2.

A WORD ABOUT ALPINE

PRECISION

KILNS

Your Alpine Kiln is designed for quality in every respect. It has been engineered to give you years of service. It has been constructed with the finest steel and refractories available. It has been built for either oxidation or ~eduction firing, and whichever type of firing you may do, you should obtain excellent results. It ha~ been designed to give close cOl1trol in either type of firing. This booklet has been prepared for your reference. Adherence to the instructions contained herein will aid you in obtaining continued excellent results from firing. It is very difficult to tell you exactly how to fire your kiln. Like models can have many variations of control from slight dimensional differences, venting and draft conditions, geographical location and weather conditions - and results may vary. We suggest that you first become acquainted with your kiln. You can expect better results from firing after you have tried several firings and have gained experience in the operation of the kiln. When you have become accustomed to your new Alpine KiJn we hope that you too will find that it is truly a precision kiln. Please read this booklet for future reference. Thank you. thoroughly and save it

4.

ALPINE

PRECISION

KILNS

bID SERIES

INSTRUCTIONS - ASSEMBLY and OPERATION

FUEL

REQUIREMENTS* IS

- NATURAL FULLY LOADED

GAS

WHEN KILN

MINIMUM GAS PRESSURE REQUIRED .::K.::.:ILN::::::.;.....;;;;II;.;.;OD;;..;,EL....;;;. NO.

MAXIMUM GAS CONSUMPl' ION

ND-4
ND-6 ND-8

(SIX)

225 CFJI 275 CFJI 325 CFJI 37S

INCHES

WATER

COLUMN

ND-10 ND-12
ND-l6

PRIISURB ~UIRED
ON ALL MODELS

400

cn cn cn
cm cm

425 CFH
475

ND-20 ND-24 ND-30

525 625

All fuel data based on natural gas of 1000 B.T.U. per cubic foot.

ALPINE PRECISION KILNS ND SERIES INSTRUCTIONS ASSEMBLY D~PERS You will find packed in your shipment two damper slabs 9 x 20 x 5/8 with 2-5/8" holes near one edge. Insert the bolts in the four steel handles through each of these holes and tighten the nut loosely. Set the dampers on the bricks alongside kiln flue opening. The steel handles should then rest in the channel iron leading to the top sid~ edge of the kiln. The handles will then protrude down towards the floor for convenient manipulation in reduction firing. SETTER SLABS and POSTS Each shelf is formed by placement which are set upon spacer posts. The following shelves: of the setter slabs (shelves) (continued) - ASSEMBLY and OPERATION

is a suggested way of setting up your posts and

Other arrangements which provide adequate support and allow for good circulation of heat through the ware are perfectly satisfactory. Shelf heights may be varied by use of various length posts to accomodate your ware.

9.

ALPINE HIFIRE PRECISION INSTRUCTIONS - ASSEMBLY

KILNS

and OPERATION

Illustration LEFT

- Alpine kiln parts and accessories RIGHT Slab - silicone carbide (is black or dark gray) Posts (5 illustrated) available in a variety of sizes

Slab - sillimanite (is buff colored) Thermocouple protector tubes (3 illustrated)

For sizes of slabs and posts offered refer to our current price list.

11.
FLAME NOZZLES

MAIN GAS BURNERS

REDUCTION FIRE GAS ORIFICE TIPS

REDUCTION FIRE MANIFOLD

RING BURNER

MAIN BURNER MANIFOLD

MAIN GAS BURNER AIR INTAKE ADJUSTMENT SHUTTER

GAS PRESSURE GAGE (OUTER) BURNERS

/ -C,; .
BURNER TOGGLE SWITC:

MAIN GAS VALVE HEARr~~ENTER)BURNERS

REDUCTION FIRE GAS VALVE PILOT GAS

VALVE AND

110VAC LEAD WIRE PLUG MAIN GASSOLENOID VALVE

RING BURNER

NI) KILN SERIES BURNER

ASSEMBl Y

NOTE: On Models ND-4 thru ND-12 burners are mounLed in vertical position. Controls are the same as shown above.

13.

ALPINE PRECISION ND SERIES INSTRUCTIONS OXIDATION FIRING

(continued)

KILNS

- FIRING

Your kiln is equipped with two valves at the side of the kiln. The first valve, or valve noarest to the back of the kiln, controls the gas which is supplied to the burners beneath the hearth of the kiln. The second valve, or valve toward the front of the kiln, controls the gas which is supplied to the burners beneath the side walls of the kiln chamber. After establishing the pilot flame ~ turn on either one o:e the main burner gas valves until the water column pressure gage irmediately above the valve registers 2". Then turn on the other main burner gas valve until the water column pressure gage fo~:, this valve also registers 2". The dampers on the top of the l'iln should be wide open during oxidation fir:1.ng. Continue firAng uutil the kiln has either reached a temperature of about 1000 F. - or about one hour then increase the gas pressure on both valves to 3" water column pressure. The kiln may fire at 3" water column pressure until cone maturity, or if desire to arrive at cone maturityeflrlier, you may fire at 4" water column pressure. These are suggested pressures you may gradually increase the pressure to as high as 6" water column pressure if you so desirso Please note that the forefoing lrocedure is !. suggested Jlrocedure only ana-ie recommend tha you ollow this during your Elrst firings. After becoming familia.r with the kiln you may wish to vary the firing to suit your own needs. For example, you might wtsh to fire very slowly during the first phase of the firing cycle. This could be done by firing the burners beneath the hearth only, at, say, 1-1/2" water column pressure, leaving the burners beneath the side walls of the kiln chamber in off position. As the firing progresses, you could then turn on the burners beneath the side walls of the kiln chamber. To increase the speed of firing, increase gas pressure. However, it should not be necessary to go above 6" water column pressure. To decrease the speed of firing 9 lessen gaspr'essure. You w111find that as you become familiar with the kiln, the manner in which you operate the kiln can be quite flexible.

.~

15.

ALPINE PRECISION KILNS ND SERIES INSTRUCTIONS - FIRING OXIDATION FIRING

(continued)

The burners are also equipped with air shutters which may be raised or lowered by spinning them. They may be locked in position by securing the locknut immediately below the shutter. Normal setting is approximately 1/2" open.

COOLING
After cone maturity you should completely damper the kiln by moving together the damper slabs at the top of the kiln along each side of the flue opening. This will cause the kiln to cool slower and lessen the chance of danger to your ware from too rapid a cooling cycle. If you wish to cool at a very slow pace, you may use the burner during part of the cooling cycle.

CONES AND USE OF PYROMETER

For the first few firings use your pyrometric cones as you normally would. and when maturity is reached, check thetemper~ture which the instrument indiOftes. If the temperature does not correspond to the following cone tables do not be alarmed. Cone tables are not intended to ~erve as an accurate measurement of temperature as such but are an approximation of cone maturity temperatures. Cone maturity as listed depends on a definite heating ~ycle of so many degrees rise per hour, ~nd\when this cycle is deviated from, temperature at maturity will vary slightly. Also kiln atmosphere may have a slight effect on cone maturity temperatures.

17.

ALPINE PRECISION KILNS

ND

SERIES

INSTRUCTIONS - FIRING REDUCTION FIRING

PRINCIPLES OF OPERATION
The following terms will aid in understanding reduction firing. Terms: Excess fuel: Volume of fuel over that required combustion with the volume of air present. Excess air: Volume of air over that required combustion with the volume of fuel present. for the principles of

for

In obtaining a reducing atmosphere through the products of combustion of the kiln burner there are three things which must be positively controlled. 1. Fuel input 2. Air input 3. A sufficient temperature to crack or break down the excess fuel introduced through the burner and form CO and Hydrogen which is a combustible gas. The above product of the reducing fire is the material which will react with your oxide glazes to give the desired effect. REDUCTION FIRING PROCEDURE

Remove all muffle slabs and center your ware in the kiln chamber. Start your reducing fire after firing in oxidation to at least . 1200 to 1500oF., which is the lowest temperature at which the excess fuel can be broken up. At this temperature or higher if deSired, utilize the damper slabs at the top of the kiln along each side of the flue opening. Work these plates in toward the center (but never completely closed), stopping and checking the draft portB around the burners beneath the kiln, making sure there is none or very little back flame. DO NOT OVER DAMPER; You will know if you have over dampered if the back flame is more than 1/2 to 2" long. At the same time slowlL open the reduction fire gas valve by turning it to the left.--rDTS introduce raw gas at the tip of each main burner to aid in obtaining a reducing atmosphere. This valve ~lould be used only as long as considered necessary during the course of the reduction fire.

wrrr

19.

ALPINE PRECISION ND SERIES INSTRUCTIONS REDUCTION PRINCIPLES FIRING (continued) (continued)

KILNS

- FIRING

OF OPERATION

effect on the body materials after a liquefaction and sealing off by the glaze. This would indicate further'that it would be very difficult to' obtain reducing effects during the cooling period. In making the statement "reducing effects" if carbon overalaze is meant, then the bulk of the effects do take place at the maturity temperature and during the cooling period. The first indication of the process of reduction would seem to be endothermic and at the very beginning of the reduction effect apparently a considerable volume of heat energy is obsorbed into the materials without a corresponding rise in temperature. In other words, there is a leveling-off period on your temperature chart, then comes the formation on CO2 from the CO contained in the products of combustion and the oxygen removed from the ceramic materials, resulting in an exothermic reaction, which will be shown on your temperature chart ~ as a distinct and rather rapid increase in temperature. When the ,reduction effect has been completed, the rate of temperature rise will tend to level off and you will have from that period on to maturity simply a normal and rather slow temperature increase. It has never been our experience that a reversal of either reduction or oxidation effect could be obtained from a glaze once matured. REDUCTION AND CARBON OVERLAY DIFFERENTIATION A sooty condition, or more exactly a metallic carbon overlay or addition to a lli>rmal glaze, is often spoken of erroneously as reduction. Actually the two terms should be very strictly used and a carbon overlay should be described as such and obtained, if desired, separately and distinctly from any reducing effect. If you are working for a metallic carbon overglaze, then the reducing effects that may go along with this are purely incidental, and as a matter of fact, are not necessary if the smoking period is done at the very end of the glaze fire and after the melt has been obtained on the glaze. By the same token it is altogether unnecessary for any carbon deposit to be made on the glaze in the course of a direct reduction fire because no free carbon need be formed and the process of reduction means that the CO formed in the firebox is later converted to CO by the process of removing some oxygen from the glaze materiil. Therefore no free carbon need ever be deposited on the ware or on the kiln walls or flue.

21.

ALPINE PRECISlON ND SERIES LPG CONSUMPTION

KILNS

OF GAS FIRED KILNS

ND-4 ND-6 NO-8 ND-IO NO-12 ND-16 ND-20 -

100 CFH or 11.8 1bs/hr or prox. 2.80 gals/hr. 120

cm cm cm cm

or 14.1 1bs/hr or prox. 3.30 gals/hr. gals/hr. gals/hr. gals/hr. gals/hr.

150 CFH or 17.0 1bs/hr or prox. 4.1 180 or 21.2 Ibs/hr or prox. 5.0

175 CFH or 21.7 1bs/hr or prox. 5.1 190 or 22.3. lbs/hr or prox. 5.3

210 CFH or 24.7 1bs/hr or prox. 5.80 gals/hr. 230 or 27.1 1bs/hr or prox. 6.4 gals/hr. gals/hr.

NO-24 ND-30 -

270 CFH or 3175 1bs/hr or prox. 7.5

(
~

Z"i " ABOVE

RIDGE OR OBSTRUCTION WITHIN Z5'FEE
I OIl(

T-I7vENTC~1
IS"---"'
I' -

~14f=n
26
H

22::--1
OPEN
f

'l
1.1

I I
~

..

~r----l&ADJU5T
I
I
j

a"MINIMUM TO AN'Y COMBUSTIBLE MATERIAL

TO ROOt PITCH 'l (IF ANY) _22."::

IMPORTANT!
LEAVE OPEN FOR AIR FLOW

VARf~S WITH CEILING HEIGHT

IMPORTANT!
LEAVE OPEN
FOR AIR. FLOW

jHOOO~

1+'

1~ \..
f~t
, ,_ t" (

aEE "~IDI'E

r--~:o;;~::,----,-L
I

~+
6-tO f8"

I~
~

SE

.R
MATERIALS:
STEEL
16-20GA. GAL\lANIZED SHE:E:T OR STAINLESS

r---.I'I. -z,. ;'/tpuee, 1~

SUGGESTED KILN HOOD AND VENT STACK

,..---

"C"I:"'~
-----,
1.-

~I
-,

(Not supplied

with the kiln as installations

vary)

Please check your local building code for conformity before using. We assume no responsibility for improper or illegal venting systems.