Orton MILL IRON TOOLS Arrow Springs AutoFire ASC/6 User manual

AutoFire® Kiln Controller
User’s Guide
Model AF4X
Orton Ceramic Foundation
The Edward Orton Jr. Ceramic Foundation
6991 Old 3C Highway
Westerville, Ohio 43082-9026
Telephone: [phone]
Fax: [phone]
www.ortonceramic.com
October 2018
Arrow Springs
ASC/6

AF4X Kiln Controller
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TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................................................ 4
PRECAUTIONS........................................................................................................................................................................... 4
FEATURES .................................................................................................................................................................................. 4
TEST FIRING WITH WITNESS CONES ................................................................................................................................ 6
KEYPAD OVERVIEW ............................................................................................................................................................... 6
DISPLAY LIGHTS.......................................................................................................................................................................... 6
STARTING A FIRING ..................................................................................................................................................................... 7
STOPPING A FIRING...................................................................................................................................................................... 7
PROGRAMMING VALUES.............................................................................................................................................................. 7
PROGRAM REVIEW...................................................................................................................................................................... 7
PROGRAM SETS........................................................................................................................................................................ 7
USER PROGRAMS..................................................................................................................................................................... 8
TEMPERATURE UNITS ................................................................................................................................................................. 8
HEATING/COOLING RATES .......................................................................................................................................................... 8
MAXIMUM RAMP RATE FOR USER PROGRAMS............................................................................................................................ 8
TARGET TEMPERATURES ............................................................................................................................................................ 9
COOLING RAMPS ......................................................................................................................................................................... 9
CHANGING A TARGET TEMPERATURE DURING A FIRING............................................................................................................. 9
HOLD TIME ................................................................................................................................................................................. 9
SET-POINT HOLD ...................................................................................................................................................................... 10
ADDING TIME TO A HOLD.......................................................................................................................................................... 10
SHORTENING A HOLD................................................................................................................................................................ 10
VENT FAN (OPTIONAL) ............................................................................................................................................................. 10
PROGRAMMING USER PROGRAMS............................................................................................................................................. 10
ERASING AUSER PROGRAM ..................................................................................................................................................... 11
USER PROGRAM EXAMPLE........................................................................................................................................................ 11
ALARMS .................................................................................................................................................................................... 12
THERMOCOUPLE ALARMS......................................................................................................................................................... 12
DEVIATION ALARMS (SEE TEDE OPTION TO ADJUST DEVIATION)............................................................................................. 12
POWER INTERRUPTION ALARMS ............................................................................................................................................... 13
DIAGNOSTIC ALARMS ............................................................................................................................................................... 13
OPTIONS MENU....................................................................................................................................................................... 13
SKIP STEP -SKIP ...................................................................................................................................................................... 14
HOLD TIME -HLDT.................................................................................................................................................................. 14
CHANGE TEMPERATURE -CHGT.............................................................................................................................................. 14
DELAY MODE -DELA .............................................................................................................................................................. 14
THERMOCOUPLE TYPE -TC ...................................................................................................................................................... 14
THRESHOLD ALARM -ALAR..................................................................................................................................................... 15
DIAGNOSTICS –DIAG /TEST .................................................................................................................................................. 15
CHANGE TEMPERATURE UNITS –F/C ....................................................................................................................................... 15
OVER-TEMPERATURE LIMIT -LIM............................................................................................................................................ 15
FIRING COST -COST ................................................................................................................................................................ 15
CONE OFFSET -OFST ............................................................................................................................................................... 16
THERMOCOUPLE OFFSET -TCOS.............................................................................................................................................. 16
TEMPERATURE DEVIATION -TEDE .......................................................................................................................................... 16
HIGH TEMPERATURE DEVIATION -HTDE................................................................................................................................. 16
PROGRAM LOCK MODE -LOCK ............................................................................................................................................... 17

AF4X Kiln Controller
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AUXILIARY OUTPUT 1-AOP1 .................................................................................................................................................. 17
ELECTRONICS TEMPERATURE -ELEC ...................................................................................................................................... 17
CONE-FIRE COOLING RAMP -COOL ......................................................................................................................................... 17
RAMP RATE UNITS -RATE....................................................................................................................................................... 18
KILOWATT HOUR COST -CENT................................................................................................................................................ 18
KILOWATT RATING -KW........................................................................................................................................................... 18
SAFETY TEMPERATURE -SFTY ................................................................................................................................................ 18
SOFTWARE VERSION -SOFT..................................................................................................................................................... 18
CONFIGURATION NUMBER -CFG.............................................................................................................................................. 18
RESET -RST ............................................................................................................................................................................. 19
HARDWARE OPTIONS........................................................................................................................................................... 19
AUDIBLE ALARM BUZZER .......................................................................................................................................................... 19
DOOR/LID SWITCH .................................................................................................................................................................... 19
COMPUTER SOFTWARE .............................................................................................................................................................. 19
SPEED PROGRAMS................................................................................................................................................................. 19
SPEED PROGRAM EXAMPLE ...................................................................................................................................................... 20
JEWELRY PROGRAMS.......................................................................................................................................................... 21
JEWELRY PROGRAM EXAMPLE.................................................................................................................................................. 21
PMC PROGRAMS .................................................................................................................................................................... 22
PMC PROGRAM EXAMPLE ........................................................................................................................................................ 22
CONE-FIRE – HOW IT WORKS............................................................................................................................................ 23
CONE-FIRE PROGRAMS ....................................................................................................................................................... 24
CONE FIRE EXAMPLE ................................................................................................................................................................ 24
REFERENCE SECTION .......................................................................................................................................................... 26
APPENDIX A–LOW FIRE CONE PROGRAMS .............................................................................................................................. 26
APPENDIX B–MID FIRE CONE PROGRAMS............................................................................................................................... 27
APPENDIX C–HIGH FIRE CONE PROGRAMS ............................................................................................................................. 28
APPENDIX D–USER PROGRAM CHARTS................................................................................................................................... 29
APPENDIX E–CONNECTING THERMOCOUPLES......................................................................................................................... 29
APPENDIX F–TYPICAL WIRING DIAGRAM,2HEATERS ........................................................................................................... 30
APPENDIX G–TYPICAL WIRING DIAGRAM,1HEATER,1SAFETY RELAY................................................................................. 30
APPENDIX G–CONFIGURATION OPTIONS................................................................................................................................. 31
LIMITED WARRANTY ................................................................................................................................................................ 32

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Introduction
This User’s Guide explains the features and operation of the Model AF4X Controller.
The controller has 3 keys for programming.
Orton controllers use P-I-D control algorithms to tightly control kiln temperature. This eliminates temperature
cycling. Cycling occurs when the controller turns the kiln on or off in a way where the actual temperature does not
closely follow the desired firing schedule.
Orton controllers store the firing program information in memory when turned off. If power is lost during a firing,
the controller remembers how far the firing has progressed and determines if it can resume the firing when power
is restored.
Precautions
The controller is not a safety device. The controller operates relays to turn the kiln elements on and off. It is
possible for relays to fail in the ‘ON’ position. The controller cannot protect against relay failure. To prevent over-
firing, never leave the kiln unattended, especially at the end of a firing.
Controller accuracy and performance depends on the condition and position of the thermocouple sensors in use.
Getting Started
Read all precautions and instructions before using your controller.
If your kiln has manual control switches for the heating elements, turn all the dials to the highest settings.
If you have a Kiln-Sitteron your kiln, you can use a Cone 10 bar under the sensing rod to shut off power if the
kiln reaches high temperatures. This bar will last many firings and can act as a backup safety device for the firing.
Features
The AF4X includes many standard features, a user-friendly keypad and robust temperature control software.

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Firing Methods and Features
•User Program method: Create up to 25 custom firing schedules with unique heating and cooling rates,
target temperatures and hold times. This method can be used for ceramics, heat treating, glass fusing,
enameling or jewelry applications.
•Speed Programs: 5 speed programs are preset with different fixed heating rates. These programs are
single set-point (one step) programs.
•Jewelry Programs: 3 preset firing schedules for burnout. The various heating and cooling steps are
preprogrammed. You can fire to a preset Jewelry schedule by simply selecting the jewelry program
along with an adjustable final hold temperature.
•PMC Programs: 5 preset firing schedules for Precious Metal Clay. The heating steps are
preprogrammed. You can fire to a preset PMC schedule by simply selecting the PMC Program. These
programs are not adjustable.
•Cone-Fire method: Select a preset program for a specific cone number from Cone 022 to Cone 12.
These programs are designed specifically for ceramic firings.
•Speed adjustments - Use with Cone-fire mode to speed up or slow down a firing and to adjust for load
size or thick pieces of ware.
•Delay start - Use with either mode to delay start the kiln up to 100 hours (99hr.59min.)
•Set-Point Control - User Program option to hold kiln at temperature indefinitely.
•Full On / Full Off - User Program option to heat or cool the kiln as fast as possible.
•Add Time – Add additional hold time to firings already in progress.
•Program edit – User Program option to change the active program settings during the firing without
having to stop and restart the controller.
Advanced Options
•Cone Offset - Use with Cone-Fire to adjust the firing temperature of the kiln by ±11°C (±20°F) to fine
tune the controller to your kilns performance.
•Skip - Skip ahead in the firing program
•Alarm - Program an alarm to sound when a specific temperature is reached.
•Thermocouple Offset - Adjust display temperature by as much as ±25°C (±45°F) to offset aging
thermocouple(s).
•Auxiliary Output - Control a relay to switch on a vent fan or safety relay.
•Power Consumption – Review the calculated cost or Kilowatt usage of the kiln firing.
Display Messages and Information
•Program Review - Review the current firing program before or during a firing.
•Temperature Units - Display Temperature in Fahrenheit (°F) or Centigrade (°C) Units
•Computer Interface – Monitor/Analyze kiln data from a PC using AutofireDLS4 datalog software.

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Test Firing with Witness Cones
A test firing will help in learning the operation and features of the controller. Follow your kiln manufacturer's
instructions for setting up your kiln.
Place a series of Orton Self-Supporting Cones on the middle shelf of your kiln so that they can be seen through a
kiln peephole. Use a series of cones close to the final firing temperature (see Appendix C). For example, if firing to
1945°F (Cone 04), use a Cone 03, Cone 04, and Cone 05 for the test firing.
To evaluate heat distribution, place a set of cones on each shelf during the test firing. Most kilns fire more
uniformly at Cone 06 than they do below Cone 06. Provide ventilation for the kiln in accordance with the kiln
manual or VentMaster
®
instruction manual.
After the firing, examine the fired cones. Some variation in the bending of the cones may occur, depending on how
the kiln was loaded and the location of the cones.
Keypad Overview
This key is for selecting a firing program and advancing through the programming steps. After
programming is complete, use this button to Start and Stop the firing.
This key is used to step forward the display values for specific program settings Also use this button
for access to the option menu.
This key is used to step backwards the display values for specific program settings. It is also used to
activate the Program Review feature.
When using the Increase and Decrease keys to program number values, the values will change more rapidly if the
key is held in.
In general, the user interface is very simple. Use the increase and decrease keys to change the display prompt,
when you see what you want on the display, press the Program key.
Display Lights
The controller uses (4) numerical displays and 3 indicator lights. The bottom light tells when the controller is
turning on the relays to power the heating elements. The top is lit when the controller is in programming mode, the
middle light is lit when the controller is in Program review mode.
Two of the four decimal points on the display are also used as indicators. The decimal point on the far right is used
to indicate if the controller is displaying temperature in degrees Fahrenheit (°F) or Centigrade (°C). If this decimal
point is lit, the controller is set to display temperatures in °C.
The center decimal point (between the second and third digit) lights whenever the display is showing a time value.
The decimal point separates Hours (on the left) from Minutes (on the right).

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When the Controller is first turned on
The controller runs a brief self-diagnostic test. The display will light up and the audible alarm should beep. After a
few seconds, the display will alternate between the kiln temperature and IDLE.IDLE is the mode where the
controller is not actively firing the kiln or being programmed for a firing.
Starting a Firing
The display shows -ON- for 5 seconds when the firing begins.
The display will show kiln temperature throughout the firing. The temperature display will alternate with
alarm messages if any alarms occur. If the controller is programmed to hold at a specific temperature, the
remaining Hold Time will alternate with the temperature during the active hold period.
Stopping a Firing
When the controller completes the firing, the display alternates 4 messages: CPLT (Firing Complete); Firing
Time (hrs.mins); Final Firing Temperature and Current Kiln Temperature. Press any key to return to IDLE.
If you stop the firing before completion with the Stop key, the display will indicate ABRT (abort) in place of
CPLT. Press Stop again to return to IDLE
Programming values
Whenever a change is made from the keys, you must press the Program/Start key to load the changes. If the
key is not pressed, the controller will simply wait for your next selection. Pressing the Program/Start key will
advance you to the next option if you are setting up a program or changing settings.
Note: If you are programming the controller options and no keys are pressed for 90 seconds, the controller will
exit the options menu automatically.
Program Review
To review the current program in the controller memory before or during a firing, press the Decrease/Review
key. The entire program will automatically scroll through the display and then return to normal operation.
Delay time is included in the review.
Repeating a firing
If power is not cycled off to the controller, you can repeat a firing without viewing the entire program, simply press
the Decrease/review key when the controller display is showing the desired program group. The controller will
scroll through the program review and advance directly to the Start prompt. Press the Program/Start key to set a
delay time and again to begin the firing.
Program Sets
The controller contains several sets of preset programs. Each set can be turned on or off depending on the user
preferences. To disable a program set, see the configuration appendix of this manual.
When first powered on, the controller will show IDLE, to view the program sets, press the Program/Start key.
Then press the Increase/Option key to see all available program sets.
Note: some program sets may be disabled or turned off by the kiln manufacturer or supplier depending on the
application.
Program sets include: SPD (Speed) – JWL (Jewelry) – CLAY (PMC) – CONE (Ceramics) – USER (custom)

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User Programs
25 User Programs are available. The User Program mode allows you to customize your firing schedule and specify
how fast the kiln heats or cools to any temperature. All Programs allow 20 ramp steps. Each ramp step consists of a
heating rate (or cooling rate), a target temperature and a hold time.
Temperature Units
If your controller is configured to display temperature values in °F, heating rates will be programmed as Degrees
Fahrenheit per hour and target temperatures will be programmed as Degrees Fahrenheit. If your controller is
configured to display temperature values in °C, heating rates will be programmed as Degrees Centigrade per hour
and target temperatures will be programmed as Degrees Centigrade. To change the temperature units, see the F/C
option.
Heating/Cooling Rates
Each program step requires you to program the desired rate value.
Rate is the speed of the ramp step. Rate is programmed as Degrees per Hour if the RATE option is set to HOUR.
Some calculations may be required to determine your desired heating rate.
Example; if you know that you want to heat the kiln from room temperature (75°F) to 212°F over a 2 hour period,
First determine the amount of temperature rise:
212 - 75 = 137 degrees
Then divide the amount of temperature rise (or drop) by the number of hours you would like it to take to get there.
(For Example, 2 hours)
137 /
//
/2 = 68.5 degrees per hour
Round the calculated rate to the nearest whole number and your heating rate would be 69 degrees/hour.
If you prefer to program heating and cooling rates in ‘degrees per minute’, adjust the RATE option in the options
menu to MIN.
If you prefer to program heating and cooling rates in ‘Hours and Minutes’, adjust the RATE option in the option
menu to TIME.
RA is the controller display for rate. Each rate segment will have its own number. The rate for the first ramp step
will be displayed as RA 1, the rate for the second ramp as RA 2 and so on.
Maximum Ramp Rate for User Programs
The range of values available for a controlled ramp rate setting is 0-1798F per hour or 0-29.97F per minute.
To program a rate that heats or cools as fast as possible, Set the rate to FULL. FULL appears as a selection for
1799F/hour or 29.98F/min. Just above the maximum ramp rate. You can also find the FULL setting by pressing
the decrease/review button one time when the display shows zero for the rate setting.
When the RATE option is set for TIME, the maximum ramp rate or FULL setting is 00.00, the range of controlled
rates is 00.01 (1minute) to 99.58 (99hours.58minutes)
When the Ramp Rate is set to FULL the controller will interpret this as full power for a heating ramp. This will
allow the kiln to heat as fast as possible to the target temperature without rate control. If the ramp is a cooling step,
the controller will interpret the same values as no power and allow the kiln to cool as fast as possible without rate
control.

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A Program Review will show the message FULL to indicate the uncontrolled rate. Deviation alarms will not be
active during the heating/cooling ramp.
Caution: Overshoot in temperature may occur when a kiln is heating at full power, especially at lower
temperatures.
Target Temperatures
Each program step requires you to program a desired target temperature.
°
°°
° For °
°°
° Cis the controller display for target temperature. Like rate, each temperature segment will have its own
number. The temperature for the first ramp step will be displayed as °
°°
° F 1 or °
°°
° C 1, the temperature for the second
ramp step as °
°°
° F 2 or °
°°
° C 2 and so on.
Caution: Do not program target temperatures that exceed the temperature rating for your kiln. The maximum
programmable value for target temperatures can be viewed in the SFTY option.
Cooling Ramps
Cooling ramps are programmed the same as heating ramps. You must program the Rate for the cooling and the
target temperature. The criteria for a cooling ramp is the target temperature must be lower than the preceding target
temperature.
If you program a target temperature at the end of the firing that is below your room temperature, the controller will
never be able to complete the firing. This may result in a FTL alarm. To avoid this alarm, manually stop the firing
by pressing the Program/Stop key or program a higher temperature to complete the firing
Changing a Target Temperature During a Firing
If the kiln is firing and you need to modify the current ramp target temperature, use CHGT option. The controller
will display the current setting and allow you to change it. See the Option menu section of this manual for more
details.
Hold Time
Each program step requires you to program a desired hold time.
Hold time refers to the amount of time you want the kiln to remain at the target temperature. Hold Time is often
referred to as Soak or Dwell Time. Each ramp allows the option of programming a hold time. Hold time is
programmed in Hours and Minutes. The decimal point light in the center of the controller display separates hours
from minutes. The two digits to the left of the decimal point indicate hours while the right side indicates minutes.
Example; A 1 hour hold time should be programmed as 01.00
or A 30 minute hold time would be 00.30
During a Hold time, the controller will count-down the remaining time of the Hold on the display.
HD is the controller display for hold time. Each Hold segment will have its own number. The hold time for the
first ramp step will be displayed as HD 1,the hold time for the second ramp step as HD 2 and so on.

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Set-Point Hold
You can program the controller to hold at a temperature indefinitely by programming a Hold Time of 99.59. The
controller will hold the kiln temperature until the Program/Stop key is pressed.
Adding Time to a Hold
If the kiln is firing and you need to increase the hold time, use the HLDT option. The controller will display the
current setting and allow you to change it. See the Option menu section of this manual for more details.
Shortening a Hold
To end a hold before the time has expired, use the SKIP option to advance to the next ramp. See the Option menu
section of this manual for more details.
Vent Fan (Optional)
If your controller has been configured to control an auxiliary vent fan, each ramp step will allow the fan to be
turned on or off during the specified ramp. Refer to the Options section for additional details on the AOP1 output.
FN is the controller display for vent fan. Each ramp will have its own fan setting. The fan setting for the first
ramp step will be displayed as FN 1,the fan setting for the second ramp step as FN 2 and so on.
Programming User Programs
During programming, default values may appear in the display. If the controller was previously programmed, the
last settings will appear.
1. Press the Program/Start key. A program group will show on the display.
2. Press the Increase/Option key until the display shows USER, then press the Program/Start key.
3. Using the Increase or Decrease key, select the desired program number (PR01-PR25) then press the
Program/Start key.
4. RA 1 shows in the display indicating the rate value for the first ramp step. Use the Increase or Decrease
keys to enter the desired heating rate. Then press Program/Start key.
5. °
°°
°F 1 or °
°°
°C 1 shows in the display indicating the target temperature for the first ramp step. Use the Increase
or Decrease keys to enter the desired temperature. Then press Program/Start key.
6. HD 1 shows in the display indicating the Hold time for the first ramp step. Use the Increase or Decrease
keys to enter the desired time for the kiln to hold at the first target temperature. Time is entered as
(Hours.Minutes). Then press Program/Start key.
7. FN 1 shows in the display (if available). Use the Increase or Decrease key to select a fan setting; either
OFF or ON for the first ramp. Then press Program/Start key. The Fan option will not appear unless the
auxiliary output option for the controller has been configured.
8. Repeat steps 4 through 7 to program additional ramp rates, temperatures and hold times. After you have
programmed your final ramp, the controller should be displaying the next available RA number. If the
value for the next available ramp rate is set to zero degrees per Hour or Minute, press Enter. The controller
will end the programming mode. For Time mode, the value should be set to 99.59.