EMC 880 User manual

EMC 880
Kiln Controller
880 Operation Manual Issue 7 EMC INDUSTRIAL GROUP LTD
Operation Manual
Software Revision 2.0 to 2.7

880 Operation Manual Issue 7 EMC INDUSTRIAL GROUP LTD Page 2 of 25
COPYRIGHT © 2001 by EMC Industrial Group Ltd
56 Tarndale Grove, Albany, Auckland
PO Box 101 444 NSMC, Auckland, New Zealand
Telephone [phone], Facsimile [phone]
E-mail [email protected]z
Web http://www.emc.co.nz/
As we are continuously improving our products, changes to this specification
may occur without notice.

Contents
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Contents
Contents .................................................................................................................. 3
Introduction............................................................................................................. 5
About this manual........................................................................................... 5
Please Read................................................................................................... 5
Quick Firing Guide.................................................................................................. 6
Establish Firing Program ................................................................................ 6
Store a Bisque Firing as Program 1 ............................................................... 6
Start Bisque Firing Instantly ........................................................................... 6
Delay Start Bisque Firing By 3 Hours............................................................. 6
Operation of Controller .......................................................................................... 7
Operation Overview........................................................................................ 7
Enter a Program ............................................................................................. 7
Select a Program ................................................................................. 7
Set Ramp 1 .......................................................................................... 7
Set Temperature 1 ............................................................................... 8
Set Hold 1............................................................................................. 8
Set Stage 2 Through To Stage 6 ......................................................... 8
Set Vent Close Set Point...................................................................... 8
Set Vent Open Set Point...................................................................... 9
Start a Firing................................................................................................... 9
Instant Start.......................................................................................... 9
Delayed Start........................................................................................ 9
Stage Start ......................................................................................... 10
During a Firing.............................................................................................. 10
Keys.............................................................................................................. 11
RUN STOP Key.................................................................................. 11
Menu (Next) Key ................................................................................ 11
Control Temp (Down) Key.................................................................. 11
Time To Go (Up) Key......................................................................... 11
Alarm Cancel (Exit) Key..................................................................... 12
Indicator Lights ............................................................................................. 12
Heat Light........................................................................................... 12
Vent Light ........................................................................................... 12
Run Stop Light.................................................................................... 12
Menu Light.......................................................................................... 12
Alarm Light ......................................................................................... 12
°C/h Ramp Light................................................................................. 12
°C Temp Light .................................................................................... 12
h.m Hold Light .................................................................................... 12
Display.......................................................................................................... 12
Large Display ..................................................................................... 12
Small Display...................................................................................... 13
Beeper .......................................................................................................... 13
Power Up Test.............................................................................................. 13
Power Failure ............................................................................................... 13
Firing Auto Continues When Power Returns ..................................... 14
Firing Does Not Resume When Power Returns ................................ 14
Alarms.................................................................................................................... 15
Alarm List...................................................................................................... 15
Fault Diagnostics.......................................................................................... 17

Contents
880 Operation Manual Issue 7 EMC INDUSTRIAL GROUP LTD Page 4 of 25
Typical Faults List......................................................................................... 17
Installation............................................................................................................. 19
Dimensions................................................................................................... 19
Mounting....................................................................................................... 19
Wiring ........................................................................................................... 19
Cable Separation.......................................................................................... 19
Power Supply ..................................................................................... 20
Electrical Interference Suppression of Relay Outputs ....................... 20
Heat Relay.......................................................................................... 20
Heat Logic for Solid State Relay ........................................................ 20
Run Relay (Option) ............................................................................ 20
Vent Relay (Option)............................................................................ 20
Alarm Relay (Option).......................................................................... 21
Thermocouple .................................................................................... 21
Resistance Thermometer – 3 Wire .................................................... 21
Resistance Thermometer – 2 wire ..................................................... 21
Field Settings ........................................................................................................ 22
Enter Field Setting Mode.................................................................... 22
Field Settings Table ........................................................................... 22
Input Sensor ................................................................................................. 22
Set Input Sensor Type Code Number Step 01 .............................. 22
Demo Mode.................................................................................................. 23
Set Demo Mode Step 02 ............................................................... 23
Auto-Continue............................................................................................... 23
Set Auto-Continue Step 21 ............................................................ 23
Hold Temperature Setting Limits.................................................................. 23
Set Maximum Hold Temperature Step 23 ..................................... 23
Set Minimum Hold Temperature Step 24 ....................................... 23
Loss of Control Timeout ............................................................................... 24
Set Loss of Control Timeout Step 25.............................................. 24
Auto Simmerstat........................................................................................... 24
Automatic Simmerstat Temperature For Full Power Step 44......... 24
SPECIFICATIONS ..................................................................................... 25
Program Settings.......................................................................................... 25
Field Settings................................................................................................ 25
Inputs.................................................................................................. 25
Other Settings .................................................................................... 25
Outputs......................................................................................................... 25
General......................................................................................................... 25
ORDERING..................................................................................................... 25

Introduction
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Introduction
About this manual
This manual is divided into several main sections to help find specific information
quickly. For example, to find detailed information about the different methods of
starting a firing see Start a Firing,page 9.
A good way to know the EMC 880 once the controller has been installed, as de-
tailed in section Installation, page 19, is simply to try it.
Turn on power and follow the simple step by step procedure in the section called
Quick Firing Guide,page 6.
As questions arise about the controllers operation refer to the appropriate section
in this manual.
Please Read
Before the kiln is fired for the first time it is very important to check the input of the
controller matches the thermocouple used.
If these do not match the kiln may over fire and cause a melt down. For instance
the kiln will over fire if the controller is set for a type K thermocouple but a type R
thermocouple is used.
To check controller:
Watch the display for the input sensor type when power is turned on as de-
tailed in Power Up Test, page 13. To change the controller to another input
sensor type refer to Field Settings, page 22.
To check thermocouple:
See if the type code is written on the probe, i.e. look under the terminal cover,
otherwise consult kiln supplier.
Check ambient temperature:
After the power up test sequence check controller is showing ambient air tem-
perature, which normally is about 20°C to25°C.
As a precautionary measure the first firing should be observed to ensure firing pro-
gresses as expected.

Quick Firing Guide
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Quick Firing Guide
Follow the procedure below to program the controller for a Bisque firing, stored as
Program 1, and then start the firing.
Establish Firing Program
Draw the temperature profile required and write down program values as shown on
the diagram and chart below, and then enter these values into the controller.
Store a Bisque Firing as Program 1
Step Action Display
1. Press MENU key. Display shows currently selected program.  ?
2. Set program number  in large display with the UP or DOWN keys. 
3. Press NEXT key and set Stage 1 Ramp to . 
4. Press NEXT key and set Stage 1 Temperature to . 
5. Press NEXT key and set Stage 1 Hold to . 
6. Press NEXT key and set Stage 2 Ramp to .  
7. Press NEXT key and set Stage 2 Temperature to .  
8. Press NEXT key and set Stage 2 Hold to .  
9. Press NEXT key and set Stage 3 Ramp to .  
10. Press NEXT key and set Stage 3 Temperature to .  
11. Press NEXT key and set Stage 3 Hold to .  
12. Press EXIT to return to normal operation and show ambient temperature. 
Start Bisque Firing Instantly
1. Check small display shows program you want to use, in this case program 1. 
2. Press RUN STOP key to start firing. 
Delay Start Bisque Firing By 3 Hours
1. Check small display shows program you want to use, in this case program 1. 
2. Press RUN STOP key and while light is flashing set large display to . 
Firing Type Bisque Program Number 1
RAMP TEMP HOLD
STAGE 1 50°C per hr 150°C none
STAGE 2 100°C per hr 650°C none
STAGE 3 150°C per hr 950°C 15 min
RAMP
RAMP 150°C/hr
RAMP 50°C/hr
TEMP 150°C
TEMP 650°C
TEMP 950°C
STAGE 1
STAGE 2
STAGE 3
TEMPERATURE
TIME
HOLD 15 minutes

Operation of Controller
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Operation of Controller
This section gives an overview on how to operate the controller, describes in detail
how to enter programs into the controller, how to start a firing and what can be
done while firing is in progress, explains the function of keys, indicator lights, dis-
play and the internal beeper, describes what to look for when power is turned on
and finally how the controller recovers from a power failure.
Operation Overview
The Kiln Controller is very easy to use.
When power is applied the display sequentially shows a display test to verify the
controller is working correctly. See Power Up Test, page 13.
Before firing can commence the correct program values must be entered into at
least one of the nine program storage containers.
A program has up to six stages. Each stage has a ramp setting, a temperature set-
ting and a hold setting. When firing is started the temperature climbs at the ramp
rate to the Hold Temperature and is maintained there for the Hold Time before ad-
vancing to the next stage.
If a ramp rate is not required, the ramp setting can be set to . The controller
will then bring the kiln to the Hold Temperature as fast as possible.
If a stage needs to be kept at the Hold Temperature indefinitely, the hold setting
can be set to . The controller will then maintain temperature until stopped
with the RUN STOP key.
If a stage is not required, the temperature setting can be set to . The pro-
gram will then skip onto the next stage.
To jump to the end of a program and skip all remaining unused stages set the
ramp setting of the next stage after the last programmed stage to .
To commence a firing ensure the correct program number is showing in the small
display, for example  is program one, then press the RUN STOP key. The firing
can also be delay started or stage started, see Start a Firing, page 9.
Once started, the kiln temperature will follow the temperature profile of the selected
program. See During a Firing, page 10.
During the firing, settings of the program can be checked and changed, other
stored programs can be changed or new programs can be entered.
When completed the alarm beeps five times and shuts power off to the kiln.
Enter a Program
How to select a program and enter a program value is explained in the following
sections. Enter program mode by pressing the MENU key. Return to normal mode
by pressing the EXIT key.
Select a Program
Press MENU key.
Large display shows current program number.
Use UP or DOWN keys to select a new program number.
Set Ramp 1 Press and release MENU key until the small display flashes .
Large display shows the ramp rate for stage 1 or shows  or .
 means the kiln temperature will ramp as fast as possible to the set tem-
perature.
 means the controller will skip to the end of the program bypassing the re-
maining stages and will not display other stage settings past this point except the
vent close and vent open settings, and .

Operation of Controller
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Use UP or DOWN keys to set the required ramp rate, or hold down the UP key un-
til display shows . Press DOWN once to set it to  or press it twice to
select 3200, which is the largest ramp number that can be set.
Alternatively, pressing the UP and DOWN keys together will cycle between a ramp
rate of 100°C/h, the setting  and the setting .
Set Temperature 1
Press and release MENU key until the small display flashes .
Large display shows either the maximum temperature kiln will climb to during stage
1 or show . means bypass stage 1 completely.
Use UP or DOWN keys to set the required temperature value, which must be be-
tween the setting limits, see Hold Temperature Setting Limits, page 23, or hold
down the UP key until display shows .
Alternatively, pressing the UP and DOWN keys together will cycle between a value
of half the Maximum Hold Temperature, see Hold Temperature Setting Limits,
page 23, and the setting .
Set Hold 1 Press and release MENU key until the small display flashes .
Large display shows length of time kiln temperature will be held for at stage 1 tem-
perature setting or show the word .  means the kiln will be held at
stage 1 temperature setting until the START/STOP key is pressed to stop the fir-
ing.
Use UP or DOWN keys to set required hold period, up to a maximum of 54 hours,
or set to  by holding down the UP key until display shows .
Alternatively, pressing the UP and DOWN keys together will cycle between a hold
time of 0.00 and the setting .
Set Stage 2 Through To Stage 6
Entering setting values for Stage 2 through to stage 6 is the same as described for
stage 1.
Set Vent Close Set Point
The Vent Close Set Point value is only shown in the display if relay option card OP-
1 is fitted.
Press and release MENU key until the small display shows .
The large display shows either the close vent set point or and the VENT light
will be flashing.
If the close vent set point is exceeded by the kiln temperature the Vent light will
turn off and the Vent will shut.
The vent limits do not operate when the setting is set to .
Use UP or DOWN keys to set the required close vent temperature value, which
must be between the setting limits, see Hold Temperature Setting Limits, page
23, or set to by holding down the UP key until display shows .
Alternatively, pressing the UP and DOWN keys together will cycle between half the
Maximum Hold Temperature, see Hold Temperature Setting Limits, page 23,
and the setting .
Press EXIT key to return to normal operation.
Note At power on, the Vent is always opened. When the RUN key is
pressed (or firing is Auto Continued after a power failure) the vent re-
mains open, unless the current kiln temperature exceeds the tem-
perature.

Operation of Controller
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Set Vent Open Set Point
The Vent Open Set Point value is only shown in the display if relay option card OP-
1 is fitted.
Press and release MENU key until the small display shows .
The large display shows either the open vent set point or and the VENT light
will be flashing.
If the kiln temperature falls below the open vent set point after the firing is com-
pleted, the Vent light will turn on and the vent will open.
The vent limits do not operate when the setting is set to .
Use UP or DOWN keys to set the required open vent temperature value, which
must be between the setting limits, see Hold Temperature Setting Limits, page
23, or set to by holding down the UP key until display shows .
Alternatively, pressing the UP and DOWN keys together will cycle between half the
Maximum Hold Temperature, see Hold Temperature Setting Limits, page 23,
and the setting .
Press EXIT key to return to normal operation.
Start a Firing
Before starting a firing, either select one of the nine programs if they have been
previously entered or enter a new program as detailed in Enter a Program,page
7.
To view the total firing duration of this program press the TIME TO GO key, before
starting the firing.
There are three ways the firing can be started.
Instant Start Starts from the beginning of a program.
Delayed Start Starts automatically after a time delay.
Stage Start Starts from any stage of the program.
Each section is described in detail below.
Note When the firing has started, the HEAT light will turn on and off at dif-
ferent times to regulate the kiln temperature.
If the kiln temperature is too low the HEAT light will turn on. This indi-
cates power has been applied to the kiln's heating elements to in-
crease the temperature.
If the kiln temperature is too high the heat light will turn off. This indi-
cates power has been cut off to the kiln’s heating elements to allow
the temperature to fall.
Instant Start This is the simplest way of starting the firing.
Press the RUN STOP key.
The small display shows and the RUN STOP light fast flashes for five seconds.
When the RUN STOP light stops flashing the small display will show the first ramp
number, the heat light will turn on, and the firing will start.
Delayed Start A delayed start allows a firing to be started after a delay of up to 99 hours and 59
minutes from when the START/STOP key was pressed.
Press the RUN STOP key.
The small display shows and the RUN STOP light fast flashes for five seconds.
During the five seconds set the large display to the delay start time required.
At the end of the five seconds the small display comes on steady and the RUN
STOP light slow flashes to indicate there is a delayed start in progress.

Operation of Controller
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The large display shows remaining time to go before firing will commence.
The delay start time can be altered while timing out.
When the time gets to  the small display will show the first ramp or tempera-
ture stage number, the heat light will turn on, the RUN STOP light will come on
steady and the firing will start.
To cancel a delayed start when in progress, press the RUN STOP key.
NOTE If power fails during this delay period and the Auto Continue feature
has been enabled, the countdown to the start of firing will continue
when power is restored, but the start time will be extended by the time
power was off.
Stage Start The Stage Start method allows a firing to be started instantly from any point within
the program.
Use the MENU key to step through the program until the small display shows the
desired starting point.
The MENU light will be on and the small display will be fast flashing.
Press the RUN STOP key.
The MENU light will be on and the START/STOP light will fast flash for five sec-
onds.
Press the RUN STOP key again during the five-second time out. Two long beeps
will sound, the heat light will turn on, and the small display and the RUN STOP light
will come on steady indicating the firing has started.
Warning If the key is not pressed, during this time out, the firing will start from
the beginning of the program.
Check the small display is showing the correct starting point in the program.
During a Firing
Once the firing is started, the kiln controller generates a temperature profile calcu-
lated from the ramp, temperature and hold settings of each stage.
Any of these settings can be adjusted during the firing to change the temperature
profile.
As the program advances, the Control Temperature follows the temperature profile
exactly.
The Heat output is turned on and off to make the kiln temperature follow the Con-
trol Temperature.
If the kiln temperature is less than the Control Temperature, heating is switched on,
if the kiln temperature is higher heating is switched off.
To see the current Control Temperature press the CONTROL TEMP key at any
time during a firing.
To view the remainder of the total firing time press and hold the TIME TO GO key
for longer than 3 seconds.
When the small display shows … the kiln temperature is ramping up to the set
temperature and the time to finish this ramp can be viewed by pressing the TIME
TO GO key.
At lower temperatures, the kiln temperature will follow the Control Temperature
very closely, but at higher temperatures the kiln temperature may fall behind the
Control Temperature, especially if the ramp rate is too high or the heating elements
are getting old.
If the Control Temperature reaches the set temperature and the kiln temperature is
lagging behind, the mnemonic … will show in the small display indicating the pro-
gram is paused while waiting for the kiln temperature to catch up.