Electrical Theory and Application for Electric Kilns _ l&l Electric Kilns - Built to Last

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ELECTRICAL THEORY AND APPLICATION FOR ELECTRIC KILNS ELECTRICAL BASICS ELECTRICAL SAFETY Electricity is a wonderful utility, but can be dangerous if not approached carefully. There are three basic hazards that cause injury or death – shock, arcflash, and arcblast. It is important to remember that even a small amount of current passing through the chest can cause death. Most deaths occurring for circuits of less than 600 volts happen when people are working on “hot,” energized equipment – PLEASE DISCONNECT AND LOCK OUT ALL ELECTRICAL POWER BEFORE ATTEMPTING KILN REPAIRS! ELECTRICAL HAZARDS SHOCK An electrical shock is a current that passes through the human body. Any electrical current flows through the path of least resistance towards ground; if an external voltage contacts a human body, e.g. by touching a live wire with the hand, the voltage will try to find a ground, and a current will develop that flows through the body’s nervous system or vascular system, and exit through the closest part of the body to ground (e.g., the other hand which may be touching a metal pipe.) Nerve shock disrupts the body’s normal electrical functions, and can stop the heart or the lungs, or both, causing severe injury or death. ARC‐FLASH An arcflash is an extremely high temperature conductive mixture of plasma and gases, which causes very serious burns when it comes into contact with the body, and can ignite flammable clothing. Arc temperatures reach up to 35,000°F! ARC‐BLAST Arcblast is a pressure wave resulting from arcing, which can carry molten metal fragments and plasma gasses at very high speeds and distances. This can not only carry very hot shrapnel to injure a person, but can actually be strong enough to destroy structures or knock workers off ladders. SAFETY PRINCIPLES Be safe! Make sure any equipment that is being installed or serviced is disconnected from all sources of power. In industry, it is important to have ‘Lockout and tagout’ procedures in place to make sure that power stays disconnected while people are servicing equipment. It is just as important in residential and commercial sites – DO NOT WORK ON LIVE EQUIPMENT UNLESS ABSOLUTELY NECESSARY! Use the right tools for the job – do not improvise. For instance, use a proper fuse puller; don’t use a screwdriver to pry out that open fuse. Protect the person; use proper gloves, shoes, and clothing. In industry it is recommended to wear safety goggles or face shields to prevent arcflash or arcblast injuries. Wear rubber soled shoes. Make sure the environment around the equipment being serviced is safe. For instance, when working around electricity, it always very dangerous for the floor to be wet. Make sure there is adequate space to work safely. Be aware that current flow across your chest can be fatal. If possible, use only one hand to manipulate test leads when conducting any necessary measurements on live equipment. Use a clamp for one lead, and use one hand to guide the other test lead. Keep the other hand as far as possible from the live circuit components. INSTRUMENTS COMMONLY USED TO MEASURE ELECTRICITY An electrician or technician charged with the responsibility of maintaining or installing devices that use electricity needs to have a number of tools close at hand. In addition to hand and power tools, these should include instruments that can be used to diagnose electrical trouble. CAUTION! Be sure to follow all instructions and safety procedures that are included with the intrument manufacturer’s package. TEST LAMP This consists of a rubberinsulated socket with an incandescent light bulb (rated for the highest voltage to which it might be subjected), to which is attached (2) two probes for attaching to the power source being diagnosed. At least one of these probes should be fitted with a clamp so that it can be attached to one of the power source leads, while the other is

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Transcript of Electrical Theory and Application for Electric Kilns _ l&l Electric Kilns - Built to Last

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    ELECTRICAL THEORY AND APPLICATION FORELECTRIC KILNS

    ELECTRICAL BASICS

    ELECTRICAL SAFETYElectricityisawonderfulutility,butcanbedangerousifnotapproachedcarefully.Therearethreebasichazardsthatcauseinjuryordeathshock,arcflash,andarcblast.Itisimportanttorememberthatevenasmallamountofcurrentpassingthroughthechestcancausedeath.Mostdeathsoccurringforcircuitsoflessthan600voltshappenwhenpeopleareworkingonhot,energizedequipmentPLEASEDISCONNECTANDLOCKOUTALLELECTRICALPOWERBEFOREATTEMPTINGKILNREPAIRS!

    ELECTRICAL HAZARDSSHOCKAnelectricalshockisacurrentthatpassesthroughthehumanbody.Anyelectricalcurrentflowsthroughthepathofleastresistancetowardsgroundifanexternalvoltagecontactsahumanbody,e.g.bytouchingalivewirewiththehand,thevoltagewilltrytofindaground,andacurrentwilldevelopthatflowsthroughthebodysnervoussystemorvascularsystem,andexitthroughtheclosestpartofthebodytoground(e.g.,theotherhandwhichmaybetouchingametalpipe.)Nerveshockdisruptsthebodysnormalelectricalfunctions,andcanstoptheheartorthelungs,orboth,causingsevereinjuryordeath.

    ARCFLASHAnarcflashisanextremelyhightemperatureconductivemixtureofplasmaandgases,whichcausesveryseriousburnswhenitcomesintocontactwiththebody,andcanigniteflammableclothing.Arctemperaturesreachupto35,000F!

    ARCBLASTArcblastisapressurewaveresultingfromarcing,whichcancarrymoltenmetalfragmentsandplasmagassesatveryhighspeedsanddistances.Thiscannotonlycarryveryhotshrapneltoinjureaperson,butcanactuallybestrongenoughtodestroystructuresorknockworkersoffladders.

    SAFETY PRINCIPLESBesafe!Makesureanyequipmentthatisbeinginstalledorservicedisdisconnectedfromallsourcesofpower.Inindustry,itisimportanttohaveLockoutandtagoutproceduresinplacetomakesurethatpowerstaysdisconnectedwhilepeopleareservicingequipment.ItisjustasimportantinresidentialandcommercialsitesDONOTWORKONLIVEEQUIPMENTUNLESSABSOLUTELYNECESSARY!

    Usetherighttoolsforthejobdonotimprovise.Forinstance,useaproperfusepullerdontuseascrewdrivertopryoutthatopenfuse.

    Protectthepersonusepropergloves,shoes,andclothing.Inindustryitisrecommendedtowearsafetygogglesorfaceshieldstopreventarcflashorarcblastinjuries.Wearrubbersoledshoes.

    Makesuretheenvironmentaroundtheequipmentbeingservicedissafe.Forinstance,whenworkingaroundelectricity,italwaysverydangerousforthefloortobewet.Makesurethereisadequatespacetoworksafely.

    Beawarethatcurrentflowacrossyourchestcanbefatal.Ifpossible,useonlyonehandtomanipulatetestleadswhenconductinganynecessarymeasurementsonliveequipment.Useaclampforonelead,anduseonehandtoguidetheothertestlead.Keeptheotherhandasfaraspossiblefromthelivecircuitcomponents.

    INSTRUMENTS COMMONLY USED TO MEASURE ELECTRICITY

    Anelectricianortechnicianchargedwiththeresponsibilityofmaintainingorinstallingdevicesthatuseelectricityneedstohaveanumberoftoolscloseathand.Inadditiontohandandpowertools,theseshouldincludeinstrumentsthatcanbeusedtodiagnoseelectricaltrouble.CAUTION!Besuretofollowallinstructionsandsafetyproceduresthatareincludedwiththeintrumentmanufacturerspackage.

    TESTLAMP

    Thisconsistsofarubberinsulatedsocketwithanincandescentlightbulb(ratedforthehighestvoltagetowhichitmightbesubjected),towhichisattached(2)twoprobesforattachingtothepowersourcebeingdiagnosed.Atleastoneoftheseprobesshouldbefittedwithaclampsothatitcanbeattachedtooneofthepowersourceleads,whiletheotheris

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    manipulated(withonehandonly).Thisisusedforveryroughdiagnosticsonopenfuses,interiorlighting,motor,andresistancecircuits.

    CLAMPONAMMETER

    Theseareveryconvenienttestinstruments,usedfordeterminingthenumberofamperesflowinginacable.Onlyone(1)cablecanbemeasuredatatime,andthecablecaneitherbebareorinsulated.Thecabletobemeasuredis(carefully)segregatedfromothercurrentcarryingcables,andshiftedenoughsothatthejawsoftheclamponammetercanbeopened,slippedaroundthecable,andthenclosed.Assoonasthejawsclose,aclearandaccuratereadingisregisteredonthescale.Thejawsareinsulated,andtheBakelitehandleandshieldprotectthetechnicianfromshock.Themeterisoperatedbythemagneticfieldsetupbythecurrent.

    OHMMETER

    Thisisusedtomeasuretheresistanceofacircuit.Usuallythisisfoundincombinationwithavoltmeter,andmilliammeter,inadeviceknownasaMULTIMETER(seebelow).SomeOhmmetersareveryprecise,forlaboratoryuse.

    CAUTION!Neverconnectanohmmetertoacircuituntilthecircuithasbeendisconnectedfromthepowersource.Theohmmeterhasitsowninternalpowersupply,andconnectingitacrossanotherpowersourcecancauseseriousdamage.

    VOLTMETER

    Voltmetersareusedtomeasurethevoltagethatexistsinacircuit.Typically,thetechnicianselectsanappropriatescale(0150volts,0250volts,0500volts,etc.),andthenclampsoneoftheprobestooneofthehotlines.Theotherprobeisthencarefullyputincontactwiththeotherhotline,andthemeterregistersthevoltage.Voltmetershaveveryhighresistance,intherangeof15,000W,sothatverylittlecurrentflowsinthevoltmetercircuitjustenoughtotocausethevoltmetertoindicatevoltageacrossitsscale.

    DIGITALMULTIMETER

    Thisisprobablythemostusefulinstrumentinanelectricianstoolbox.Itisacombinationohmmeter,voltmeter,andmilliammeter.Agoodmetermeasuresohms,ACvolts,DCvolts,andACandDCamperes(atleastupto300milliamperes),aswellasprovidesacontinuitytester(audible)thatmeasurescontinuitywithinacomponent(suchasafuse).Typicallythemultimeterhasdifferentsocketsfortheprobestoconnectto.OneprobegoestoCommon,andtheotherisconnectedeithertoVolts/Ohms,ortoAmps.(Clickheretoseehowtouseamultimeter)

    CAUTION!NeverconnectthemultimeterHotprobetotheAmpssocketwhenmeasuringVolts.ThereisaninternalpowersourcewhichsuppliesitsownvoltagewhenmakingAmperagemeasurementsapplyinganexternalvoltagetothisinternalcircuitcancauseseriousdamage.Mostgoodmultimetershaveaninternalfusetopreventthemostseriousdamagehowever,itisstillanuisancetoreplacefuses.

    Afterconnectingtheprobestotheappropriatesockets,thetechnicianselectsthetypeofmeasurementbeingmade.Thecorrectscalemayhavetobeselectedalso,ifthemultimeterisnotautoscaling.Oneprobeshouldthenbeclampedtoonepartofthecircuitbeingmeasuredforsafety,andthentheothercarefullyputintocontactwiththeotherside.Themeterdisplaysthevalue,andusuallytheunitofmeasurement.

    SOME BASIC ELECTRICAL THEORYSimplyput,electricityisnothingmorethantheflowofelectronsthroughaconductor.Someunderstandingofthestructureofmatterisnecessaryinordertounderstandthefundamentalnatureofelectricity.

    ATOMS,PROTONS,NEUTRONS,ANDELECTRONSMatterisanythingthatoccupiesspaceandhasmass.Someexamplesarewater,glass,wood,andsteel.Allmatterconsistsofmolecules,whichareextremelysmallparticles.Theseparticles,eventhoughtiny,stillretainsomechemicalproperties.Moleculescanbefurtherdivided,intoatoms,orelements.Dividingmoleculesintoatomscreatesachemicalchangei.e.,watermoleculesundergoachemicaltransitiontobecome2partsofhydrogenand1partoxygen(2hydrogenatomsand1oxygenatom.)

    Atoms,orelements,areknownasthebuildingblocksofmatter.Singly,orincombination,atomsarethematerialsthatconstituteallmatter.Someexamplesofelementsareiron,hydrogen,andcarbon.Thereareapproximately115knownelements.Thestructureofeachatomcanberoughlycomparedtoastaranditsplanetarysystem.Likethestar,thenucleusofanatomisatthecenter.Surroundingthenucleusaretinyelectrons,whichhaveanegativecharge,thequantitydependingontheelement.Thenucleusconsistsofprotons,whichhaveapositivecharge,andneutrons,whichcarrynocharge.

    Thesimplestatomisthehydrogenatom,whichhasasingleproton(+)inthenucleus,andasingleelectron()orbitingthenucleus.Amorecomplexatomisthecopperatom,whichhas29protons(+)and35neutrons(nocharge)inthenucleus,and29electrons()orbitingthenucleus.Intheirnaturalstateatomscontainanequalnumberofprotonsandelectrons,andhaveaneutralcharge.Theelectronsarearrangedinseverallayers,orrings,aroundthenucleus,andtheseringsarecalledshells.Thenumberoftheshelldeterminesthemaximum

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    numberofelectronsthatcanexistinashellthefirstshellisclosesttothenucleus,andthenumbersincreaseconsecutivelythefurtherawaytheyarefromthenucleus.Themaximumnumberofelectronsthatcanexistinashellisasfollows:2electronsinthefirstshell,8inthesecond,18inthethird,32inthefourth,18eachinthefifthandsixth,and2intheseventh.

    Theabilityofamaterialtoletgoofitselectronsiscalledconductivity.Forvariousreasons,materialsthataregoodconductorshavefrom1to4electronsintheiroutermostshells.Forexample,thetwomostcommonconductorsusedforelectricalwiringarecopper,whichhas1electroninitslastshell,andaluminum,whichhas3.Atomswith5,6,or7electronsintheiroutermostshellsarecallednonmetalsandarepoorconductorsatomswith8electronsareinsulators.

    STATICELECTRICITYStaticelectricityisanelectricchargethatbuildsupinanobject.Frictioncanbuildanelectricchargeupinanobject.Weareallfamiliarwithrubbingourstockingfeetonacarpet,buildingupachargeinourbodies,andthentouchinganuncharged(neutral)objecttoreleasethecharge(sometimeswithanaudiblecrackandavisiblespark.)Thischargeconsistsofanexcessnumberofelectronsrelativetotheprotonsintheobject,andthisexcessbuildsupfromrubbingagainstadifferentmaterialthatreleaseitselectronsmorequicklythantheobjectbeingcharged.

    Thischargecanaccumulateinanobjectifisnotdischarged.Forinstance,rubbingaglassrodwithsilkcauseselectronstoflowfromthesilktotheglassrod,andthusbuildsupachargeinboththesilkandtheglassrod.Also,rubbingarubberrodwithfurcauseselectronstoflowfromthefurtotherubberrod.Iftheglassrodisbroughtinproximitytotheanothersimilarlychargedglassrod,theyrepeleachother.Also,tworubberrodsrepeleachother.Butifaglassrodisbroughtclosetoarubberrod,theyattracteachother,becausetheyhaveoppositecharges.Thestorageofthischargeiscalledelectricityatrest,orstaticelectricity.

    Therearetwobasicrulesforelectricalcharges:

    1. Likechargesrepel,andoppositechargesattract.2. Thestrengthofthisrepulsionorattractionisdirectlyproportionaltothestrengtyhofthe

    electricalchargeandinverselyproportionaltothesquareofthedistancebetweenthechargedobjects.

    ELECTRICITYINMOTIONMostelectricitythatweusetodoworkisintheformofanelectriccurrent,whichiselectricityinmotion.Electronsmovethroughaconductorbypassingfromoneatomtoanother.Amaterialthathassomeelectronsthatarefreetoflowinthismannerarecalledconductorsmaterialsthatdonothavefreeelectronsareinsulators.Rubberandceramicsaretypicallygoodinsulatorsmetalsaretypicallygoodconductors.Ifacopperwireisconnectedbetweentwobodiesofoppositecharge,electronswillflowfreelythroughthewire,attemptingtobalancethecharge.

    Therearetwocommontypesofelectriccurrents,DCordirectcurrent,andACoralternatingcurrent.DCisacurrentthatalwaysflowsinthesamedirection.Commonexamplesareautomobilecircuitsthatarepoweredbybatteries,andflashlights,alsopoweredbybatteries.Abatteryisadevicethatuseschemicalstocreateanunbalancedchargebetweenitsterminals,andthuscausesadirectcurrenttoflowfroma(+)terminaltoa()terminal.ThisDCelectricitycanbeharnessedtoperformsuchtasksaslighting,playingmusiconaradio,etc.

    ACelectricityistypicalinhouseholdsandbusinesses.Inthisformofcurrent,thedirectionofelectronflowisreversedatregularintervalsbytheelectricalgeneratorthatproducestheAC.Thevoltage(levelorpressureofelectricity)asitisgeneratedincreasesfromzerotoamaximumvalueinonedirection,thenreversesdowntozero,andcontinuestoamaximumvalueintheotherdirection,andincreasesbacktozerointheoriginaldirection,andsoon.Ifplottedonagraph,thecurveappearsliketheoneintheaccompanyingfigure.

    Electricityhasfourbasiccharacteristics:Voltage(Pressure),Amperes(Flow),Ohms(Resistance),andWatts(Power).Theflowofelectronsthroughacircuitcan(andcommonlyis)becomparedtotheflowofwaterthroughapipe.TherateofflowofwaterisanalogoustoAmperes,Ohmstopipediameter,waterpressuretoVoltage,andWattstogallonsofwater.Wecantalkabouteachoftheseindividually,andthendiscussspecifictypesofelectricalcircuitssuchasSeriesCircuitsandParallelCircuits.

    ELECTRICCURRENT(AMPERE)Thebasicunitofelectricityisthecoulomb,andisequaltoapproximately628x1016electrons.Sincetherateofflowofelectricityiswhatistypicallyofinterest,ratherthanthe

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    totalquantityofelectricity,thecoulombisnotgenerallyofpracticaluse,exceptasthefundamentalquantityonwhichotherelectricalcharacteristicsarebased.

    AnAmpererepresentstheflowof1Coulombpersecond.TherelationshipbetweentheAmpereandtheCoulombcanberepresentedmathematicallyas:

    Q=It

    WhereQ=quantityofcoulombs(C)

    I=current,inamperes(A)

    t=time,inseconds.

    Amperagewouldbeanalogoustotherateingallonsofwaterflowthroughapipe.

    ELECTRICALRESISTANCE(OHMS)Allmaterialshavesomeoppositiontocurrentflow,andthisoppositionresultsinsomeoftheelectricalenergybeingconvertedtoheat.Thisconversionisinaccordancewiththeformula,W=I2R,whereWisWatts,I=Intensityofelectricalcurrent(Amperes),andRisresistanceinOhms.SeethesectiononOHMsLaw,below.Electricalresistanceisanalogoustotherestrictionofthepipediametertotheflowofwater.

    Aswesawabove,differentmaterialshavedifferentquantitiesoffreeelectrons.Theoppositioniscausedbythetypeofmaterialthatthecurrentisattemptingtopassthrough,aswellasbyfrictioncausedbythemotionofelectrons.Thisfrictionisaffectedbythediameterofthewire,aswellasbythelengthofthewire.

    Theoppositionoftheflowofelectronsiscalledresistance.Theunitofresistancemeasurementistheohm(W).One(1)Ohmistheoppositiontoelectricalflowthatresultsinelectricalenergybeingconvertedintoheatattherateofone(1)WattperAmpereofeffectivecurrent.Theinstrumentthatisusedtomeasureresistanceistheohmmeter.

    Somematerialsthataregoodconductors:Copper,silver,gold

    Somematerialsthataregoodinsulators:Rubber,glass,bakelite,wood,porcelain(especiallyelectricalgradeporcelain)

    Othermaterialsareconductorsdespitehavingsomeinsulatingpropertiesthesearecalledresistors.Examplesofresistorsarealloyssuchasironaluminumchrome,andnickelchrome,whichareusedasheatingelementsinkilns,furnaces,andovens.

    ELECTROMOTIVEFORCE(VOLTAGE)AvoltisaunitofEMF,orelectromotiveforce,andisinternationallydefinedasthatemfwhichwillestablishacurrentof1Amperethrougharesistanceof1Ohm().Voltageisanalogoustowaterpressure,andistheforcethatpushesthewaterthroughapipe.

    Referringtothepreviousdiscussionconcerningatoms,electrons,andmatter,itcanbesaidthatallmatterconsistsofelectricity.Instrictterms,electricitycannotbegenerateditcanonlybemadetomove,andthereforetransmitpowerfromonesourcetoanother.Electricalenergy(asopposedtoelectricity)canandisgenerated(orconverted)fromotherformsofenergy.Thereareseveralcommonmethodsofgeneratingelectricalenergy,someofwhicharemechanicalinduction,chemical,thermoelectric,andfriction.Thisishowvoltageissuppliedinmostcommonapplications.

    Forinstance,mechanicalinductionisthemethodwhichACproducesvoltage.AnACgeneratorproducesavoltagefirstinonedirection,andthenanother.Thisisdonebyrotatingalargecoilofwirethroughamagneticfield(orviceversa).Asthewirecoilmovesthroughthemagneticfield,avoltagedevelops.

    ELECTRICALPOWER(WATTS)Strictlyspeaking,poweristhetimeratefordoingwork.Thefasterworkisdone,thegreaterthepowerthatwillberequiredtodoit.Horsepoweristhebasicunitmeasurementofpower,andisdefinedas33,000ftlb/min.Theformulais:

    hp=LxW=ftlb/min

    33,000xt33,000

    wherehp=horsepower,L=distanceinfeetthroughwhichWisraisedorovercome,W=weightinpoundsoftheobjectbeingmoved(orthepushorpullinpoundsofforcebeingexertec),andtistimeinminutesrequiredtomoveweightWthroughdistanceL.

    Electricpoweristherateofdoingelectricalwork.Itsunitisthewatt,orkilowatt,whichis1000watts.One(1)wattisdevelopedwhen(1)ampereismaintainedthrougharesistancebyanemfof(1)volt.TherelationshipbetweenkWandhpis:

    (1)hp=746W

    Electricalenergyisexpressedintermsofkilowatthours(kWh),and(1)kWhistheenergyexpendedifworkisdoneatarateof(1)kWfor1hour.

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    OHMSLAWTherelationshipbetweenelectricalpower,current,voltage,andresistanceiscalledOhmsLaw.Themathematicalformulaisexpressed:

    P=E*Ior:I=E/Ror:R=E/I

    Where

    P=Power,inkW

    I=current,inamperes(A)

    E=electromotiveforce,involts(V)

    R=resistance,inohms()

    Thefollowingdiagramexpressesmostofthecommonrelationshipsingraphicalform.

    Ohmslawcanbeappliedtoanentirecircuit,ortoanyportionofit.Thismaybestated:

    Thetotalcurrentflowinginacircuitisequaltothetotalvoltageappliedtothecircuitdividedbythetotalresistanceofthecircuit.Thecurrentflowinginanypartofacircuitisequaltothevoltageacrossthatpartofthecircuitdividedbytheresistanceofthatpartofthecircuit.

    ELECTRIC CIRCUITSAnelectriccircuitisthepathoverwhichelectronsflow.Thetwobasickindsofcircuitsareseriesandparallel.Acombination(orseriesparallel)circuithaselementsofbothbasickindsofcircuits,wherecomecomponentsareconnectedinseriesandothersarejoinedinparallel.

    Allcircuitsarecomposedofthesamebasiccomponents:

    Avoltagesource(1)Ormoreelectricalloads(1)Ormorecontroldevices(switches,relays,etc.)

    Asimplecircuitasillustratedconsistsofavoltagesource(L1andN),aSPSTswitch,andaheater.

    SERIESCIRCUITSAcircuitthatonlyhasonepathoverwhichcurrentcanflowisaseriescircuit.Abreakinanypartofaseriescircuitstopscurrentflow.Allcomponentsinaseriescircuitseethesameamountofcurrenttherefore,eachcomponentmustbecapableofcarryingthatnumberofamperes.

    RULESFORSERIESCIRCUITS

    Thevalueofacurrentflowinginaseriescircuitisthesamethroughallpartsofthecircuit.Thetotalvoltageofaseriescircuitisequaltothesumofthevoltagesacrosseachpartofthecircuit.Thetotalresistanceofaseriescircuitisequaltothesumoftheresistancesacrosseachpartofthecircuit.

    Linevoltageisdividedacrosseachcomponentinaseriescircuitinproportiontothecomponentresistancevalues.Referringtotheschematicbelow,thetotalresistanceis(25+30=55).VoltagemeasuredbetweenpointsAandBis(240Voltsx25/55)=

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    109Volts.

    Iftherewere(2)resistanceswhosevalueswereequal,thevoltagewouldbedividedequallyinhalf,andwouldmeasure120Volts.

    PARALLELCIRCUITSAcircuitthathastwoorcurrentpathsisaparallelcircuit.Eachcomponentisconnectedtolinevoltage,andcurrentstillflowsthroughpartofthecircuitifonecomponentfails.Eachcomponentmustbecapableofwithstandinglinevoltage.Thenumberofamperesvariesaccordingtotheresistanceofthecomponent.

    Themorecircuitpaths,thelessoppositiontotheflowofelectrons.Totalcircuitresistancedecreaseswhenmorepathsareadded.

    RULESFORPARALLELCIRCUITS

    Thetotalcurrentsuppliedtoaparallelcircuitisequaltothesumofthecurrentsthroughthebranches.Thevoltageacrossanybranchofaparallelcircuitisequaltothesupplyvoltage.Thetotalresistanceofaparallelcircuitisalwayslessthantheresistanceofanyofthebranches.

    ThefollowingparallelcircuitistypicaloftheDavinciandJ2900kilnringsthereare(3)elementsperring,connectedinparallel.Inthisexample,eachelementhasaresistanceof49.8at240VAC,eachelementdevelops(240VAC/49.8)=4.82Amperes.Thetotalcircuitamperes,then,is4.82+4.82+4.82=14.46Amperes.

    SERIES/PARALLELOrCOMBINATIONCIRCUITSCertaincircumstancesrequiretheuseofSeries/Parallel,orCombination,circuits,inwhichseriesandparallelcircuitsarecombined.Insomefrontloadingindustrialfurnacesthesecircuitsareusedtocombine,forinstance,sidewallheatingelementsandbackwallheatingelements(oftenshorterthansidewall)inabranchcircuitthatiscontrolledbyapowerrelay.

    Intheaboveexample,thetotalresistancecanbefoundbyfirstdealingwitheachbranchcircuitindividually.Startingfromtheright,thiscircuitisaseriescircuitaddthe(24+24=48).Theothertwocircuitsareparallelandareequalinvalue(12each)therefore,theresistancevalueofthesetwocircuitsisequalto(12/2=6).Drawinganequivalentcircuitwith(2)parallelcircuits,oneof6andoneof48,lookslikethefollowing:

    Solvingforthiscircuit:Rt=(6*48)/(6+48)=5.33.

    Thetotalresistanceislowerthanthatforanyofthebranchcircuits.

    CONDUCTORS AND WIRING METHODS

    CONDUCTORSAconductorisanymaterialthatofferslittleopposition(resistance)totheflowofanelectriccurrent.Mostfamiliarconductorsareeithercopperoraluminumwire,coveredinanyofvariousformsofinsulation.Thesizeofconductorsvariesgreatlywiththeamountofcurrent

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    theycarry,andtheirintendeduseandenvironment.Becausemostconductorsarerelativelysmallindiameter,theunitcalledcircularmilshasbeenselectedtomeasurethesizeofconductors.Onemilisequaltoonethousandthofaninch(.001inch).Onecircularmilistheareaofacircleonemilindiameter.Thesymbolformilism,andforcircularmiliscm(nottobeconfusedwiththemetricsymbolsformeterandcentimeter).TheformulaA=m2canbeusedtodeterminethecircularmilareaofwire,where

    A=area,incircularmils(cm)

    M=diameter,inmils(m)

    IntheU.S.,aspecialscalehasbeendevelopedforthemostcommonwiresizes.ThisistheAmericanWireGauge,orAWG.Thefollowingtableisbasedonthe1999NationalElectricCode,Tables31016and31018.ThisistheallowableampacitiesofInsulatedConductors,(3)currentcarryingconductorsinaracewayorcable,andisbasedonanambienttemperatureof86F.

    AWG/

    kcmilCircularMils

    MaximumAmpacityofCopperWirewith60CInsulation

    MaximumAmpacityofCopperWirewith90CInsulation

    MaximumAmpacityofCopperWirewith105CInsulation

    14 4,110 20 25 34

    12 6,530 25 30 43

    10 10,380 30 40 55

    8 16,510 40 55 76

    6 26,240 55 75 96

    4 41,740 70 95 120

    3 52,620 85 110 143

    2 66,360 95 130 160

    1 83,690 110 150 186

    1/0 105,600 125 170 215

    2/0 133,100 145 195 251

    3/0 167,800 165 225 288

    4/0 211,600 195 260 332

    250 250,000 215 290 X

    300 300,000 240 320 X

    350 350,000 260 350 X

    400 400,000 280 380 X

    Inpractice,mostelectriciansuseTable31016,andusethevaluesforthe60Cinsulation,becausethesearethemostconservativevaluesofampacity.Therearecorrectionfactorsthatmustbetakenintoaccountforsuchvariablesasambienttemperature(lessampacityastheambienttemperarurerises)andnumberofconductorsinacableorracewaythesefactorsarefullydetailedintheNationalElectricalCode.

    INSULATION TYPESVarioustypesofplasticarebyfarthemostcommoninsulationsusedonconductors.Forgeneralpurposebuildingwire,typesTW,THW,andTHWNareusedmorethananyothertype.Othertypeshavebeendevelopedformachinetools(MTW)wheretheconductorsarelikelytoencounterharshcuttingfluids.Likewise,forhighambienttemperaturesseveraltypesofinsulationhavebeendeveloped,includingthetypefavoredbyL&L,whichisSEWF.Thisisahightemperaturesiliconrubberbasedinsulation.

    VOLTAGEDROP220VVersus230VVersus240VWherelongwirerunsareexperiencedbetweenthepowersupplyandthepointofconnection,itispossibleforthemeasuredvoltageatthepointofconnectiontobelowerthanthemeasuredvoltageatthepowersupply.Thisiscausedbytransmissionlossesthroughthewires,andcanalsobeaggravatedbyhavingexcessiveconnectionsfromonetransformerinaneighborhoodpowergrid,orwithinasinglefacility.Forinstance,manyoftheU.S.electricalutilitiessupply240Vfromthetransformer,butthemeasuredvoltage

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    comingintoaresidencemaybe230Voreven220V.Forresistanceheatingdevicessuchaselectrickilns(andovensorranges)thislowervoltagecanresultinslightlyslowerfiringsthanwouldbethecaseiftheactualvoltagewere240Vbutinpracticethisdoesnotusuallycauseproblems.

    Topreventoramelioratethisvoltagedrop,largersizeconductorscanbeusedforlongruns.Oneruleofthumbistouseonesizelargerwireforevery50feetofrunfromthepowersupplytotheconnectionpointtheelectricianshouldbeabletomakethisdeterminationonsite.

    Also,usingawirematerialoflowresistivitycankeepvoltagedroptoacceptablelevels.Aluminumwirehasaresistivity(Ohmscircularmilperfoot)of17.0copperhasaresistivityof10.4.Therefore,theresistivityofcopperis10.4/17.0=0.61,or61%ofaluminumsresistivity.L&Lrecommendsusingonlycopperwireforconnectionfromakilntoanypowersupplyinadditiontotheresistivitydifference,therearedifferencesintherateofcorrosionthatareaggravatedbythehighambienttemperaturescommonatthekilnconnectionpoint.

    WHY 230V AND 460V RATINGS?Undervoltageconditionscanaffecttheoperationandservicelifeofmotorstheseareusuallyratedat10%ofnameplatevoltagethusthecommonratingof230Vor460Vformotors,whichcanusuallybesafelyoperatedatthelowervoltagessometimesfoundatserviceconnectionpoints.Inmanyindustrialplantsthemostcommonequipmentisoperatedbyelectricmotors,anditiscommontorefertotheactualpowersupplyas230Vor460Veventhoughthenormalsupplyvoltagefromtheutilityis240Vor480V.

    FUSESANDCIRCUITBREAKERSFusesandcircuitbreakersareovercurrentdevicesdesignedtoprotectelectricalcircuitcomponents.Ifacircuitdevelopstoomanyamperes,theyaredesignedtoopen,interruptingtheflowofcurrentinthecircuit.Fusesselfdestructwhentheysenseanoverloadinthecircuit.Circuitbreakersarecommonlyusedinnewconstructiontheytrip(turnoffpower)whentheysenseanoverload,andcanbereset(turnedbackon)whenthecircuitisreturnedtonormal.

    Circuitbreakersaremoreconvenientbecauseofthisfeature.However,theycancausenuisancetrippingandruinkilnfiringswhentheytrippartwaythroughafiring.Thisisbecausemostcircuitbreakersareactivatedthermallyifthecircuitbreakertemperaturerisesaboveapresetlevel,abimetallicelementinsidethecircuitbreakeropens,andthepoweristurnedoff.Thisworkswellmostofthetimehowever,overtimethebimetallicelementbecomesweakerbecauseresistanceheatingcircuitsareattheirratedloadlongerthanothertypesofelectricalloadssuchasmotors.Eventuallythecircuitbreakerbecomestooweaktoholditselfclosedoveralongenoughtimetofinishakilnfiring,unlessthecircuitisdrasticallyoversizedtocompensateforthisgradualagingprocess.

    Therearemanydifferenttypesoffuses,includingdualelementtimedelay,onetime,subcycle,etc.Mostofthesedesignationsrelatetohowquicklyafusewillblowinresponsetoanoverload,andthesetypesoffuseshavebeendevelopedtoprotectnotonlythecircuits,butalsovaryingtypesofequipment.Forinstance,SCRs(siliconcontrolledrectifiers)needtobeprotectedfromvoltagespikeswhichcanoccurwithin1/60ofasecondanddestroythedevicetheseareusuallyprotectedbysemiconductorfuseswhichareveryfastacting,currentlimiting,andhavenotimedelay.

    Anotherconsiderationinselectingfusesistheinterruptingcapacityinamperesinotherwords,howbigashortcircuitcanbeopenedbythefuse.Inlargeindustrialplantsthiscanbeanimportantfactor,becauseifenoughpowerisavailableitwouldbepossiblethatashortcircuitwouldallowtoomanyamperestoflowintoacircuitforageneralpurposetypefusetointerruptwhichcouldpotentiallycauseanelectricalfire.Mostresidencesandsmallcommercialshopsdonothaveenoughpoweravailablebeforethemaincircuitprotector(usuallya200ampcircuitbreaker)wouldopen,andasmallinterruptingrating(10,000Ampsor50,000Amps)isenough.

    Forprotectingkilncircuits,onetimegeneralpurposetypefusesshouldbeused.Theseareinexpensive,havenoappreciabletimedelay,andareavailableinalargevarietyofsizes.Theyarealsowidelyandeasilyavailable,andaremadebyseverallargefusemanufacturers.Differentmanufacturershavedifferentdesignationsfortheironetimefusessomeofthemorecommononesare:

    MANUFACTURER MAXRATEDVOLTSINTERRUPTRATING

    FUSEDESIGNATION

    LITTELFUSE 250VOLTS 50,000AMPS NLN

    BUSSMAN 250VOLTS 50,000AMPS NON

    GOULDSHAWMUT 250VOLTS 50,000AMPS OT

    LITTELFUSE 600VOLTS 50,000AMPS NLS

    BUSSMAN 600VOLTS 50,000AMPS NOS

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    GOULDSHAWMUT 600VOLTS 50,000AMPS OTS

    Allovercurrentdevicesmustbesizedtocarry125%ofthecontinuousampereloadforinstance,a240V/1PhaseModelJ230kilnisratedat44amperes.Theovercurrentdevicemustberatedat125%,or(1.25x44=55Amperes)minimum.Theclosestcommerciallyavailabledeviceisratedfor60Amperesa50Amperedeviceisnotadequate.

    ELECTRICAL DISTRIBUTIONElectricaldistributionfromtheelectriccompanyspowergenerationplantisgenerallybyhighvoltage3phaselines.Thesecanbebranchedtosubstationsthattransformtheasgeneratedpowertoalower(butstillrelativelyhigh)voltageforfurtherdistribution.Ultimately,foreachservice(whetherasingleindustrialplant,shopsinashoppingcenter,orhousesinaresidentialneighborhood)thissupplyisconnectedtoatransformer,whichchangesthehighvoltagesupplytolinevoltagesrangingfrom208Vto480V.

    SINGLE PHASE SERVICESMostresidentialservicesaresinglephase,butmanyofthesearedistributedfrom3PhaseWyetransformers.TheyincludetwohotlegsfromtheWyeplusagroundedneutral,and,ofcourse,asystemground.Atruesinglephaseservicecomesfromatransformerthatisconnectedtoonlyonephasefromasubstationhighvoltagesupply.Thesecanbefoundinmanyresidentialneighborhoods,andsometimesinindustrialplants.Usuallythevoltagesuppliedis240V,with120Vfromphasetoneutral.

    120/240VOLTS/1PHASEThisthemostcommonhouseholdpowersupplyfoundintheU.S.Theprimaryofasinglephasetransformerisconnectedtotoonephaseofthethreephasedistributionsystem.Thesecondarycontainstwocoilsconnectedinserieswithamidpointtaptoprovideasinglephase,threewiresystem.Thetwohotwires,orlines,provide240Volts,andeitherofthehotlinestoneutralprovides120Volts.Youwillsometimesseethisexpresseda110/220.(Forpurposesoforderelementsyouwillstillget240voltelementswhenyousee110/220.)

    120/208VOLTS1PHASEForsomecommercialfacilitiesandsomenewerresidentialsupplies,theelectricalsupplyisdistributedwithinaneighborhoodpowergrid,andeachsupplyis120/208V1Phase.Twohotlegsat208V,agroundedneutralfor(2)120Vcircuits,andofcoursethesystemground,comprisetheelectricalsupply.Inthesecasesappliancesareratedfor208V1Phase,andkilnsshouldbeorderedassuch.

    THREE PHASE SERVICES

    WYEVERSUSDELTA3PHASESYTEMSA3PhasepowersupplyisclassifiedasDeltaifthehotlegsareconnectedphasetophase,withagroundedneutral.Whendiagrammed,thecircuitlookslikeatriangle(thereforethetermDelta),withthehotlegsshownasthethreepointsdefiningthetriangle,andthethreepowercircuitsdrawnbetweenthem.Thevoltagebetweenthegroundedneutralandanyoneofthehotlegsmeasuresofthesuppliedphasetophasevoltage.Avariationofthiscanbesuppliedwheretwoofthephasetoneutralvoltagesaremeasuredasthephasetophasevoltage,andtheotherismeasuredatanothercommonlyseenvoltagesuchas208V.Thistypeofelectricalserviceisusuallyfoundinindustrialplants,andthephasetoneutralvoltageisnotcommonlyusedforelectricalcircuits.

    InaWyepowersupplythehotlegsofthe3phasesystemareeachconnectedtoagroundedneutral.WhendiagrammedthecircuitlooksliketheletterYwitheachofthehotlegsshownatoneoftheouterarmsoftheYandthegroundedneutralatthecentraljunctionpoint.Thephasetoneutralvoltageisreducedbythe3phasefactor(SquareRootof3=1.73).E.g.,foraphasetophasevoltageof208V,divide(208Vby1.73=)120Vcircuitvoltage.Thistypeofservicecanbefoundinindustrialplants,commercialsites,andresidentialareasthephasetophasevoltagesandphasetoneutralvoltagesareallcommonlyusedforelectricalcircuits.

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    240VOLTS/3PHASEMost240Volts/3PhasesystemsareprovidedasDelta,withagroundedneutraltosupply120Voltsasaphasetoneutralvoltage.Averycommontypeis240VACDelta,threewirewithagroundedcentertapononeofthephaseshighlegtoobtain120Voltsbetweentwoofthephasestoneutraland208Voltsbetweenthethirdphasetoneutral.Anothercommonserviceissimilar,butis120voltstoneutralonallthreephases.

    Agroundedneutralconductorisalsousuallyincludedwiththesetypesofelectricservicetoobtainlowervoltagessuchas110120oreven208volts,andmaybeusedinmanyresidentialorcommercialinstallationstohelpindistributingthetypical110120lightingandoutletcircuits.Iftheloadsbetweenthephasetoneutralcircuitsareclosetobeingbalanced(similarinamperes),theneutralconductorendsupcarryinglittleornoamperesbecausethethreephasesaregenerated120apartintime,andthereforecanceleachotheroutwhenconnectedtogetherontheneutral(hencethenomenclatureneutral.)

    208VOLTS/3PHASEManyschools,institutions,andcommercialorlightindustrialfacilitiesarewiredwith120/208Volts,3Phase,Wyeconnectionelectricalpowersupply.Thistypeofsupplyisanefficientmethodofsupplyingheavy120Vloads,andisalsoincreasinglybeingusedinresidentialserviceforthatreason.

    TheWyeconnectionworksbyputtinganelectricalcircuitfromonehotlegofthe3phasesystemtoagroundedneutral.Thisreducestheeffectivevoltagebythe3phasefactor(SquareRootof3=1.73).Therefore,withaphasetophasevoltageof208V,dividethe208Vby1.73=120V.

    Innonresidentialuse,mostfacilitiesaresuppliedwiththefull120/208Vsystem,andthedistributionisdoneinsidethefacilityforthe120Vcircuitsandforthe208V3Phasecircuits.Itisgenerallymosteconomicaltousethe3Phasesupplyforequipmenttherefore,itisrecommendedthatsuch208Volt/3phasekilnsbeorderedforthesefacilities.Singlephasekilnscanbeusedhowever,theywouldrequireheaviergaugewireforhookup,andwouldtendtounbalancethedistributionsysteminsidethefacility.

    480VOLTS/3PHASEDELTAANDWYEManyindustrialfacilitiesareequippedwith480Vservices,whichareveryefficientforsupplyingequipmentwithhighpowerrequirements.ThesecanbefoundaseitherDeltaorWye.Ineithercase,linetolinevoltageis480Volts.WhensuppliedasaWyesystem,phasetoneutralvoltageis277Volts,whichisveryefficientforsupplyinglightingloads.Inbuildingswherethisserviceisfound,astepdowntransformerisusedtosupply208120Volts/3PhaseWye,for120Voltloads.Thismakesforaversatilepowersupply,butcancauseconfusionastowhatvoltageisavailableforequipment.Besuretomeasurelinetolinevoltagesonallthreephasessothatthetypeofvoltageavailablecanbedeterminedforcertain.Itisagoodideatotalktothebuildingsuperintendentorelectrcianwhenorderingkilnsoranyotherkindofelectricalequipment,becausetheywouldknowforsurewhichofthepowersupplieswouldbeavailable.Itiscostlytoconverttoadifferentvoltagethantheoneorderedafterthefact.

    ELECTRICAL CONNECTION NOTES FOR L&L KILNS

    208,220AND240VOLT,SINGLEPHASECONNECTIONMoststandardL&Lkilnsaresuppliedfor208,220or240volt,singlephaseservice.Connectingthesekilnstoapowersupplyisrelativelystraightforward.Thereare(2)hotlinesandaground.SinglephaseL&LKilnsdonotuseaneutralwiretopoweranyofthecircuitsallcircuitsarebasedonlinevoltage.Forsinglephasekilnsratedfor44Amperesandless,aNEMA650Pcordsetisprovided.ThepowersupplymustfeedaNEMA650Rreceptacle.TheexceptiontothisistheModelGS1714,whichusesa30AmpNEMA1430Pcordset,whichisthetypicaldryercordfoundinmostpartsoftheU.S.AllsinglephaseL&LKilnsratedformorethan48Amperesmustbewireddirectthesearenocordsetsprovided.

    1PHASE,30AMPEREDRYERCIRCUITPOWERSUPPLYFORJUPITERKILNS

    L&LsuppliessinglephaseJUPITERKilnswithaspeciallyconfigured,hightemperatureNEMA650Pcordset,eventhoughforsomemodelsitwouldbepermissibletousea30Ampcordsetbasedontheampacitiesinvolved.TheseKilnshavebeenlistedtoUL499standardsthislistingisdependentoncertainspecificcomponentsthataretestedtoULstandardsunderstrictguidelines.

    Becausetherearedifferent"standard"dryeroutletconfigurations,indifferentjurisdictions

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    anddependingonwhentheoutletwasoriginallyinstalled,thereisnosetanswertothequestionofwhetheryoucanutilizeanexistingdryercircuitforasinglephaseJupiterkilnequippedwiththeNEMA650PplugandcordassemblythatL&Lusesonthesekilns.IfaKilnownerdecidestomakethischangeonhis/herown,beadvisedthattheULlistingnolongerappliesbecausethislistingisdependentoncertainspecificcomponentsthataretestedtoULstandardsunderstrictguidelines.Oneofthemostimportantofthesecomponentsisthemainpowercord,whichwouldnecessarilybemodifiedtomakethischange.UNDERNOCIRCUMSTANCESSHOULDANYONEEVERSUBSTITUTEANOFFTHESHELFDRYERCORDFORTHENEMA650PCORDSUPPLIEDBYL&LSUCHOFFTHESHELFCORDSARENOTRATEDFORTHETEMPERATURESTHATARENORMALATTHEKILNPOWERTERMINALBLOCK.

    NEMACONFIGURATIONSFORL&LPOWERCORDSETSL&Lsuppliescordsetsfor1phaseKilns(andsome3phasekilns),ratedfor48Amperesorless.MostoftheseareNEMA650P.The3PhaseplugweuseontheEasyFirekilnsisa1550P.TheDoll/TestkilnissuppliedwithwitheraNEMA515Ror520R.LibertyBellekilnsuseavarietyof30ampcordsets(seetheLibertyBelleSpecificationsheetformoreinformation).

    208,220AND240VOLT,THREEPHASEDELTACONNECTIONALLSTANDARDL&LKILNSSUPPLIEDFOR208OR240VOLT,THREEPHASESERVICEMUSTBEWIREDINDELTA,ORPHASETOPHASE,RATHERTHANPHASETONEUTRAL.DELTAmeansthattheelectricalload(s)areconnectedbetweenthehotleads,thatis,oneloadisconnectedbetweenL1andL2,anotherisconnectedbetweenL2andL3,andthethirdisconnectedbetweenL1andL3.

    Thereisalotofconfusionconcerningthreephaseservices,becausetherearesomanydifferenttypesthatarecommonintheU.S.A.However,whenorderinganL&LKilnfor208OR240Volt,ThreePhaseoperation,makesuretomeasurethevoltagesbetweenallcombinationsoftheLinewires(L1toL2,L2toL3,andL3toL1.)Thisshouldbeclosetoeither240VACacrossallthreephases,or208VAC,withsometolerance(nomorethan10%)allowedforvoltagedrops.

    IntheseStandardL&LKilnsalltheheatingandcontrolcircuitsaredesignedtooperatefromLinevoltage,andtherearenocircuitsthatareoperatedfromthepossiblereducedvoltagesavailablefromLinetogroundedneutral.

    480/277VOLTAnd380/220VOLT,THREEPHASEWYECONNECTIONTherearesomeexceptionstotheaboverule:therearesomespeciallydesignedkilnstooperateon480VAC/277VAC,threephaseWYE,inwhichtheheatingcircuitsoperatefromLinetoneutral,andthecontrolcircuitisoperatedfromanisolatedcontroltransformer.Inaddition,somekilnsforoverseasoperationarewiredfor380VAC/220VAC,threephaseWYE,inwhichtheboththeheatingandcontrolcircuitsareoperatedfromLinetogroundedneutral.

    OVERSEAS ELECTRICAL DISTRIBUTIONOverseaselectricalvoltagesvaryfromcountrytocountry,andrangefrom220/380VWyepowersupplywhere220Visacommonhouseholdvoltage,to240/415VWyewhere240Viscommon,andcangoashighas575or600VoltsDelta,whichisrelativelycommoninCanada.ThelowervoltageinWyesystemsisdeterminedbythe3Phasefactor,whichisthesquarerootof3(approximately1.73).Dividethephasetophaselinevoltagebythe3phasefactortoobtainthephasetoneutralvoltage(e.g.,380/1.73=220V).L&LKilnsareavailablefor380/220V3PhaseWye,aswellas220V1Phaseand415/240V3Phase"Wye".

    ELECTRONICS AND KILN CONTROLWiththeadventofAutomatic,orComputercontrol,Kilns,Electronicshastakenonmoreimportanceintheceramicsindustry.ElectronicKilncontrollersarecalledupontocontroltheflowofelectricitytotheheatingelements,inordertoachieveadesiredtime/temperatureprogram.Thereisabasicfeedbackloopinvolved,inwhichameasurementoftemperatureiscomparedbytheelectronicmicroprocessortoadesiredprogramwhichisstoredinthememoryofthecontroller.Inresponsetotheoffsetbetweenthemeasuredtemperatureandtheprogrammedsetpoint,thecontrollerallowselectricityflowtotheheatingelements.

    THERMOELECTRIC EFFECTSReferringtothediscussioninprevioussectionsconcerningatoms,ittakesalotofenergytodislodgeaprotonoraneutronfromanatom.Butelectronsmovewiththeslightestnudge,especiallyinmetals,whereasmallvoltage,atinyamountofheat,ortheimpactofafewphotonsisallittakes.Thermalandelectricalenergyworktogether,oneenhancingtheeffectsoftheother,asseveralscientistsisthe19thcenturydiscovered.Threeinparticular,

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    (c)2015L&LKilnMfgInc.AllRightsReserved.505SharptownRoad|Swedesboro,NJ08085|8007508350

    ThomasJ.Seebeck,JeanPeltier,andSirWilliamThomson(LordKelvin),madesomediscoveriesthatareveryinfluentialintheheatprocessingindustrytoday.

    In1821,Seebeckdiscoveredthatapairofwiresmadefromdissimilarmetalsandjoinedatbothends,wouldmoveamagneticneedleiftheendswereheldatdifferenttemperatures.Theneedledeflectionindicateselectronflow,orcurrent.Afurtherdevelopmenthasbeentoopenoneoftheends,andexposethejoinedendtotemperature.Averysmallvoltage,whichdependsonthetemperatureatthejunctionandthecompositionofthetwometals,canbedetectedattheopenend,andthisiscalledtheSeebeckvoltage.ThisvoltageisproportionaltothechangeintemperaturetheproportionalityconstantisknownastheSeebeckcoefficient.Thiscircuitisknownasathermocouple.Thevoltagesfoundareverysmall,andmeasuredinunitsofthousandthsofavolt,calledmillivolts.

    Thermocouplesaremadewithvarioustypesofdissimilarmetals.AutomaticL&LKilnsareequippedwithavariationofTypeKthermocouplesasstandardequipment.ThesearemadewithanegativeNickelChromium(Chromel)wirejoinedtoapositiveNickelAluminum(Alumel)wireThesearetwoalloysmadefrombasemetalswhichhavebeendevelopedtoworkwellinthetemperaturesnormallyfoundinceramickilns.

    Overthedecades,thermocoupletechnologyhasbecomeverymature.Standardindustrialpracticehasbeendevelopedtoidentifythermocouplewires.Allnegativethermocouplewiresareidentifiedwitharedinsulationcovering.ForTypeKthermocouples,thepositivewireismarkedwithayellowcovering.Anotherthermocouplegrade,TypeS,ismadefromplatinumandplatinumrhodium,whicharepreciousmetalsthatstandupverywelltothehightemperaturesandoxidizingconditionsencounteredinceramickilns.TheyusuallyhaveamuchlongerlifethanTypeKthermocouples,butareverycostly.TheyareavailableforL&LKilnsbyspecialorder.

    FEEDBACK CONTROLAsappliedtoKilns,feedbackcontrolisthemeanswherebytheKilntemperatureiscontrolled.Theoperatorprogramsadesiredtime/temperaturecycleintothememoryofthecontroller.Whenthecontrollerisstarted,itimmediatelystartstocomparetheSetpointasitisgeneratedfromtheinternalprocessor,totheKilntemperature.TheKilntemperatureismeasuredbyathermocouple,whichgeneratesamillivoltage,whichflowstotheControllerinputterminals.TheControllercalculatestheoffsetbetweenthegeneratedSetpointandtheKilntemperature,andattemptstocorrecttheoffset.IftheKilntemperatureislowcomparedtoSetpoint,thecontrollercallsforheat.IfthekilntemperatureishighcomparedtoSetpoint,thecontrollerrefrainsfromcallingforheat,andtheKilntemperaturedropsduetoheatlossesthroughtheinsulationwall.ForL&LKilns,heatissuppliedbyclosingthecontactsofpowerrelays,whichcarryelectricalenergytotheheatingelements.Thefeedbacklooplookslikethefollowing.

    ThetemperatureinsidetheKilnisconstantlybeingadjustedbythecontrollerinresponsetothethermocouplesignal.

    THREEZONECONTROL(DYNATROL)L&LisoneofthepioneersofthreezonecontrolwiththeDYNATROL.Inthismethodofcontrol,threethermocouplesareplacedinsidetheKilnfromtoptobottom,andconnectedtothecontroller.Thecontrollerhasthreeinputconnections,andthreeassociatedoutputs.Theoutputsareconnectedtopowerrelays.TheDYNATROLisconstantlyadjustingthethreeoutputsinresponsetothesignalsfromthethreeinputs,andtherebycontrollingtheKilntemperatureineachofthethreezones.Toptobottomtemperaturegradients,ordifferences,canbecontrolledveryaccurately.Fordetailedinformationonthis,pleaserefertodynatrolinstructblue.pdf.