MeltTech Kiln Controller Comprehensive Operation Manual

Interface Overview

The main interface is the central hub for all kiln operations. It provides immediate access to profile selection, control buttons, status indicators, and real-time monitoring tools. Every element is designed to be intuitive, ensuring that even on touch devices, you can easily navigate the system.

From the top navigation bar to the status displays, every component has a dedicated function that helps you manage the firing process with precision. The interface is organized into sections for quick reference and easy access to key features.

This section gives you a complete overview so you can quickly learn how to start, pause, stop, and modify kiln operations.

Familiarize yourself with the layout to improve your efficiency and ensure safe operation.

Regularly check for any updates or new features as the system evolves.

Graphical Data Display

The central graph provides a real-time plot of temperature over the firing cycle. It clearly displays the current temperature alongside the target temperature for each stage of your profile.

Energy cost and elapsed time are also plotted, allowing you to gauge the efficiency and progress of your firing run. Every change is updated live to help you make informed decisions.

This dynamic display is vital for identifying any deviations from your set profile and ensuring the kiln is operating within the desired parameters.

High-quality graphics and smooth transitions help you monitor the process without distraction.

Use this graph to quickly diagnose issues and to confirm that your profile settings are accurately implemented.

Real-time graph displaying temperature, target, cost, and runtime.

Starting, Pausing, and Stopping

Starting the Kiln: Begin by selecting the desired firing profile from the dropdown menu. Click the Start/Stop button to open the control panel, then press Start to initiate the run. Monitor the graph and status indicators to confirm that the kiln begins heating according to the set profile.

Pausing the Kiln: If you need to temporarily halt the process, press the Pause button. You can choose a pause duration from 30 to 180 minutes. During this time, the kiln maintains the current temperature, allowing you to safely adjust settings or wait for optimal conditions. The system logs the pause and retains the current runtime.

Resuming the Kiln: To resume a paused process, click the Resume button. The controller recalculates the runtime and adjusts the PID settings to seamlessly continue from where it left off. This feature is crucial for maintaining the integrity of the firing schedule.

Stage Skipping: If you need to bypass a stage in the firing profile (e.g., to skip an unnecessary hold), use the Stage Skip feature. This updates the runtime and target temperature based on the next stage in your profile. It is especially useful when adjustments are needed on the fly to meet production demands.

These controls are designed for precision and ease of use, ensuring that every operation is smooth and responsive. Always verify the changes on the graph before proceeding.

Firing Profiles

Firing profiles determine the temperature schedule for each kiln run. They are stored as JSON files with a defined structure that includes the profile name and an array of stages, where each stage is represented by a pair: [time in seconds, target temperature in °C].

Editing Profiles: Use the built-in profile editor accessible from the main interface. Here you can add new stages, delete unwanted ones, or modify existing stages. Each change dynamically updates the ramp rate (the slope between stages) and overall duration.

When setting times, note that they are defined in seconds. The system calculates the ramp rate in °C per minute based on these values, so ensure that time values are appropriate for your desired temperature changes.

Carefully review your profile in simulation mode to see the predicted temperature curve. This step is essential to avoid thermal shock and to ensure that the process meets your material’s requirements.

Documentation of each profile, including notes on its intended use and any special considerations, is highly recommended for future reference.

Adaptive & Auto Tuning

This feature continuously monitors the kiln's performance and automatically adjusts the PID parameters if the temperature error exceeds a certain threshold. The system uses both adaptive control and auto-tuning processes to optimize the firing run.

If both adaptive_tuning_enabled and autotune_enabled are set to true in the configuration, a background thread periodically checks the error margin. When the error surpasses ai_adaptive_error_threshold, auto-tuning is triggered.

The auto-tuning process involves heating the kiln up to a preset target (e.g., 500°C), then cooling it down while capturing data. This data is used to compute optimal PID settings which are then applied to future runs.

Adaptive tuning ensures that the kiln can adjust to changes in its environment or wear in its elements over time, maintaining efficient and accurate control.

All actions performed during auto-tuning, including adjustments made and data recorded, are logged and sent to the dashboard for review. This transparency helps in troubleshooting and continuous improvement.

Compensation & Catch-Up

The controller employs dynamic compensation to adjust for any discrepancies between the actual and target temperatures. If the kiln falls short of the target, it automatically extends hold times or slightly reduces the target temperature to make up for the deficit.

The "Kiln Must Catch Up" feature is activated when the temperature deviation becomes significant. In such cases, the kiln is temporarily paused to allow it to recover and reach the desired temperature before resuming the run.

These features are critical for ensuring that the final firing outcome is consistent with the programmed profile, even when external conditions or hardware limitations come into play.

Parameters like compensation_enabled, compensation_factor, temp_drop_value, and extra_time_trigger can be tuned to suit the specific thermal behavior of your kiln.

All compensation events are logged in detail, and AI messages are generated to keep you informed of any adjustments made during the firing process.

Automatic Restart & Recovery

The kiln controller periodically saves its current state, including temperature, runtime, and profile data. In the event of an unexpected shutdown, the system can automatically restart the run if the saved state is recent (within the automatic_restart_window).

This feature minimizes downtime and ensures that the firing process can be resumed with minimal disruption.

To enable this, configure automatic_restarts and automatic_restart_window appropriately. The system checks these values upon restart and attempts to reload the last known state.

If the saved state is outdated or invalid, the system will not perform an automatic restart, ensuring that only reliable data is used to resume operations.

All restart attempts are logged, and any failures are flagged for manual intervention.

Error Handling & Troubleshooting

No Connection: If the controller reports no connection, inspect all wiring and power supplies. Loose cables, disconnected sensors, or power fluctuations may be the cause. Ensure every connection is secure before restarting the system.

Temperature Sensor Errors: Erratic readings or sensor errors typically indicate a faulty sensor or misconfiguration. Check the sensor’s wiring, validate the sensor type in your configuration, and perform a calibration if necessary.

Stuck Relay Warning: This warning is triggered if a relay fails to disengage, which can lead to overheating. Immediately stop the process and inspect the relay circuitry. Adjust the configuration parameters if false positives occur.

Emergency Shutoff: The kiln will automatically shut down if temperatures exceed a critical limit. This safety feature prevents damage but requires you to verify the emergency threshold settings. If the shutoff is triggered frequently, investigate the thermal dynamics and adjust the PID parameters accordingly.

Each error is logged in detail, and troubleshooting tips are provided through AI-generated messages on the dashboard for additional support.

Creating and Editing Firing Profiles

Firing profiles are essential for controlling the kiln’s temperature over time. Each profile is a JSON file containing a name and an array of stages. Each stage is represented by a pair: [time in seconds, target temperature in °C].

Conceptualization: Begin by planning the firing process. Determine the required stages, including ramp-up, hold, and cool-down phases. Consider the material’s properties and the desired chemical or physical transformations.

Defining Stages: For every stage, specify a target temperature and duration. The ramp rate between stages is calculated automatically by the system based on the time and temperature differences. This calculation is in °C per minute, so ensure your time values (in seconds) accurately reflect the desired heating or cooling rate.

Editing Tools: Use the intuitive profile editor available in the interface. This tool allows you to add new stages, modify existing ones, and delete unnecessary stages. Every change is reflected in the overall temperature curve, which you can review in simulation mode.

Validation and Backup: Always test new profiles in simulation mode before using them on the actual kiln. Validate the JSON structure using online tools and document every profile’s purpose, materials, and specific instructions. Back up your profiles to prevent data loss.

Additional Resources & Final Tips

For further reading and support, here are some resources and final tips:

• Visit the MeltTech Website for technical documentation and updates.
• Review the API documentation if you plan to integrate the controller with other systems or customize its functions.
• Join the MeltTech community forums to share experiences, tips, and custom profiles with other kiln operators.
• Maintain a log of your firing runs and profile adjustments to identify trends and optimize performance over time.
• For immediate assistance, contact support at support.melttechau@gmail.com.

Regular review and adjustment of your kiln settings and profiles will ensure optimal performance, energy efficiency, and product quality. Keep this manual handy for reference during setup, operation, and troubleshooting.