temperature and all switches are off.
Dangerous voltage: do not touch the heating ele
ments with anything.
Disconnect kiln before servicing.
Do not leave kiln unattended while firing. Do not
leave a kiln turned onat your
studio while you are at home
sleeping.
Wear firing safety glasses
when looking intoa hot kiln.
Unplug the kiln, or turn off
the electrical shut-off box or
circuit breaker when the
kiln is not in use, especially
if you are concerned that
someone could turn it on
while you are away.
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Keep the kiln lid or door
closed when thekiln is not in
use. This keeps dust out of
the kiln. Also, should some
­one turn onthe kiln whileyou are away, the closed lid will keep the heat safely inside the firing chamber.
Never place anything on the kiln lid, even when the kiln is idle. If people become accustomed to placing papers and otherobjects onthe kiln,they may forget and do that while the kiln is firing.
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“Centering the clay has a way of putting me into that altered state where time doesn’t hap pen.”
—Millie Carpenter
4 Monitor the kiln during operation!
Remove all tripping hazards from around the kiln. Keep the kiln’s supply cord out of traffic areas.
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Do not let the cord touch the side of the kiln; it be comes hot enough to damage the cord.
Avoid using extension cords.
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Wear gloves when you
load and unload your
kiln. The gloves should
be thick enough to pro
­tect you from glaze shards and bits of pyro
­metric cones that have stuck to shelves, sharp edges of broken ware, and sharp stilt marks on the bottom of glazed ware. Razor-sharp glaze fragments can be so small that they are difficult to see.
never feel hot. Make sure the plug is pushed all the way into the receptacle.
Never place extra insulation around the kiln in an at tempt to conserve energy. The extra insulation can cause the switch box wiring to over-heat and the steel case to warp.
Do not wearloose-fitting clothing around a hotkiln.
Remove flammable materials from the kiln room. If you fire a kiln in the garage, park your car outside. Remove the lawn mower, gasoline, and other flam mable materials. Keep packing materials such as shredded newspapers out of the kiln room.
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Do not remove the ware from the kiln until the kiln has cooled to room temperature. It is possible for thermal shock to break hot ceramic pieces. The sharp edges of broken ware can injure hands.
After firing glazed ware in your kiln, examine the shelves for glaze particles. Sharp slivers of glaze stuck to the shelf can cut hands. Before rubbing a hand over a shelf, be sure the shelf is free of glaze shards.
Fire only approved materials purchased from a knowledgeable supplier. Do not fire marbles, pieces of concrete, rocks, and other objects. Rapid heating to high temperature can cause violent reactions in many materials.
Avoid firing toxicmaterials such asmoth balls inside the kiln. Moth balls create toxic fumes inside a kiln and can even explode.
Never fire tempered glass inside a kiln. It could ex­plode.
Greenware, which is unfired clay, must be bone dry be
­fore firing. Moist greenware can explode inside the kiln, damaging the ware and the kiln. Place a piece of greenware against the inside of your wrist. If it feels cool, it is too wet to fire.
Do not fire cracked shelves. They can break during firing, damaging the ware inside the kiln.
Store kiln shelves in a dry area.Moist shelves can ex plode inside a kiln.
If you smell burning plastic, turn the kiln off. Exam ine the wall outlet and supply cord for signs of burn ing.
As the kiln fires, it is a good habit to place your hand on the kiln’s power cordto check the temperature. It is okay if the cord is slightly warm, but it should
Keep unsupervised children away.
Keep a Class C fire extinguisher and a smoke alarm in the kiln room. Mount the extinguisher near the door to the room.
Do not breathe brick dust, kiln wash, or kiln repair cement. Prolonged exposure may cause lung injury. Vacuum the kiln with a HEPA filtered vacuum cleaner or a central vacuum that takes the dust out­side.
Only vitrified ware should be used in a microwave oven. (Vitrified clay has been fired to a point where the particles becomeglass-like and nolonger absorb water.) Non-vitrified clay such as earthenware is generally not suitable for microwave use, because the clay absorbs water. The water in the pores of the clay can expand rapidly enough in a microwave to cause the ware to crack or even explode. Ware that has been decorated with metallic glazes should not be used in a microwave oven.
Whenever you turn off the circuit breaker to your kiln, tape the breaker box door shut and leave a note saying, “WORKING ON KILN. BREAKER OFF.”
How to Avoid an Over-Fire
Suggestions by Mel Jacobson, Potter
1 Useanalarmclock.Iusetheoldwind-up
kindwithaloudringer.Setitforacertain time, and make sure you follow the ring. Place a small battery-operated oven timer in your pocket if you need extra reminders.
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2 Get a large bulldog clip and paint KILN in
red. Clip it to your jacket, or hang it from a doorknob. Or place a sign where you hang your apron: KILN ON.
3 When I was a high school teacher, I had the
janitor turnoff the master breaker to the kiln every night at 8. No kiln would ever be on past 7, ever, anyway.
Fire only in a well ventilated area! 5
SETTING UP
Setting Up The Stand
Operate your Paragon kiln only on the stand provided.
(Sometimes people buy used kilns that are missing the original stand and place the kiln on cinder blocks or bricks. This is not a good idea,because bricksmay inhibit the flow of air under the kiln. Cinder blocks could also change the kiln’s heating characteristics.)
We recommend that you wear tight-fitting gloves such
as mechanic’s gloves while assembling the stand.
You will find 2 shelves, 2 side frames, and a bag of nuts
and screws in the stand kit. The shelf with the hole in the center is a top shelf. The solid shelf goes on the bottom. Thesideframeshavebottommountingholesforcasters.
1 Insert a short tab
from the solid shelf into a side frame. The tab goes on the out side of the side frame.
2 Repeat Step 1 for
the other side frame.
3 Lay the top shelf
(the one with the hole in the center) over the side frames. The short tabs goon the out­side of the side frames. The long tabs go on the in side of the side frames.
4 Insert the screws
and nuts.
5 Install the casters. You can leave off the casters if
you want to make the stand shorter.
Caution: You MUST lock the casters before
placing the kiln on the stand.
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Short tab goes on out­side.
The short bent tab goes on the outside of the side frames.
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Short tabs go outside.
The long bent tabs go on the inside of the side frames. The short bent tabs go on the outside.
Install the Orton Vent Cup
Skip this stepif your kilndoes not have an OrtonVent.
1 Attach the hose to the vent cup with the clamp
that came with the Orton Vent.
2 Slide the ventcup up insidethe standand into the
flange supports in the top shelf. Rotate the vent cup a littleas you slide it into the flange supports.
3 Place the gasket that came with the vent over the
vent cup.
Side frame
Long tabs go inside.
Attach the Lock-In Lid Support
Models with the lid support: Connect the lid support to the studonthesideofthekiln. Tighten the lock nut until it is snug.
Where to Locate Your Kiln
In addition to these guidelines, please see “Safe Instal lation of the Electric Kiln,” a separate publication shipped with your kiln.
Plan your firing area near a present electrical outlet or where a new circuit can easily be installed.
Place your kiln in a well-ventilated, covered, and pro tected area such as the garage, basement, storage building, utility or ceramic hobby room.
Caution: The fumes from ware fired in a kiln can
corrode metal and etch windows. If you are in­stalling your kiln in a living area such as the base­ment or in the garage, it should be vented with a motorized vent. Please see “Safe Installation of the Electric Kiln.”
Q Is it okay toplace thekiln on a covered porch or
in a carport?
A Yes. As long as the kiln is protected from the
weather,itcanbeinstalledinaroofed-inarea withopensidessuchasacarport.Butespecially in humid areas, the kiln may rust faster than it would inside an enclosed building.
Do NOTstore gasoline, paint, or other flammable liq uids in the kiln room.
Never allow the room temperature of your firing room to exceed 100 - 110°F. (Room temperature is the tem perature measured three or more feet away from the kiln.) If necessary, use a fan to move the heat away from the kiln’s switch box.
Electrical components such as switches, the digital controller, relays, and wiring lastlonger when theystay cool. The easiest way to lower the temperature of a kiln’s switch box is to blow air into the side louvers with a fan. It doesnot need to be alarge fan; one with 4"
- 8" diameter blades on low speed is effective. The air shouldgoinonesideoftheswitchboxandoutthelou vers of the other side. Do not allow air to blow into the kiln through the peepholes or lid.
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6 Monitor the kiln during operation!
Lower the switch box temperature with air movement. This is especially useful during hot summers.
Provide a minimum of 12” clearance between the kiln and the closest wall.
Never place the kiln near curtains or other combusti ble materials such as art room supplies.
Position the kiln stand on a level surface that will not be damaged by heat. We recommend a cement floor. However, a sheet of protective material may be used under the stand. Consult your hardware or building supply store for a recommendation.
Avoid placing the kiln stand on rubbertile, linoleum or any surface that might tend to mar or discolor when heated.
Place the kiln in an area where it can be easily loaded and unloaded yet out of the way when not in use. For convenience in moving the kiln when not in use, con­sider the reinforced, deluxe stand with casters.
Keep unsupervised childrenaway from the firing area.
Do not allow the kiln’s power supply cord to contact thesideofthekiln.Thiscouldburnthecord.Before each firing, check all around the kiln to make sure nothing is touching the kiln case.
Cold Weather
It is okay to store and firethe kiln in an unheatedbuild ing during winter. But before operating, raise the tem perature of the kiln’s switch box to at least 32°F (0°C) with a space heater.
Q What is the difference in the cost to fire a kiln
in a warm room compared to firing in a cold room?
A Room temperature has almost no effect on the
electrical cost of firing a kiln. However, if your kiln is under a carport that has open sides, pro tect the kiln from wind. Air blowing against the case can raise the electrical cost slightly. If you use a fan to lower the temperature of the switch box, position the fan so that the air blows into the
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switch box louvers but not onto the firing cham ber case.
Installing the Kiln in an Institutional Setting
Sometimes maintenance employees are not familiar with kilns. For this reason you might want to place a sign on top of the kiln when the kiln is not in use:
Do not stand on the kiln.
Do not move the kiln.
Do not place anything on top.
(Reminder: Remove any signs from your kiln before you fire it.)
Place a signon the door of thekiln room: Kilnis Firing.
Every year hold a short kiln orientation session for the maintenance staff. You could also send the same infor mation by e-mail to the school principal and the mainte nance department. Explain the following:
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1 The kiln is fragile.
2 During operation, the kiln makes a clicking noise.
This is normal.
3 If you use a temperature alarm on your digital kiln,
explain the beeping noise. Otherwise it will frighten students and maintenance people be­cause they will assume that something is wrong.
Seating the Elements
Shipping may dislodge the elements of your kiln. Please performthe kitchen knife test to make sure the el­ements are seated in their grooves.
Kitchen Knife Test
Caution: Always unplug the kiln before touching
an element with anything.
Caution: Touch only a cold element, never a hot
one, with a plastic object such as a comb. Plastic will melt on and ruin a hot element.
Press the ele ments into their
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grooves by running a
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blunt kitchen knife, plastic comb, orsimi lar blunt object com pletely around each groove. Do this be fore the first firing, because it may not be evident to the eye whether the coil is in its groove.
Note: Don’t force the element into the groove
corners. If the element won’tfit easily, lengthenit with automotive snap-ring pliers (available from auto parts stores). Stretch the space between the
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Fire only in a well ventilated area! 7
Expanding coils with automotive snap-ring pliers.
As shown here, new elements do not lie flat in a curved groove.
coils just a little where the element fits into the wall brick corners. It should then easily seat into the corners.
If the element doesn’t lie flat in the bottom of its groove, you needn’t be concerned as long as the element fits all the way back into each corner and doesn’t bulge outside the groove. In fact, elements will not lie flat in their ter minal bricks (right behind switch box).
Before the kiln is fired, the elements are mallea ble; there is no danger of breaking the elements when you bend them. After firing, however, the ele mentsbecomebrittleand must be reheated if they bulge out of the groove. See “Reseating a Bulging Element,” page 38.

THE ELECTRIC CIRCUIT

Please have only a qualified electrician install your kiln circuitincompliancewithlocalcodes.Ifyouplantouse an existing circuit, have a qualified electrician check the circuit and compare the wire and breaker sizes with those shownintheParagoncatalogandwebsite.Thecircuit must never be used by other appliances while the kiln is firing.
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Electrical Shutoff
We recommend an electrical shutoff box near the kiln in addi tion to having a circuit breaker at
­the electrical panel. The shutoff
box is a must for direct-wired kilns, which can’t be unplugged to disconnect the power. We rec
­ommend disconnecting the
power when the kiln is not in use. If you unplug the kiln frequently, the spring tension on the wall outlet may eventually weaken. The shutoff box disconnects the power without having to unplug the kiln.
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Cleaning the Kiln
Cleanyourkilnbefore firing. Use a a vacuum cleaner (preferably with a soft brush nozzle) to re­move brick dust from in­side the kiln, especially from the grooves. A damp cloth or damp sponge may also be usedto gently wipe dust from the sidewalls and brick bottom. Clean the kiln again whenever you notice dust inside.
Note: Vacuum the kiln with a HEPA filtered vac
uum cleaner or a central vacuum that takes the dust outside. Keep the vacuum hose away from the controller on digital kilns.
“What is it about that meditative quiet when kids are working with clay? I teach 3rd, 4th and 5th graders in a very poor neighborhood, and even the toughest 5th grader will let down his ‘cool and tough’ act for clay.”
—Grace Sheese
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Note: The shutoff box is not needed for 120 volt
kilns.
Circuit Breaker Panel
Install the kiln within 25' of the fuse or circuit breaker panel. For every additional 50' from the panel, increase the circuit wire size by one gauge.
But do not place the kiln right in front of the electrical panel. Keep the panel at least 3' - 4' away. Otherwise, the breakers may trip more easily on a hot day. This is be cause a circuit breaker is triggered by heat, and a nearby kiln can raise the temperature of the electrical panel.
Note: Do not use the circuit breaker to discon
nect the kiln. Frequently switching the circuit breaker will weaken it. Instead, use a shutoff box located near the kiln.
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Circuit Wire
Useacircuitwiresizelargeenoughforthewallrecep tacle amperage, even if the kiln amperage is less than the wall receptacle amperage.
WARNING: Changing the cord plug on Paragon kilns mayvoid your warranty.
Trying to save money on the circuit installation by us ing a smaller diameter wire is not cost effective, because the thinner wire generates more heat than the thicker
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8 Monitor the kiln during operation!
wire. The heat means wasted electricity and sometimes slightly lower voltage.
Use copper wire. Do notallow an electrician to usealu minum wire on your new circuit. Aluminum terminals corrode worse than copper and require greater installa tion care. Avoid using extension cords.
The Paragon kiln catalog and website show recom mended breaker and wire sizes for the circuit. (These recommendations assume that the circuit is dedicated, which means that it powers only the kiln and no other appliance.) Local codes supersede our catalog recom mendations.
You may already have a heavy-amperage circuit conve niently located where you will keep your kiln. But do not assume that the circuit is the correct size. Clothes dryer circuits are too small for most studio kilns. Even if you have the correct wall outlet,you shouldverify that the wire and breaker sizes are also correct.
Voltage Affects Firing Time
Voltage fluctuation can vary the firing time for a given pyrometric cone from as little as one half to more than twice the average time. If the voltage is too low, the kiln will never reach full temperature. This can be corrected only by having the utility company adjust the voltage. (However, 208 volts cannot be adjusted to 240 volts, and vice versa.)
Check the Electrical Installation
Check the receptacle voltage with a voltmeter before plugging in your kiln. Measure between the two slots where the flat blades on the plug are inserted. Only a qualified person should perform this test, because improper use of a voltmeter can result in shock to the user.
Verify that the safety grounding wire is prop erly connected in accor dance with the National Electric Code (or equiv alent for your country). Thiscanbeprovenonly by visual inspection of the receptacle wiring. Sometimes circuits have been installed by home owners with limited electrical experience.
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Checking the voltage of a wall outlet in the Paragon factory.
PREPARING
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THE KILN
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Kiln Features
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Kiln Firebricks
Premium, hand-selected insulating refractory bricks
are lightweight, porous, and precision cut tofit tightly and
­store heat in the walls, bottom, and lid. The form-fitted
jacket snugly holds the bricks together. Because the fire
­bricks store heatso efficiently,the cost ofelectricity to fire
the kiln is surprisingly low. Kiln brick is extremely fragile and will chip easily; always handle your kiln and its brick with care. Never let a shelf bump against the firebrick. Firebrick damage is not covered by warranty.
Note: Allow only trusted people to load and un
load your kiln. Beginners may not understand that the firebricks are fragile.
The temperature required for ceramics is well above the melting pointofmostmetals,andtremen­dous stressesare generated during the firing. The insulating fire­bricks expand and contract with each firing. In time, cracks will ap­pear in the brick while the kiln is cold. This is normal and will notaf­fect your kiln’s operation.
Heating Elements
The heating elements in your Paragon kiln are heavy duty for long life. All high temperature, heavy duty ele­ments are quite brittle after being heated to a high tem perature and will break if bent while cold. By heating to a dull red glow with a propane torch, an element may be bent safely.
Never allowglaze, glass, silica sand, kiln wash, or other foreign materials to touch the elements since they will destroy the element when the kiln is fired.
Peepholes
Large peepholes (view ports), tapered for a wide view without heat loss, are used for observing theprogressofyourfiringsoyou can see when the pyrometric cones bend. Use at least one large cone on the shelf during every fir ing—even in a digital kiln. With venting as their secondary func tion, peepholes allow oxygen to be drawn into the kiln’s chamber and serve as anescape pas sage for smoke and water vapor.
When looking through the peepholes, always wear fir ing safety glasses, which areavailable from Paragon.They
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Fire only in a well ventilated area! 9
Monthly Kiln
Maintenance
1 Make sure the kiln is centered on the stand
and that the stand is stable. Check the area around the kiln and remove flammable ma terials that have accumulated.
2 Vacuum the kiln with the soft brushnozzle of
avacuum.(Youcanuseahardplasticnozzle as long as you don’t touch the bricks with it.) Remember to vacuum the brick grooves. If you have difficulty removing debris inside the grooves,use anarrow wand-typevacuum cleaner nozzle being careful not to scrape the brick walls. (See page 17.)
3 Vacuum around and
under the kiln: floor, shelves, and walls. This keeps the kiln interior cleaner and adds life to the op­tion vent motor.
protect your eyes from the bright glareof the firing cham
­ber and make it easier to see the cones at high tempera
­tures.
Peephole plugs are used to
stop air from entering the kiln,
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not to prevent heat loss. It is beneficial to have some air en
­tering the kiln at all times, so it is not necessary that the plugs fit tightly.
Wear firing safety glasses when looking through a peep hole into a hot kiln.
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You can leave the peephole
plugs out for some firings. This improves oxygenation in
­side the kiln. However, this may cause cold spots in the kiln, especiallyif there are air drafts in your firing room. If you leave the peephole plugs out, keep ware at least 3" from the peephole. If your ware develops problems from cool air drafts, such as a glazed piece with a crazed spot, insert the peephole plugs after the kiln reaches 1000°F (537°C), or about half way through the firing. If you use a motorized downdraft Orton Master Vent, keep peephole plugs inserted and the lid closed all the way for the entire firing.
Prop-R-Vent
4 Check the kiln wash
on shelves and kiln bottom for cracks and bare spots in the coating. Remove any glaze drips. Reapply kiln wash if needed. (See page 19.)
5 Check the power
cord and outlet for heat damage. Has the cord touched the side of the kiln during firing? This will damage the cord insulation. Replace the cordsetorwalloutletthatshowssignsofheat damage.
6 Make sure elements are not bulging out of
the grooves. Repair if necessary. (See page
38.)
7 Kiln Downdraft Vent: Check the vent duct
for leaks. (See page 26.)
8 Digital kilns: Make sure the thermocouple
extends far enough into kiln:
¼" diameter thermocouple: 1" into the kiln
1
" diameter thermocouple:
8
5
" into the kiln
8
Leave the lid closed if you have a motorized downdraft vent.
The Prop-R-Ventin the first position.
The Prop-R-Vent in the extended position.
Ceramic pieces release gases and water vapor during firing. Venting allows these gases to escape. Paragon’s fall away Prop-R-Vent is installed on the switch box of most top-loading kilns. The prop supports the lid in an open position during the venting period. The Prop-R-Vent vents the lid in two stages.
To close the lid after venting, lift the lid handle an inch to let the Prop-R-Vent fall. Lower the lid gently; warranty does not cover damage to the kiln or the ware due to a dropped lid. For lusters and overglazes, engage the Prop-R-Vent in its second position for additional venting. Do not rush the cooling of your kiln with the Prop-R-Vent. This can damage your ware.
Do not drop the lid. Some people touch the lid handle for the first time to lower the lid from venting and drop the lid because the handle is hot. Use a heat-resistant glove or a lid lifter (sold by Paragon) to lower the lid.
10 Monitor the kiln during operation!
Full-Formed Steel Base
The galvanized steel base under the brick bottom strengthens the kiln. It cov
­ers the entire bottom from edge to edge.
The Lid Support
Your kiln has either the lock-in lid support or the LiteLid spring coun
­ter-balance. Please do not let unat tended chil
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­dren raise the lid. Do not let the lid drop. It is fragile and mustbe lowered gently.
Keep the kiln lid closed when
the kiln is not in use. This keeps
Do not exert downward pressure on the lid until the lock-in lid support is completely disengaged.
dust out of the kiln. Also, should someoneturnonthekilnwhileyouareaway,theclosed lid will keep the heat safely inside the firing chamber.
The LiteLid Support
1 Begin raising the lidusing
the center lid handle. When the lid feels weightless, hold a side lid handle with your other hand to guide the lid the rest of the way up.
2 Donotletgoofthesidelid
handle until the lid
The LiteLid spring can pinch fin gers. Please keep unattended children away from the kiln.
reaches its fully opened position. Otherwise the lid could slam upward, damaging the firebricks near the hinge. (Please note: This type of damage is not covered by war
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ranty.)
3 Stay clear of the lid when
raising or lowering. This is to prevent injury should
Do not let go of the side lid han dle until the lid reaches its fully opened position.
the lid drop.
Dust-Free Refractory Coating
The dark coating on the lid, the top rim of firebricks, and in the peepholes reduces dust and hardens the fire brick surface for longer life. Though it will lighten after the first firing, the coating will last for several years.

PYROMETRIC CONES

Ceramists of early times judged when the fir ing was completed by the color of the kiln interior and the length of firing. In 1886, a German ceramist named Seger made clay cones that bent when the
A selection of self-supporting cones. See the cone charts on pages 12 and 13 for a list of cone colors.
could see the cones bend and knew when to turn off the kiln. His cones took the guesswork out of firing.
Today westill use Seger’s cones. They are called pyro metric cones and are small pyramids of clay and mineral oxide that soften and bend when exposed to heat. They indicate when your ware has fired to maturity. When con­sulting your dealer with a glaze problem, you should have abentconefromthatfiring.Theconewillhelptrouble shoot the problem. The cone lets you compare one firing to the next. Cones are manufactured by the Orton Ce­ramic Foundation andare available fromyour distributor.
Cone Numbers
The most confusing thing about cones is the way they are numbered. They are easier to understand when you know the reason behind the numbers. Pyrometric cones are numbered from 022 through 01 and 1 through 10. Cone 022 matures at the lowest temperature, and 10 ma
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tures at the highest.
Seger numberedhis original cones from 1 to 20, with 1
being the lowest temperature. Later, cones of even lower temper atures thancone 1 were needed. To avoid changing all the cone num bers, thenew numbers started with “0” and went from 01 to 022, with higher numbers getting progres sively cooler.
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place the “0” with a minus sign. Numbers without the “0” are posi tive. The higher the positive num
ber, the higher the temperature. Numbers with the “0” (or a minus sign) are negative. The higher the negative number, the lower the tempera
­ture.Withthisinmind,youcanquicklyseethatcone5is
hotter than 05.
Note: Store boxes of cones in numerical order
from lowest to highest temperature so that you
ceramic ware received the proper heat work. He posi tioned the cones on a shelf inside the kiln. By looking through a peephole, he
To avoid confusion, mentally re
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Fire only in a well ventilated area! 11
will be less likely to inadvertently pick up the wrong box.
The number is stamped on the base of the cone. The cone number for each material is usually stated on the la bel by the clay or glaze manufacturer. Your supplier can also give you the cone number.
Heat Work
Cones are rated by temperature. But it is more accu rate to think of themas measuring heatwork, not temper ature alone. Heat work is the combined effect of time, temperature, and the atmosphere inside the kiln. All thesefactorsaffectthematurityofyourwareandnotjust temperature. For instance, firing to a lower temperature for a longer time will produce the same maturity as firing to a higher temperature for a shorter time. The “Tem perature Equivalents” chart (next column) shows that a self-supporting 05 cone requires a temperature of1911°F to bend to 6 o’clock, yet when fired slower, it will bend at 1870°F.
During the last 100 - 200 degrees of firing, the firing rate affects the bending temperature of a pyrometric cone. The faster the rate, the higher the temperature whentheconebends.Butthefiringspeedbeforethelast 100 - 200 degrees has no influence on the final tempera­ture of the pyrometric cone. The exception is an ex­tremely fast firing that bloats the cone.
Consult your supplier for therecommended firing rate of yourclays andglazes. Thethicker theclay, theslower it should be fired. Firing clay is like making cookies in an oven. Heat the cookies fast, and they will be brown on the outside but still gooey on the inside. Heat the cookies slowly, and they will be brown all the way through.
Using Cones
Place the cones on a kiln shelf with the ware. As the cones heat and bend, they form a glassy material that will stick to a bare shelf. Therefore, apply kiln wash to the shelvestopreventsticking.Donotapplykilnwashtothe cones.(Seepage19forkilnwash.)Theconesslant8de grees from vertical and bend in the direction of the slant. They will not bend accurately if they are slanted at the wrong angle. Position a cone so it will not touch nearby ware as it bends.
Large cones come in ei ther standard or self-sup porting. Standard large cones must be mounted in a clay or wire plaque with 2" of the cone exposed above the cone holder. Or you can mount largecones ina patof clay. The clay should be dry before firing. To speed dry ing, make indentions in the clay with the end of a small
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Standard large cones in clay cone packs.
°F Temperature Equivalents For Orton
Self-Supporting Pyrometric Cones
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Cone Self-Supporting Cones Pre-Fire
Number Color
Heated at: 27° F 108° F 270° F
Per Hour* Per Hour* Per Hour*
022 1087 1094 Green 021 1112 1143 Fuschia 020 1159 1180 Orange 019 1213 1252 1283 Yellow 018 1267 1319 1353 White 017 1301 1360 1405 Pink 016 1368 1422 1465 Light Blue 015 1382 1456 1504 Violet 014 1395 1485 1540 Gray 013 1485 1539 1582 Green 012 1549 1582 1620 Fuschia 011 1575 1607 1641 Orange 010 1636 1657 1679 Dark Red 09 1665 1688 1706 Dark Red 08 1692 1728 1753 Dark Red 07 1764 1789 1809 Dark Red 06 1798 1828 1855 Dark Red 05 1/2 1839 1859 1877 Dark Red 05 1870 1888 1911 Dark Red 04 1915 1945 1971 Dark Red 03 1960 1987 2019 Dark Red 02 1972 2016 2052 Dark Red 01 1999 2046 2080 Dark Red
1 2028 2079 2109 Dark Red 2 2034 2088 2127 Dark Red 3 2039 2106 2138 Dark Red 4 2086 2124 2161 Gray 5 2118 2167 2205 Green 5 1/2 2133 2197 2237 White 6 2165 2232 2269 Fuchsia 7 2194 2262 2295 Orange 8 2212 2280 2320 Yellow 9 2235 2300 2336 White
10 2284 2345 2381 Pink
*Rate of temperature increase during last 90 ­120 minutes of firing. Tables by courtesy of the Ed ward Orton, Jr. Ceramic Foundation.
Cone
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12 Monitor the kiln during operation!
°C Temperature Equivalents
For Orton Self-Supporting
Pyrometric Cones
Cone Self-Supporting Cones Pre-Fire
Number Color
Heated at: 15° C 60° C 150° C
Per Hour* Per Hour* Per Hour*
022 586 590 Green 021 600 617 Fuschia 020 626 638 Orange 019 656 678 695 Yellow 018 686 715 734 White 017 705 738 763 Pink 016 742 772 796 Light Blue 015 750 791 818 Violet 014 757 807 838 Gray 013 807 837 861 Green 012 843 861 882 Fuschia 011 857 875 894 Orange 010 891 903 915 Dark Red 09 907 920 930 Dark Red 08 922 942 956 Dark Red 07 962 976 987 Dark Red 06 981 998 1013 Dark Red 05 1/2 1004 1015 1025 Dark Red 05 1021 1031 1044 Dark Red 04 1046 1063 1077 Dark Red 03 1071 1086 1104 Dark Red 02 1078 1102 1122 Dark Red 01 1093 1119 1138 Dark Red
1 1109 1137 1154 Dark Red 2 1112 1142 1164 Dark Red 3 1115 1152 1170 Dark Red 4 1141 1162 1183 Gray 5 1159 1186 1207 Green 5 1/2 1167 1203 1225 White 6 1185 1222 1243 Fuchsia 7 1201 1239 1257 Orange 8 1211 1249 1271 Yellow 9 1224 1260 1280 White
10 1251 1285 1305 Pink
*Rate of temperature increase during last 90 ­120 minutes of firing. Tables by courtesy of the Ed ward Orton, Jr. Ceramic Foundation.
brushhandleaftertheconeisinserted.Self-supporting cones stand upright without holders. We recommend self-supporting cones; they are easier and faster to use than standard large cones.
Handle cones carefully. They are fragile because they are unfired clay. If dropped, they may develop cracks that could affect their performance. Age and normal humidity do not affect the accuracy of cones. Even if a box of cones is 20 years old, you can still use them. However, do not use them ifthey become wet.
Standard pyrometric cones come in two lengths: 1
1
" and 2 ½". The small cone
8
is used in the Kiln Sitter and the large cone is used on the kiln shelf.
Note: The Kiln Sitter is
a mechanical shut-off device that is triggered by the bending of a smallcone.Digitalcon trollers do not use the
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A self-supporting cone next to a small Kiln Sitter cone.
small Kiln Sitter cone.
Self-supporting conesare
3
2
" long. They are packaged
8
as sets of double cones so that they will be less fragile in shipping. You will need to separate the cones. Hold the large section of the cones with the thumb and forefin­ger of each hand and twist. They will snap apart.
Check the accuracy of
Separate the cones with thumb pressure.
yourKilnSitterordigital controller by placing cones on the shelf. Mount behind each peephole a large cone of the same number you are firing to. This is the firing cone. Next to the firing cone placealargeconeofthenextlowertemperature;thisis the guard cone. For example, if you are firing to cone 05, place large cones 05 and 06 on the shelf behind the peep holes. We recommend at least one large shelf cone in ev
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ery firing.
Place large cones on the shelf at least 3" away from a peephole. This is to avoid cool air drafts.
Always use Paragon firing safety glasses when looking into the peepholes. These glasses are specially coated to filter out the infra-red and ultra-violet light inside a kiln. They also protect your eyes from heat and reduce glare, making the pyrometric cones easier to see.
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Fire only in a well ventilated area! 13
How to Position Cones
mit placing a shelf at peephole level, use a post to raise the cones.
on the Shelf
A cone seen through a peephole while the kiln is at room tempera ture.
A same cone silhouetted by a heat
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ing element at cone 7—2262°F (1239°C).
4 The element thatsilhouettes the cones should be
level with the lower part of the cone. If the ele
­ment is in line with the upper part of the cone, the cone willdisappear from view when itbends.
Note: The center ele
­ments in some kiln models do not glow brightly even at high temperatures. In this case, position the wit
­ness cones level with a top or bottom element.
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The element must glow brightly to silhou
The top and bottom elements glow brighter than thecenterelementsin
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some kilns.
ette the cones.
5 If you use the three-cone system, always have the
higher temperature cone onthesamesideinevery firing. Otherwise you can lose track of which cone is which.
6 Wear kiln firing safety
glasses when viewing the cones through the peep­hole.
Wear firing safety glasses when viewing a witness cone.
Position the witness cones so that you can see them through a peephole during firing. If the kiln takes longer than usual to fire, you may wonder if something has gone wrong and the kiln is over-firing. But by seeing the cones, you will know how the firing is actually progressing.
If you follow these guidelines,you shouldbe able to see the cones even at cone 10:
1 Place the cones8" - 12" away from a peephole.Po
­sitioning them closer makes them difficult tosee and may also subject them to cool air drafts.
Note: Keep cones at least 2" from an element.
2 Have enough space
around the cones to keep them from touching a piece of ware when they bend.
3 Position cones so that
when viewed from the peephole, they are sil houetted by an ele
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­ment on the opposite kiln wall. If the size of your ware doesn’t per
Line up the heating element with the lower part of the cones.
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Note: You may find it easier
to see the cones by holding a small mirror at a 45° angle in front of the peephole. You will still need firing safety glasses.
Caution: Some ceramists blow into the peephole
to momentarily darken the cone so they can see it better. Please do not do this. This can blow brick dust onto the ware and is a safety hazard. Cool air also changes the temperature at which the cone bends.
Caution: Some ceramists coat the witness cones
with red iron oxide to make them easier to see. Avoid this. It changes the temperature at which
theconebends.
“Working in my small studio keepsmesaneandhappy.Ifor get about everythingelse and am grateful to do what I do.”
—Heidrun Schmid
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14 Monitor the kiln during operation!
The Bending
Q When a kiln is taking longer thanusual tocom
plete a firing, how do you know whether some thing has gonewrong and the kiln isover-firing?
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of the Cone
You can watch the cones as they bend. If you want to slow down the bending for greater con trol, add a digital temperature hold near the end of the firing. (See the separate controller man ual.)
The large standard and self-supporting wit ness cones have reached maturity when the tip bends to the 6 o’clock position.
Large standard cone: The tip should bend straight down until it just begins to touch the cone holder.
Self-supporting cone: The self-supporting cone should bend downward until the tip is even with the top of the base. The tip should be about ½" above the shelf surface. If the self-supporting cone tip touches the shelf, the cone is over-fired by a few degrees of temperature.
Self-supporting cones: Left, over-fired or “puddled”; Center, fired to maturity; Right, under-fired.
UsingConesin
A You should place pyrometric witness cones on
the shelf so that you can see them through a
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peephole.
Here’s another way to help prevent an over-fire: Learn to estimate kiln tem perature by the color of light showing around the lid and peepholes. That way, you can tell at a glance if all is well with your kiln when you check it.
Q Is it okay to use old
cones?
A Yes. Age does not af
fect the cones.
Q Do you need to look
at witness cones dur­ing a firing or only after the kiln has cooled?
A Position the cones so that you can see them
through a peephole. Form the habit of looking at the cones near the expected shutoff time espe­cially if thefiring is taking longer thanexpected.
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The light around the edge of the lid
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and inside the peephole changes color as the kiln gets hotter. You can learn to estimate temperature by the color of that light.
“My grandmother, who has taught china painting for 60 years,coached me duringmy first firing. I treasure the memory of that moment of my life with her.”
—Darcy Giesseman
Digital Kilns
Although the digital controllers do not need cones to operate, we recommend them anyway. Place at least one self-supporting cone on a shelf behind a peephole in ev ery firing.
If the bending of the witness cones varies slightly from firing to firing, you need not be concerned. Slight varia tions in the bending of the cone are normal and may be due to the location of the cones on the shelf, the distance of the cones from ceramic ware, and even variations in cones from box to box. This normal variation will have no effect on your ware.
If your digital kiln shutsoff before the large coneon the shelf bends and you’re there when it happens, program the controller to a higher temperature or add a hold. (See the separate digital controller manual for your kiln.) Then turn the kiln back on.
“When I couldn’t get my first little half pound ball of clay to center, my teacher kneeled down beside my wheel, waited for me to stop, and said,
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‘Hey, it’s just mud. Don’t let it control you. You control it.’ When I have a problem, especially
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with centering, I just zone out with my hands in position on the clay, relax my shoulders, and tell myself, ‘It’s just mud.’ And the clay obeys.”
—Sheron Roberts
“I love the impossibility of ceramics. Just when I think I’ve got it figured out, something bursts my bubble once again. It keeps me hum ble. It keeps me interested, challenged, en thralled.”
—Kelley Webb Randel
Fire only in a well ventilated area! 15
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