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Saturday, January 28, 2012

Repairing my glass kiln

The other day I was getting ready to do some fusing in my kiln, had it all set up with firing schedule set and ready to go.  I pushed the start button on my RampMaster II and my kiln barely began to start to work.  I thought about something and quickly raised the lid on the kiln to check on my glass art project when suddenly the RampMaster blew up!  It sounded like a gun shot, right next to me and needless to say, it scared the shit out of me!  I quickly shut off the RampMaster's power and unplugged the kiln.   I also noticed that smoke was coming from the RampMaster.  It totally smelled like burning electronics.

I went online to the Evenheat webpage trying to find out what to do next.  I use my kilns regularly at my studio and I need them in working order plus I paid quite a lot of money for this kiln and don't want to have to replace it with a new one. I was hoping that they'd say something about unplugging the RampMaster from the kiln and sending it in to their factory for repairs.  But their web page said that for repairs,  have a qualified electrician work on the kiln.  It sounds like an easy thing to do except when you live in a very rural area.  And after calling basically everyone that seemed qualified in the yellow pages in my area, I gave up.  

Now I am on my own.  For this reason, I thought I'd dedicate this entire post to how I am going to repair my kiln.  So I began working on it yesterday, Friday.  I can't tell anyone else how to repair their kiln especially since I have just barely begun fixing this one.  But maybe I can help someone else out there that has issues with the electronics on their kiln and not able to use it anymore.  I see some really cheap kilns listed on Craigslist occasionally and now I'm thinking they probably have an electrical issue that the owner does not know how to fix and the manufacturer won't do repairs.

To begin with, when the RampMaster blew up, I quickly unplugged the kiln from the wall and have kept it unplugged.  You don't want to start a fire or get electrocuted.  Then I unscrewed the four screws that hold the front cover on the RampMaster II.  Once done I very carefully looked into the controller to see if I could see something that looked burned.  I did see a wire that perhaps looked slightly melted (which I will look at more closely later), but more importantly I found part of the broken piece laying on the bottom of the RampMaster itself.  I carefully fished that broken part out, it wasn't easy to do since there are a lot of twisted heavy wires in there, yet I was amazed to see that the part had all of the information I needed right there!  What luck!  

This is the broken part of my kiln, the RampMaster II,  that decided to "blow up" on me!  

Here's the remains of the broken piece that I fished out of the RampMaster.

I googled Potter & Brumfield and found out that this piece belongs to a relay.   

On Monday I'll call Evenheat to order a new relay plus I'll need to get a schematic or some sort of procedure so that I know how to disassemble the RampMaster so that I can replace the relay.  I saw that to get the relay out to replace it, I'll have to remove a lot of the electronic insides of the RampMaster!   I also want to know why the relay blew up so that I can prevent that from happening again.   

Stay tuned for updates!

January 30,  Update 
Inside the RampMaster II view 1

Inside the RampMaster II view 2

Relays in the RampMaster II.

As of today, I ordered the new part from the Evenheat company.  When ordering parts for your kiln you will need to know your model number.  You can find that number etched onto the side of your RampMaster.  This unit (my kiln) has two relays sitting side by side on the bottom right in this picture. 


February 6, Update:
Still waiting for the part to arrive from Evenheat, should be here sometime early this week!

February 11, Update:
Well I replaced the broken relay with the new part that I ordered from Evenheat.  When I plugged the kiln in the LED's didn't light up so it's still not fixed.  

March 23,2012 Update:
I forgot to give my final update on repairing the kiln.  I replaced the relay and I couldn't get the kiln to work at all.  I then went and checked my breakers and....  success! 


April 1, 2012 Update:  (not an April fools joke either!)
Well the kiln worked once and a relay blew up, again!  So the other day I ordered two new relays plus some other parts from Evenheat.  Today I decided to work on the kiln.  I replaced the original relay and tested out the kiln.  The element in the lid began heating up without me even starting up a program!  I  shut it off and tried to figure out what was wrong now.  I came across this Evenheat manual for the GTS-23.  And found this paragraph:


Kiln won’t stop firing (won’t shut off)
Error Codes associated with a kiln not shutting off are E– 2 or E-4 or E– d.
Most likely a failed relay (failed closed). A failed relay may cause the kiln temperature to increase when it should be decreasing. Depending upon your 
particular kiln model you may see up to 3 relays used in its design. Identifying the failed relay is fairly simple as the element connected to it will remain on. 
Unplug the kiln and remove the kiln control panel. Simply follow the element leads to the relay to identify it. Relays are maintenance items and we 
recommend replacing all of them when needing to replace one.
Check your program. While you won’t see the error codes if you’ve programmed incorrectly this problem is possible.


After reading that, I replaced the relay that I had replaced not long ago.  And this time when I plugged in the kiln and turned on the RampMaster, it powered up correctly.

I decided to thoroughly inspect the kiln at this point since there had to be a reason why the relay I just replaced in February had died so quickly.  And that's when I discovered the culprit.  One of the elements in the wall of the kiln is broken.  Below is a pic of the bad element.





Now I'm thinking that for some reason the relay kept blowing up because of the element being broken and not making a connection.  The ends of the element in the picture above have glass on them.  The glass must have coated the element and eventually it broke right at that spot.  There is also a dark black spot below where the element is laying, I'm not sure what that is, but when I go to replace the element I will find out!

So on Monday I'll order a new element and replace it.  I will also have to gouge out the glass that melted and broke the element in the first place, since it has now melted into the firebrick.  More pics to come!



April 10,2011
I ordered two side elements from the manufacturer and received them a yesterday.  I started the element repair this morning.  Actually, it didn't take very long either!



I unplugged the kiln first.  I can't stress how important safety is, especially when working on an electric kiln!  Then I removed the front panel of the RampMaster.  I sat it on a little box so that it wasn't hanging by it's wires.  Then, as seen in the picture above I removed the wire from the top part of the element where it protrudes from the inside of the kiln.  So as not to get confused with wiring the elements (since I replaced both of them) I removed one part of an element at a time.


Above shows how I removed the element.  The top two rows of element are really just the first element, it wraps around the kiln twice.  I gently removed the old element by hand, didn't need any tools for this.


In the picture above you can see how the element is wrapped around inside of the kiln.  The element has already been removed from the top right "ledge".


Now you can see that as I removed the old element, right behind it, I put in the new element.  The new element has two long straight twisted wires that you insert through a little hole in the kiln wall.  They are the wires that protrude through the kiln wall into the RampMaster controller, where they are attached to wires in the controller itself.



When putting your new element back into the ledge, try to compress the element slightly.  I ended up with extra element when I finished installing it.  I had to then go back and refit the element more compactly into the ledge so that I didn't have any extra hanging out.  It's important to do this uniformly which isn't easy to do!  Also don't forget to make sure that the element fits correctly into the ledge, especially on the corners.


Above is the second element being replaced.  This is the spot where this element was broken by being melted completely through by a piece of rogue glass.


Above, after removing the broken element I had to remove the remains of the rogue glass (that blackish looking area) that has also melted deeply into the firebrick.  If the glass is not removed and a new element added, that glass will melt back onto the new element and eventually ruin it.  Plus that glass will melt deeper into the firebrick as well.  Unfortunately to remove that glass I had to remove the front of the lip of the ledge because I couldn't get to it.  I did that with an Exacto knife.


Above shows pieces of contaminated firebrick that I dug out of the area with a flat head screwdriver.


The picture above shows my patch job after I removed all of the melted glass.  It isn't pretty!  I could have put a piece of new firebrick in the spot and cemented that, and it would have looked much better.  Unfortunately I didn't buy any replacement firebrick and I didn't want to wait another week, again, to order more.  Instead I used my kiln cement and "glued" back the good pieces of firebrick.  I let all of the cement dry, including a few cracks and broken pieces that I repaired, then continued with the element repair.


The picture above shows the twisted wires from the new second element protruding through the kiln wall into the RampMaster.  The two thick brown wires that are connected to round pieces of spacers which are seen in the upper area of this picture (the spacers are made of the same clay material that kiln posts are shelves are made of) are the ends of the first new element that I replaced.  There are screws that hold on a brass fitting which in turn hold the twisted wires from the element together with the thick wires from the RampMaster.  The long twisted wires were cut by me, to fit exactly into the length of the brass fitting.


The picture above just shows more of the element installation process.  You can see the twisted wire before I cut it and attached the RampMaster's wires back together.

Once done I put everything back together again.  During the entire repair process I made sure to vacuum the inside of the kiln frequently.  The element instructions said to heat the kiln for three minutes to burn a coating off of the brand new elements.  Once done, I was ready to fire!

Because of all of the repair work that I have recently done, I decided to start my kiln early in the morning and monitor it often during the entire firing process.  

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