BONIS ST535 Instruction Manual

User Handbook
Electric Top Loading Kilns For Ceramics
- Controller ST535 -
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TEL: [phone]
Email. [email protected]
1

Dear Customer,
Thank you for choosing a kiln made by Bonis SA.
Your kiln is especially made for firing ceramics, it is a high
performance product made by high uality raw materials, sourced
from the best known European manufacturers.
It features high uality insulation for low power consumption.
This instruction manual includes all the important information and
guidelines you will need to start using you kiln as safe and simple
as possible.
Please read the instruction manual carefully, before the first
operation and become familiar with the features and functions of
the kiln and the controller.
Our team is always available to provide more information and help
you in operating your kiln.
Your Bonis Team
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1. KILN SPECIFICATIONS.........................................................4
2. SAFETY INSTRUCTIONS.......................................................4
2.1 Sign recognition...........................................................4
2.2 KILN PLACEMENT..........................................................5
3. CONNECTION TO POWER SUPPLY..........................................5
4. ABOUT THE KILN................................................................7
4.1 Knowing your kiln.........................................................7
4.2 Transport of kiln.........................................................10
4.3 Kiln Operation............................................................10
4.4 Maintenance...............................................................11
4.5 Insulation..................................................................11
5. USING YOUR KILN.............................................................11
5.1 Kiln shelves................................................................11
5.2 Kiln loading................................................................13
5.3 Kiln Cooling................................................................14
5.4 Kiln unloading.............................................................14
6. Controller ST 535..............................................................15
6.1 Controller ST215 Features............................................15
6.2 Controller overview.....................................................16
6.3 Turning On.................................................................16
6.4 Quick Start Guide........................................................17
6.5 Firing Program............................................................18
6.6 Program Samples........................................................19
6.6 Entering a program.....................................................19
6.7 Altering, Reviewing a program......................................22
6.8 Program Start.............................................................22
6.9 Indications during firing...............................................23
6.10 Functions during firing...............................................24
Program Pause Facility:.................................................25
6.11 Program STOP..........................................................25
6.12 Completion of firing...................................................26
6.13 Useful operations......................................................26
6.14 Error Messages.........................................................27
7. Kiln Drying – First firing.....................................................30
8. Pre installed Programs.......................................................31
9. My Programs....................................................................32
10. Notes............................................................................33
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1. KILN SPECIFICATIONS
A label with all kiln specifications is placed on the kilns control
panel.
1. Year of manufacture
2. Type
3. Serial Number
4. Maximum temperature
5. Installed power - Kw
6. Amper (for single phase kilns)
7. Plug type / Power supply
8. Amper per phase (for three phase kilns)
2. SAFETY INSTRUCTIONS
2.1 Sign recognition
arning
HIGH VOLTAGE
arning
DANGER
arning
HOT SURFACE
arning
RISK OF FIRE
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Declaration of Conformity
This kiln is manufactured in accordance with EC
directives
Copyright by BONIS SA
No responsibility is accepted for the correctness of this information.
We reserve the right to make technical alterations.
2.2 KILN PLACEMENT
• Do not place the kiln on a flammable table / floor
• Place the kiln on an even surface
• The distance to the walls should be at least 25 cm
• Do not place / store any flammable materials close to the kiln.
Always have a safety distance of 50cm from the kiln.
• Do not store flammable li uids / gas in the same room with
the kiln.
• Place the kiln in a well ventilated area. If this is not the case a
ventilation system has to be installed.
• Place the kiln in a place that is protected from water / rain
• Place the kiln in a room
where kids and pets have no
access.
3. CONNECTION TO PO ER SUPPLY
Kiln connection to power supply must be
completed by a certified electrician.
Do not attempt to connect the kiln by your
self if you are not a certified electrician.
5

Before proceeding to connecting
the kiln please make sure that
power supply is OFF
Power supply: The phases are connected to the copper bridge of
the relays.
The copper bridges the contacts 2 / T1, 4 / T2, 6 / T3 of the relay.
Depending on the type of furnace, the two phases are connected in
red insulators, and the third phase in a copper relay truss.
Attention: The controller power cable is also connected to contact 2
/ T1.
Neutral: Attaches to the red insulator
Grounding: Attaches to the yellow screw at the base of the panel
The lower ring is electrically connected to the electrical panel
(upper ring) with an industrial type plug.
There is a terminal on the electrical panel to connect the
thermocouple. ATTENTION to the polarity of the cables
Η type kilns (1300C):
White cable connects to ( - ) contact
Red cable connects to ( + ) contact
L type kilns (1200C):
Green cable connects to ( - ) contact
Red cable connects to ( + ) contact
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4. ABOUT THE KILN
4.1 Knowing your kiln
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1. Exhaust air
Kiln features an exhaust air hole on the center of the lid. This hole
must be always open.
ARNING: Hot air will come through the
hole.
2. Lid safety support
Three position lid support. In the two lower positions the lid support
keeps the lid open.
The third position, is a uick cooling
position. It keeps the lid open for few
centimeters, and it helps the kiln to cool
faster.
Fast cooling can be done when the
kiln temperature is below 100C.
CAUTION:
Kiln handle may be hot
Hot air may come out from the kiln
3. Kiln stand
Kiln features a metallic stand. You must always use the kiln while it
is on the stand. DO NOT PLACE THE KILN ON FLAMMABLE FLOOR
4. Lid closure
You must always close securely the lid closure before starting a
firing. Do not use the kiln with the lid closure unsecured.
5. Bottom closures
All bottom closures must be always secured.
6. Kiln handle and bottom handles
Both kiln handles and bottom handles are to be used during
transportation of the kiln, ONLY IF the kiln is disassembled.
Do not lift the assembled kiln from kiln handles or bottom handles.
8

Please note:
In case you need to move the assembled kiln, lift it from the kiln
stand. Please ask for the kiln dis assemble manual if you need to
move the kiln.
Do not move the kiln while it is connected to
the power supply
Do not move the kiln with the lid open
7. Main Switch
Kiln power switch. When the kiln is not firing, main switch must be
to OFF position
8. Heating Element Switches
Heating element power switches. These switches must always be to
ON position
9. Heating Element Operation Lights
This indication light will light on during firing ONLY when the
heating elements are working.
During a firing this light will switch OFF and ON indicating the
heating elements operation.
10. Main Fuse 6Α
11. Controller plug
Controller is connected
to the kiln by a simple
plug and play plug.
Controller connection
can be done by the kiln
user with no danger.
Before connecting the
controller please
make sure that the
kilns main switch is
OFF
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4.2 Transport of kiln
In case you need to move the assembled kiln, lift it from the kiln
stand.
Do not lift the assembled kiln from kiln handles or bottom handles.
Do not move the kiln while it is connected to the power supply
Do not move the kiln with the lid open
Kiln handles and bottom handles are to be used during
transportation of the kiln, ONLY IF the kiln is disassembled.
Please ask for the kiln dis assemble manual if you need to
move the kiln.
4.3 Kiln Operation
Before operating the kiln please make sure that there is nothing
flammable inside the kiln.
Please make sure there are not any cables or other flammable
materials close or in contact with the kiln.
When loading unloading the kiln the main switch must be OFF.
Do not place in the kiln any material with unknown reaction to
firing.
Do not move the kiln while in operation
Do not open the kilns while in operation
Always open the kiln after cooling down to 50C
Do not place flammable objects in the kiln.
Note At high firing temperatures a slit may become visible
along the edge of the lid. This is normal and does not
compromise the kiln's function or safety.
This kiln is EXCLUSIVELY for firing ceramics ONLY.
Any other use is prohibited.
In case of malfunction please switch OFF the main switch,
and cut off the power to the kiln
DO NOT ATTEMPT TO FIX ANY PROBLEM BY YOURSELF.
PLEASE CONTACT OUR TECHNICIANS, OR A LOCAL CERTIFIED
ELECTRICIAN.
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4.4 Maintenance
Before proceeding to any maintenance or
service operation Kiln main switch must be
OFF, kiln must be unplugged or safety switch
must be OFF
1. Kiln chamber must be kept clean, and any broken ceramic pieces
must be taken out carefully. You can use a vacuum cleaner to clean
the chamber.
2. Use a vacuum to clean kilns lid (inside) from time to time.
3. Before starting a firing inspect all cables for any kind of damage.
In case of damage, do not use the kiln before replacing the
damaged cables.
4. Inspect thermocouple connections and cables that are properly
placed and free from any kind of lesions.
5. Heating elements must be kept clean, and any piece from
broken ceramic, glaze etc, must be taken out before using the kiln.
You can use a vacuum cleaner to remove particles from the heating
elements. Please not that when cold, heating elements are
extremely brittle
4.5 Insulation
The kiln insulation is made from high-grade fireproof material. Due
to thermal expansion, cracks in the insulation will occur after a few
heating cycles. These have no influence on the function, safety or
uality of the kiln.
The refractory bricks (insulation) are of a particularly high uality.
Due to the manufacturing process small holes or cavities may
occur. These are uite normal and underline the uality features of
the bricks.
5. USING YOUR KILN
Before using your new kiln please make sure you fully read
and understand the complete kiln operation manual
5.1 Kiln shelves
Kiln shelves are available as whole, or half (depending on your kiln
size whole shelves may not be available)
Placing two half plates will make one whole shelf, or you can load
half of the kiln with plates as shown in the below image
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Kiln shelves must be smaller from the kiln interior diameter, as you
need a gap between the shelf and kiln wall, for your hand to fit in,
and for the hot air to circulate evenly.
Supporting kiln shelves
We advise you to support whole kiln shelves in 3 points.
Always position the stilts one above the other for each layer, to
avoid kiln shelf deformation or cracking.
Please Note:
You must always leave a gap
between kiln floor and the first kiln
shelf.
You must place small stilts, or
pieces of broken kiln shelves on
the bottom of the kiln, and you
first kiln shelf will be placed on top
of these stilts.
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5.2 Kiln loading
During loading / unloading of the
kiln, the main switch must be OFF,
the kiln must be unplugged from
power, or the power switch must be
also to OFF position
Make sure the lid is well supported
before loading / unloading the kiln.
To enhance even temperature distribution we strongly suggest to
load your kiln evenly.
Please Note:
In top load kilns it is recommended
not to place low height ceramics on
the bottom shelf.
We strongly recommend to place
medium height ceramics on the
bottom shelf (approximately 5cm or
more)
If you place low height ceramics on
the bottom shelf you must use stilts
of bigger height to have the re uired
gap for firing properly your ceramics.
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5.3 Kiln Cooling
Your new kiln features a multilayer insulation, which ensures
minimum heating loss, and very slow cooling.
To cool the kiln faster you can use the
uick cooling position of the kilns lid
support.
This position keeps the lid open for few
centimeters, and it helps the kiln to cool
faster.
Fast cooling can be done when the
kiln temperature is below 100C.
CAUTION:
Kiln handle may be hot
Hot air may come out from the kiln
5.4 Kiln unloading
During loading / unloading of the
kiln, the main switch must be OFF,
the kiln must be unplugged from
power, or the power switch must be
also to OFF position
Make sure the lid is well supported
before loading / unloading the kiln.
CAUTION: Ceramics may still be hot during unloading
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6. Controller ST 535
6.1 Controller ST215 Features
· Multiple zone control (2 or 3)
· 32 programs each with 32 segments
· 1 controlled heating / cooling ramp + soak per segment
· Soak times up to 99 hours 59 mins
· Ramp rates from 1 to 999°/hour + FULL
· Ideal for glass or ceramics use
· Programs can be altered while firing
· Program pause and advance facilities
· Keyboard lockable
· Delayed start facility - up to 99 hours 59 mins
· Power failure recovery
· Energy used display
· Setpoint display
· Alarm buzzer & alarm output
· °C/°F operation
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6.2 Controller overview
6.3 Turning On
When turned on the ST535 performs a
display test by lighting all of the display
segments and illuminating all of the front
panel indicator lamps.
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The version number of the software
embedded within the ST535 is now
displayed. If you need technical support
you might be asked for this code together
with the serial number.
Next displayed is the thermocouple type
setting.This should match the type of
thermocouple fitted to the kiln and can be S
for 1300C, or K for 1200C
The final display will show the kiln
temperature.
All other lamps should be off.
Next to the main display, zone indication will light (1, indicates the
temperature of the lower zone, 2 of the middle zone and 3 of the
upper zone)
All other indications must be OFF
If any other indications are ON, press START/STOP ▶
6.4 Quick Start Guide
Press button ▶(arrow to the right)
Main display will show a program
number
Use buttons ▲ or ▼ until display shows the desired program
number
Press START/STOP ▶
Main display will show the program
start delay time (00.00) After 10
seconds program will start
automatically
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6.5 Firing Program
Controller ST535 can store up to 32 programs.
Each program can have up to 32 segments.
A firing segment comprises of a ramp rate (degrees per hour), the
final segment temperature, and a soak period.
Two segments can be used for simple firing (biscuit firing for
example) or several segments can be used per program for
complex firing (crystal glazing or glass-making for example).
The ST535 ramps the kiln temperature at the re uired ramp rate
until the kiln reaches the soak / target temperature It then soaks
(dwells) at the soak temperature for the soak time. It then runs the
next segment until the end of the program is reached.
The ST535 is capable of both positive (heating) ramps and negative
(cooling) ramps - as used in glassmaking for annealing. The type of
ramp is clearly shown on the mimic display during firing.
The ramp rate is settable in the range 1°C/hour to 999°C/hour or
FULL (full power is for uncontrolled, fast heating. To enter full
power you must increase heat rate to 1000°C/hour. Display will
then show FULL).
Entering “0” as ramp rate will show “End” (end of program).
The soak / target temperature is settable over the range 0 to 1200
or 1300°C (depends on kiln model).
The soak time is settable over the range 00.00 (no soak) to 99
hours 59 mins.
Note: during soaking the ST535 display alternates every 5
seconds between kiln temperature and soak time remaining.
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6.6 Program Samples
The below table shows three different programs:
NORMAL rate– The basic program, suitable for most ceramics
SLO rate – Suitable for thick and large ceramics
FAST / GLAZE – Suitable for small thin ceramics, as well as for
Glaze firings
<
HEATING RATE C/h SEGMENT
FINAL
TEMPERATURE
SOAK
SEG NORMAL SLO FAST
GLAZE hh.mm
1 60 40 80 250 00.00
2 100 80 120 540 00.00
3 80 60 100 600 00.00
4 150 120 150 *MAXIMUM
TEMPERATURE 00.00**
5 END
*Set the desired maximum temperature, according to your clay
needs
** Usual soak time:
- Bis ue 10 minutes (00.10)
- Glaze 20 to 30 minutes (00.20 – 00.30)
You can use this program template, and only change the
maximum temperature and soak time at segment 4.
6.6 Entering a program
When not firing there are no indicators
lit on the mimic panel, the run indicator
is off and the display shows the current
kiln temperature.
The controller settings can be reviewed by pressing the ► key.
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The first push of the ► key flashes the
program number display.
The re uired firing program can now be selected with the ▲ & ▼
keys.
Note: holding down the ▲ or ▼ keys causes rapid change
of the displayed value
When the desired program number is displayed push ► to enter
program values.
Small, segment display will show
number “1” which indicates the first
segment of the selected program.
Main display shows the ramp rate in the
range End , 1-999°C/HR or FULL.
This can be altered with the ▲ & ▼
keys.
The heating ramp ( ◥ ) or the cooling
ramp (◢ ) indicator on the mimic panel
will flash.
If End is shown but another segment is re uired then push the ▲
key to obtain the re uired ramp rate (in the range 1°C/hr to
999°C/hr).
If FULL is shown but another segment is re uired then push the ▼
key to obtain the re uired ramp rate (in the range 1°C/hr to
999°C/hr).
When the desired rate is set press button ►
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