Copyright: Version 1.1
Citation: Copyright 1999 ~ FireRight/Warner Instruments


Table of Contents

The AutoMatePC

An Automatic Turn-Up System for Ceramic Kilns

Contents:

Purpose of the AutoMatePC

Description of the System

Installing the Hardware

About Communication Ports

Determining Which Port to Use

Software Installation

Visual Basic Runtime Files

Program Setup

Uninstalling the Software

Operating Instructions

Logging Firing Data

Maintenance and Troubleshooting

Electrical Problems

Computer/Software Problems

Technical Support and Repair Services

Warranty

Contact Information

.


Purpose of the FireRight PC

Purpose of the AutoMatePC

The AutoMatePC is a simple control system that is used to regulate the heat-up rate of electric ceramic kilns.

Firing ceramics is a heat-treating process, wherein most of the “work” occurs at high temperatures. The process is a very simple one, which involves subjecting ceramic items to extreme heat for a specified period of time. In the simplest analysis, the process changes the original material (clay or formulations of clays) into glass or a glassy substance through heat fusion.

What happens during the early stages of such firings is ordinarily of little consequence to the finished result, except for the possibility of destructive stresses imposed on the pieces being fired if the heat is applied too rapidly. These may occur in either of two ways:

1.	Moisture in the material may turn to steam as its temperature increases beyond 100°C/212°F, the boiling point of water. If this occurs within the body of the material, and the expanding steam is not readily vented, it may cause the piece to crack or burst.

1.	As ceramic materials are heated up, they pass through two zones, called “inversions”, wherein they expand very rapidly. One of these zones occurs at about 225°C/437°F and the other in the area of 550°C/1022°F.  Pieces which are not uniform in thickness are likely to have temperature variations within their mass, since lighter areas will follow the kiln’s temperature closely, while the thicker areas lag behind. The non-uniform temperatures within the piece cause different areas to expand at different rates and the resulting stresses produce cracks.

Ceramic kilns are designed to achieve temperatures as high as 1370°C/2500°F, and therefore have the greatest heating capacity in just these areas where too much heat, applied too rapidly, can cause problems. It is therefore necessary to throttle them during the early firing stages in order to prevent damage to the ware being fired. Practical kilns have always been equipped with simple switches of some sort, which enable the user to do this. Kiln instructions are usually quite simple, advising the user to start with these switches set at “Low”, then in a hour or two move them to “Medium”, and finally perhaps two or three hours after that, to “High”.

This is a simple, “low-tech”, low-cost solution to a simple problem. However, the trade-off is one of convenience and efficiency. Once a firing begins, the user must be on-hand for several hours to do the “switch schedule”. That’s inconvenient. Furthermore, because of the relatively long periods involved, it's easy to forget or become involved in some other matter which makes it difficult or impossible to get back to the kiln at the appointed time. The excess time spent at low temperature is then simply a waste of electricity and kiln time.

The AutoMatePC is the latest version of a control that has been successfully used to turn kilns up automatically for several years. Originally designed as a discrete electronic device, the “PC” version provides the same function in software. This yields the advantages of …

•	improved accuracy

•	enhanced reliability

•	improved ease of use

•	easily updated

•	expanded utilization of your small-office computer systems

The accuracy of the system is improved since the computer works in the digital domain, which is not subject to electronic component variations and tolerances. Removing delicate electronics from the heat of the kiln room enhances reliability; the computer need not be near the kiln. The system is based on the familiar Windows95/98 operating system so the user interface will be immediately familiar to anyone acquainted with these operating systems. Since the major functions are implemented is software, updates and improvements can easily be achieved by simply installing the latest version of the control. Finally, as a Windows program, the AutoMatePC is fully capable of working in a “multitasking” environment … working in the background while the computer is being used for other things. It also provides an opportunity to make use of otherwise idle computer time.

 Registered Trademarks ~ Microsoft Corporation

 Tradename ~ FireRight/Warner Instruments


Description of the System

Electric kilns are simple heating chambers made of soft (synthetic) firebrick, with electric heating elements made of windings of high-temperature resistance wire. In this respect, kilns are, more or less, all the same. Larger kilns simply have more elements, and they’re all connected in parallel across in the input power line. When the power is turned on, all of the heaters will be turned on at the same time, and unless throttled by some sort of switching arrangement, they will all begin to produce their maximum possible output.

The AutoMatePC throttles the heaters using a method known as “time proportioning”. This is a simple method which involves repetitively switching the heaters on and off on a regular basis, then varying the “ON” time within each cycle. When the “ON” time during each switching cycle is short, the equivalent of a “Low” setting is produced just as if the electric power had been reduced by an equal percentage. Because kilns have a very long “thermal time constant”, the On/Off heat pulses are dampened out and are actually never seen by the ware being fired.

The AutoMatePC system is compatible with “PC” type computers running under the Windows95 and Windows98 operating systems. It has three components:

•	an output adapter for your computer’s serial port,

•	an electrical power interface or control box for your kiln, and

•	a modular cable which connects the above two items.

The output adapter isolates your computer from the kiln and its electrical system. It uses an optical link to transfer heating signals produced by the computer from the kiln and its electrical system. There is no electrical connection between your computer’s sensitive circuitry and the kiln’s high-voltage system.

The electrical power controller contains a large power contactor, which is used to connect your kiln to the power source whenever the computer calls for more heat. The contactor in the standard AutoMatePC system is capable of handling up to 50-amps on 208/240vac single-phase power systems. This accommodates all but the very largest kilns. This box may be mounted on the wall of the kiln room, and either connected to a 50-amp wall receptacle or wired directly to the kiln.

Systems installed by kiln dealers and manufacturers often have the heating relay built right into the kiln. In this case, a small “Interface Panel” replaces the power controller box.

A common 6-wire (RJ12) modular-type telephone cable connects the output adapter to the power controller (or Interface Panel). The length of this cable is unimportant, so your computer need not be physically near your kiln. A twenty-five foot (7.6m) cable is provided.

 Registered Trademarks ~ Microsoft Corporation

 Tradename ~ FireRight/Warner Instruments


Hardware Installation

Plug the output adapter into the mating connector on the back of your computer. This connector is sometimes labeled “Com 2” or “Serial Port”. In any case, the adapter will not fit any inappropriate connector.

The electrical power control box contains a large relay which is used to switch your kiln on and off. Standard power controllers will accommodate kilns wired for 208/240vac and drawing up to 50-amps. Check the nameplate on your kiln to verify compatibility. Ideally, this box should be mounted on the wall in your kiln room, just below the switchbox or electric service box that is the source of your kiln’s electrical power. Hooking up this box is a simple matter of connecting power from the electrical service to one side of its large relay, or “power contactor”.

Notice that either side of the contactor has two large screw-clamp connectors that will accommodate wires up to size 6, and that one side of the relay already has connections made at smaller auxiliary terminals. The power source should be connected to this side of the contactor.

Connect your kiln’s power cable to the other side.

A detailed wiring diagram is also provided inside the power controller box. You can verify that the connections you’ve made are correct by referring to this diagram.

Having installed both the computer output adapter and the electrical power control box, connect the modular cable between these two units. The cable uses the same type connector on either end, so it makes no difference which end is connected to which component. The connectors are also keyed to assure that they are correctly plugged into a mating receptacle.

About Communications Ports

Standard “PC” and compatible computers have, as a matter of convention, two “serial ports”. A serial port is an input/output connector on the back of the computer that is used to communicate with external devices. These communication ports pass data bi-directionally in serial (bit-by-bit) form. A chip inside the computer converts this “data stream” to the “parallel” form ordinarily passed around between the components on the motherboard and within the CPU itself. It also converts parallel data to serial bit streams for transmission to remote devices over a simple pair of wires.

The two serial ports on your computer will conventionally be referred to a COM1 and COM2. COM1 is ordinarily equipped with a small 9-pin connector. COM2 is usually equipped with a 25-pin connector. The standard output adapter fits the 25-pin connector.

Determining Which Port to Use

To determine which port to use and verify that it is properly set up, do this:

1	The mouse frequently uses COM1. Follow your mouse cable to see if it is plugged into the 9-pin connector on the back of your computer. If not, you might be able to use this port for the AutoMatePC, using the 9-to-25-pin adapter that was supplied with your computer. These adapters are also commonly available wherever computers are sold, or are available from FireRight.

2	Although COM2 is usually available, if you have an external modem it will be probably be plugged into this port. Scanners also sometimes (rarely) use this port. You will not be able to use the COM2 port for the AutoMatePC and another device at the same time. To use COM2 for the AutoMatePC, temporarily unplug whatever is connected to it and plug in the AutoMate PC adapter.

3	If the 25-pin connector appears to be available, Internal modems are sometimes configured as “COM2” and this secondary serial port is then either disabled in the computer’s CMOS setup, or configured as “COM3” or “COM4”. If you have an internal modem, look into this matter by doing this:

a)	Click on Start|Settings|Control Panel|System|Device Manager”.

b)	Click on the [+] next to the “Modem” item, then on the name of your internal modem, and then on the “Properties” button.

c)	Click on the “Modem” tab to reveal the “Port” setting.

d)	Ideally, the port setting should be “Communications Port (COM3).

e)	Make a note of this setting.

4	Check for the presence of your secondary serial port by expanding the “Ports [COM and LPT]” item in the “Device Manager” window.

If you see …

Communications Port (COM1)

Communications Port (COM2)

Communications Port (COM3)

Printer Port (LPT1)

… your secondary serial port is present. It will be either COM2 or COM3, whichever port is not being used by your internal modem. If you see only two communications ports listed, and one is your modem, your secondary serial port has probably been disabled in your CMOS setup in order to permit COM2 to be used by an internal modem. To enable it, do this:

a)	Close all windows and running applications, then reboot your computer.

b)	One of the first screens in your boot-up process will tell you how to enter the CMOS setup program … often by simply pressing the DEL key, or some other key or key combination. Press that key or key combination to enter the setup program.

c)	CMOS setups vary, but you should look for some reference to “Serial Ports” or “Communications Ports”. If you find “COM2” or “Secondary Serial Port” listed as “OFF” or “DISABLED”, change the setting to …

(i)	“ON”,

(ii)	“ENABLED”,

(iii)	2F8h (to use this port as “COM2”), or

(iv)	2E8h (to use this port as “COM3” if an internal modem is configured as “COM2”)

d)	Then exit the CMOS setup by selecting “Save Changes and Exit”, or the equivalent.

e)	When Windows restarts, it should automatically install the secondary serial port. Click on Start|Settings|Control Panel|System|Device Manager”, the click on the [+] next to “Ports (COM and LPT). If you do not have an internal modem installed in your computer, the new port will have been installed as COM2, otherwise it should appear as COM3.

f)	If Windows failed to detect and automatically install your secondary serial port, you can do this manually:

(i)	click on Start|Settings|Control Panel|Add New Hardware

(ii)	click on “Next” two times, allowing Windows to search for Plug-and-Play hardware.

(iii)	if Windows detects the COM port, click “Yes, I am finished installing devices”’ then click “Next”, the “Finish”

(iv)	if Windows failed to automatically detect the port, at the “New Hardware Wizard” select “No, I want to select the hardware from a list”, then click “Next”

(v)	in the list provided, select “Ports (COM and LPT)”, the click “Next”

(vi)	in the resulting selection box, click on “Communications Port”, then click “Next”

(vii)	in the “New Hardware Wizard” accept the settings Windows proposes, click “Next”, then “Finish”.

(viii)	if Windows offeres to restart your computer, permit it to do so

5	Serial ports each require an “interrupt line” to your computer’s CPU, and each port must have it’s own private IRQ line. To verify that Windows has configured your ports properly, do this:

a)	click on Start|Settings|Control Panel|System|Device Manager

b)	click on the “Computer” icon at the very top of the Device Manager tree

c)	click on View Resources|Interupt Request (IRQ)

d)	notice the “Settings” used for your COM ports, and verify that each one uses a different IRQ number. The standard settings are:

e)	if you have only two communications ports installed, the IRQ settings you see should comply with the above table.

f)	if you have three communications ports installed (one being an internal modem) some other IRQ number should be assigned to COM3, preferably IRQ5 or IRQ7

g)	if your secondary communications port has been assigned the same IRQ as your internal modem, look at the IRQ numbers listed under the “Setting” column to find an available number. The usual possibilities are IRQ5, IRQ7, IRQ10, IRQ11 or IRQ15:

h)	Make a note of the unused IRQ numbers.

i)	The availability of IRQs depends upon how much hardware is installed on your machine. If none are available, you will not be able to install the AutoMatePC on this machine without first removing some other hardware.

(i)	To temporarily remove hardware, go to Start|Settings|Control Panel|System|Device Manager and select “Properties” for the hardware you wish to disable. On the “General” tab, place a check mark in the “Disable in this hardware profile” box, then click “OK”. It is not necessary to remove the hardware profile from the Device Manager. When you wish to reinstall your device, return and uncheck this box, then disable the hardware profile for the device previously installed in its place.

6	if you need to change the IRQ setting for your secondary serial port, do this:

a)	click on Start|Settings|Control Panel|System|Device Manager|System

b)	click on the [+] next to Ports (COM and LPT)

c)	click on the “Communications Port (COMx)” which represents your secondary serial port, click on “Properties”, the click on the “Resources” tab

d)	The “Input/Output Range” should agree with the above table. To change the IRQ number, remove the checkmark from the “Use automatic settings” box, then select a “Basic Configuration” with the correct “Input/Output Range” that permits you to change the IRQ setting:

e)	Highlight “Interrupt Request”, then click on the “Change Setting …” button …

f)	Select a “Value” corresponding to one of the unused IRQ numbers noted in Step h. The “Conflict information” box should indicate that the number you have chosen does not conflict with the settings for any other device. If not, choose another number.

g)	Click on “OK” three times to dismiss the dialog boxes. If Windows offers to reboot your computer, permit it to do so.


Software Installation

The AutoMatePC software is provided as a self-installing file. To install the software:

1	Insert the diskette in your floppy drive (drive A:\)

2	Click on Start|Settings|Control Panel|Add/Remove Programs

3	Click on “Install” then “Next”, permitting Windows to find the a:\setup.exe file

4	Click on “Finish” to complete the installation

Setup will install the necessary files in the folder of your choice, and a program group will be created in your Start Menu system at “Start|Programs|FireRight”. An AutoMatePC shortcut will also be provided on your desktop.

Visual Basic Runtime Files

The AutoMatePC software is authored using Microsoft Visual Basic 5. To make the most efficient use of limited storage space on your computer, such programs share certain common files, which they expect to find in your Windows|System folder.

Since many other applications use these files, it’s likely that they will have already been installed on your system. All the necessary runtime files are distributed on the installation diskettes. These will be installed only if more up to date than your existing versions. To shorten download times, a version of this software is provided which does not include these “runtime” files. If you receive error messages indicating that a necessary file is not available on your system when you attempt to run the program, simply download and install the “full installation” version of the software from the FireRight web site http://www.fireright.com.

Program Setup

When running the AutoMatePC program for the first time, click on the “Options” menu and choose the correct COM port, as determined above. This is the only setup requirement for the AutoMatePC software.

Uninstalling the Software

To remove the AutoMatePC software from your computer, use the Windows Control Panel “Add/Remove Programs” applet. This will properly remove the software and setup information from your computer. Files created after the original installation, such as log files, will not be removed. To remove these, delete the c:\program files\fireright folder, or the folder where you originally installed the software.

If you uninstall the software by simply deleting its folder, none of the shared runtime files will be removed, the shortcuts will remain, and setup information will remain in your system’s registry.

 Tradename ~ FireRight/Warner Instruments


Operating Instructions

When you use the AutoMatePC, the switches on your kiln, if any, become superfluous. You should set these switches on “High” or the full “On” position and leave them in that setting.

Click on the desktop short cut, or use Start|Programs|FireRight|AutoMatePC to start the program.

When the AutoMatePC window appears, only it’s “ON” and “OFF” buttons are enabled. Move the mouse pointer over the ON button and observe that within a few moments a “ToolTip” pops up which briefly explains the purpose of the control. Tool tips are available for most of the controls and indicators on the panel, but they will only be available when the control is enabled. Notice that controls and indicators that are not enabled are “grayed out”.

Click on the ON button to turn the control system on.

This turns the system on. The control starts up in the Manual mode, with the Heating Rate set at zero. Notice the display in the upper-left section of the control panel. You can control your kiln manually using this mode. You adjust the heating rate by moving the “thumb” of the horizontal scroll bar, which is now labeled Set Heating Rate. Move the thumb by clicking on it, and sliding it to the right. Notice that as you move it back and forth, the Heating light operates, and if you’re close enough to your kiln, you’ll hear the heaters hum or the contactor in the power controller clicking on and off.

The Manual mode can be used at any time, and is handy for “smoking out” kiln loads before beginning the firing process.

Move the thumb back to the left to set the Heating Rate at zero, then click on the Automatic button. Notice that several things change. The legend over the scroll bar now reads Set Turn-Up Time and the digital read-out is now set to indicate the Turn-Up Time rather than the heating rate. The mode indicator light also changes color, and its legend suggests that you should now adjust the turn-up time.

Clicking on the Automatic button also enables the Run button. Click on the Run button. If you have not moved the scroll bar’s thumb, the turn-up time will still be set at zero, and the program will pop up a warning box to remind you to adjust this parameter. Click on OK to dismiss the warning, then adjust the thumb to increase the turn-up time. Notice that you can adjust the thumb in any of three ways …

•	you can click and drag it to the desired setting

•	you can click on its left or right arrow buttons to move it in small one unit steps, or

•	clicking in its channel either side of the thumb moves it ten units per click.

Set the Turn-Up Time at exactly one-hour, then click on the Manual button and set the Heating Rate at exactly 80%. Notice that when you now alternately click the Automatic and Manual buttons, the thumb “remembers” these settings and automatically moves back and forth between them.

Adjust the Heating Rate back to 0%, leaving the Turn-Up Time set at one-hour. Now click on the Run button once again.

Notice that the mode indicator has changed color once again, and now reads Turning Up. With the settings you’ve established, the AutoMatePC will now turn up your kiln’s heating rate from 0% to 100% (full ON) during the next hour. Within a few moments, the red Heating indicator will flash briefly, and for the first time. If you watch the panel for a while, you’ll see that this light operates at regular 60-second intervals. You’ll also notice that the Heating Rate indication steadily increases, and that the “On” time simultaneously becomes progressively longer as time goes on. When exactly one-hour has passed, the heating rate will have reached 100%, and the Heating indicator light will come on a final time, then remain on indefinitely. At this point, the mode indicator changes color once again, from orange to red, to indicate that the system is now operating at Full Heat.

At this point, the kiln will continue to heat until the operator determines that it is time to turn it off, based on experience or the observation of witness cones. Alternatively, many kilns are equipped with a KilnSitter, which is a mechanical cone-actuated shut-off device that provides this function automatically.

When ready to turn the system off, click on the OFF button. If finished with the program, you may dismiss it by choosing File|Exit from the menu system, or simply by clicking on the Close “X” in the upper right corner of its window.

Logging Firing Data

The AutoMatePC can keep a log of each firing, recording information about the firing in a file saved on your hard drive. To choose this option, click on the “Options” menu and place a check mark next to “Log”.

The log file will be saved in the same folder where the AutoMatePC program resides, and will be named “automate.log”. It shows the date, time, operating mode, and firing rate recorded every five-minutes during the firing. This is a text file, which may be viewed using Windows NotePad, QuickView or any text editor or word processing program.

A new log file will be generated for each firing. If you have used the logging function before, the program will ask you to choose whether you wish to save the existing log file, or erase it.

KilnSitter is a trademark of W P Dawson Company


Maintenance and Troubleshooting

Electrical Problems

Problems with this system are usually electrical in nature, rather than problems with the program itself.

Contactors switching high-current circuits can easily develop loose connections, which impair the system’s efficiency and reliability. What’s more, because these loose connections arc, they’re subjected to heating and cooling action, which promotes expansion and contraction, which only serves to loosen the connection even more. If left without attention, the heat generated at the loose connection will become severe enough to damage the terminal area of the contactor and burn the wiring connected at that point. Good maintenance practice therefore includes regularly inspecting the kiln’s electrical connections, especially those on the contactor in the power controller box, and assuring that all such connections are as tight as can be.

WARNING

Your kiln’s electrical system operates at electrical potentials that are high enough to produce serious … even lethal …  electrical shock. Prior to removing any protective covers, unplug your kiln from the electrical service if possible. Otherwise switch off its power source either at its switch-box or circuit breakers, and tape over these switches to assure against their accidental actuation while you are servicing your kiln.

Software/Computer Problems

If it appears that the software is having problems, follow these steps in attempting to clear the fault …

1.	Close and restart the program to see if this clears up the problem.

1.	Close all operating applications, reboot your computer, then restart the program.

1.	If it appears that the computer is still having problems with the software, try reinstalling the software, including the runtime files, from your installation diskettes or the full download archive.


Technical Support and Repair Services

If you have questions, please give the dealer or kiln manufacturer from whom you purchased your controller the first opportunity to assist you.

FireRight Controls warrants its products for one-year from the date of purchase.  We will repair or replace, without charge, units that fail because of defective material or workmanship. See your registration card for the full text of the warranty.

Beyond the warranty period, factory service is available at reasonable flat rates, and can be handled through your dealer, or factory-direct. Service information in the form of “Tips and Tricks”, FAQ and TechMemo’s are always available free of charge on the FireRight web site. Minor software updates and maintenance releases are also provided to registered users of FireRight products without charge, and may be freely downloaded from the FireRight web site.

Personal technical assistance is available to you without charge and without limitations. Please feel free to contact our support staff whenever you wish. Technical support hours are normally 9:00 a.m. to 5:00 p.m., Monday through Friday. If you wish to contact us by FAX or e-mail, you can ordinarily expect a response to your inquiry within 24-hours during the workweek.

Replacement parts can be ordered from your ceramics supply service or directly from the factory at the contact points shown below. Parts information and pricing is available on the FireRight web site. All repair service is handled at the factory. Although you are encouraged to let your dealer assist you in obtaining prompt service, you may also send your repairable hardware directly to the address given below for service. Prior authorization is not required. Please include a brief description of the problem, and an address to which UPS can redeliver your repaired property. Service is billed at flat rates, which are published on our web site, and is ordinarily accomplished within one working day.

Contact Information:

FireRight / Warner Instruments

1320 Fulton Street   PO Box 604

Grand Haven  MI   49417-0604 USA

Phone: 616-842-7658

Toll Free: 877-842-7658

Fax: 616-842-1471

E-mail mailto:support@fireright.com

Internet: http://www.fireright.com