2.

A WORD ABOUT ALPINE PRECISION KILNS

Your Alpine Kiln is designed for quality in everyrespect. It has been engineered to give you years ofservice. It has been constructed with the fineststeel and refractories available. It has been builtfor either oxidation or ~eduction firing, and which-ever type of firing you may do, you should obtainexcellent results. It ha~ been designed to give closecOl1trol in either type of firing.

This booklet has been prepared for your reference.Adherence to the instructions contained herein will aidyou in obtaining continued excellent results fromfiring. It is very difficult to tell you exactly howto fire your kiln. Like models can have many variationsof control from slight dimensional differences,venting and draft conditions, geographical locationand weather conditions - and results may vary. Wesuggest that you first become acquainted with yourkiln. You can expect better results from firing afteryou have tried several firings and have gained experiencein the operation of the kiln. When you have becomeaccustomed to your new Alpine KiJn we hope that youtoo will find that it is truly a precision kiln.

Please read this booklet thoroughly and save itfor future reference.

Thank you.

4.

ALPINE PRECISION KILNS

bID SERIES

INSTRUCTIONS - ASSEMBLY and OPERATION

FUEL REQUIREMENTS* - NATURAL GAS

WHEN KILN IS FULLY LOADED

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

PRESSURE REQUIRED

6 (SIX)ND-4ND-6 INCHES

ND-8

ND-10ND-12ND-l6

ND-20ND-24

WATER COLUMN

PRIISURB~UIREDON ALL

MODELS

ND-30

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

\

MAXIMUM GASCONSUMPl' ION

225 CFJI

275 CFJI

325 CFJI

37S cn400 cn425 CFH

475 cn525 cm625 cm

7 •

ALPINE PRECISION KILNS

ND SERIESINSTRUCTIONS - ASSEMBLY and OPERATION

ASSEMBLY (continued)

D~PERSYou will find packed in your shipment two damper slabs 9 x 20 x 5/8with 2-5/8" holes near one edge. Insert the bolts in the foursteel handles through each of these holes and tighten the nutloosely. Set the dampers on the bricks alongside kiln flue opening.The steel handles should then rest in the channel iron leading tothe top sid~ edge of the kiln. The handles will then protrudedown towards the floor for convenient manipulation in reductionfiring.SETTER SLABS and POSTSEach shelf is formed by placement of the setter slabs (shelves)which are set upon spacer posts.The following is a suggested way of setting up your posts andshelves:

-I••

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

9.

ALPINE HIFIRE PRECISION KILNS

INSTRUCTIONS - ASSEMBLY and OPERATION

Illustration - Alpine kiln parts and accessoriesLEFT RIGHTSlab -- sillimanite(is buff colored)

Slab -- silicone carbide(is black or dark gray)

Thermocoupleprotector tubes(3 illustrated)

Posts(5 illustrated)available in a varietyof sizes

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

11.

MAIN BURNER MANIFOLD

FLAME NOZZLES

MAIN GAS BURNERS

REDUCTION FIRE GAS ORIFICE TIPS

REDUCTION FIRE MANIFOLD

RING BURNER

MAIN GAS BURNER AIR INTAKEADJUSTMENT SHUTTER

GAS PRESSURE GAGE(OUTER) BURNERS

/ -C,; .BURNER TOGGLE SWITC: I

110VACLEAD WIRE PLUG

MAIN GAS VALVEHEARr~~ENTER)BURNERS

\REDUCTION FIRE

GAS VALVE

PILOT GASVALVE ANDRING BURNER

MAIN GASSOLENOID VALVE

NI) KILN SERIES BURNER ASSEMBl Y

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

13.

ALPINE PRECISION KILNSND SERIES

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

15.

ALPINE PRECISION KILNSND SERIES

INSTRUCTIONS - FIRINGOXIDATION FIRING (continued)The burners are also equipped with air shutters which may beraised or lowered by spinning them. They may be locked inposition by securing the locknut immediately below the shutter.Normal setting is approximately 1/2" open.COOLINGAfter cone maturity you should completely damper the kiln bymoving together the damper slabs at the top of the kiln alongeach side of the flue opening. This will cause the kiln tocool slower and lessen the chance of danger to your ware fromtoo rapid a cooling cycle.If you wish to cool at a very slow pace, you may use the burnerduring part of the cooling cycle.CONES AND USE OF PYROMETERFor the first few firings use your pyrometric cones as younormally would. and when maturity is reached, check thetemper~-ture which the instrument indiOftes. If the temperature doesnot correspond to the following cone tables do not be alarmed.Cone tables are not intended to ~erve as an accurate measurementof temperature as such but are an approximation of cone maturitytemperatures. Cone maturity as listed depends on a definiteheating ~ycle of so many degrees rise per hour, ~nd\when thiscycle is deviated from, temperature at maturity will vary slightly.Also kiln atmosphere may have a slight effect on cone maturitytemperatures.

17.

ALPINE PRECISION KILNSND SERIES

INSTRUCTIONS - FIRINGREDUCTION FIRINGPRINCIPLES OF OPERATIONThe following terms will aid in understanding the principles ofreduction firing.

Terms:Excess fuel: Volume of fuel over that required forcombustion with the volume of air present.

Excess air: Volume of air over that required forcombustion with the volume of fuel present.

In obtaining a reducing atmosphere through the products of combus-tion of the kiln burner there are three things which must bepositively controlled.

1. Fuel input2. Air input3. A sufficient temperature to crack or break downthe excess fuel introduced through the burner and formCO and Hydrogen which is a combustible gas.

The above product of the reducing fire is the material which willreact with your oxide glazes to give the desired effect.

REDUCTION FIRING PROCEDURERemove 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 excessfuel can be broken up. At this temperature or higher if deSired,utilize the damper slabs at the top of the kiln along each side ofthe flue opening. Work these plates in toward the center (but nevercompletely closed), stopping and checking the draft portB around theburners beneath the kiln, making sure there is none or very littleback flame. DO NOT OVER DAMPER; You will know if you have overdampered if the back flame is more than 1/2 to 2" long. At the sametime slowlL open the reduction fire gas valve by turning it to theleft.--rDTS wrrr introduce raw gas at the tip of each main burnerto aid in obtaining a reducing atmosphere. This valve ~lould beused only as long as considered necessary during the course of thereduction fire.

19.

ALPINE PRECISION KILNSND SERIES

INSTRUCTIONS - FIRINGREDUCTION FIRING (continued)PRINCIPLES OF OPERATION (continued)effect on the body materials after a liquefaction and sealing offby the glaze. This would indicate further'that it would be verydifficult to'obtain reducing effects during the cooling period.In making the statement "reducing effects" if carbon overalaze ismeant, then the bulk of the effects do take place at the maturitytemperature and during the cooling period. The first indication ofthe process of reduction would seem to be endothermic and at thevery beginning of the reduction effect apparently a considerablevolume of heat energy is obsorbed into the materials without acorresponding rise in temperature. In other words, there is aleveling-off period on your temperature chart, then comes theformation on CO2 from the CO contained in the products of combustionand the oxygen removed from the ceramic materials, resulting in anexothermic 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 willtend to level off and you will have from that period on to maturitysimply a normal and rather slow temperature increase. It has neverbeen our experience that a reversal of either reduction or oxidationeffect could be obtained from a glaze once matured.REDUCTION AND CARBON OVERLAY DIFFERENTIATIONA sooty condition, or more exactly a metallic carbon overlay oraddition to a lli>rmalglaze, is often spoken of erroneously as re-duction. Actually the two terms should be very strictly used anda carbon overlay should be described as such and obtained, if de-sired, separately and distinctly from any reducing effect. If youare working for a metallic carbon overglaze, then the reducingeffects that may go along with this are purely incidental, and asa matter of fact, are not necessary if the smoking period is doneat the very end of the glaze fire and after the melt has been ob-tained on the glaze.By the same token it is altogether unnecessary for any carbondeposit to be made on the glaze in the course of a direct reduc-tion fire because no free carbon need be formed and the processof reduction means that the CO formed in the firebox is later con-verted to CO by the process of removing some oxygen from theglaze materiil. Therefore no free carbon need ever be depositedon the ware or on the kiln walls or flue.

21.

ALPINE PRECISlON KILNSND SERIES

LPG CONSUMPTION OF GAS FIRED KILNS

ND-4 100 CFH or 11.8 1bs/hr or prox. 2.80 gals/hr.

ND-6 120 cm or 14.1 1bs/hr or prox. 3.30 gals/hr.

NO-8 150 CFH or 17.0 1bs/hr or prox. 4.1 gals/hr.

ND-IO - 180 cm or 21.2 Ibs/hr or prox. 5.0 gals/hr.

NO-12 - 175 CFH or 21.7 1bs/hr or prox. 5.1 gals/hr.

ND-16 - 190 cm or 22.3. lbs/hr or prox. 5.3 gals/hr.

ND-20 - 210 CFH or 24.7 1bs/hr or prox. 5.80 gals/hr.

NO-24 - 230 cm or 27.1 1bs/hr or prox. 6.4 gals/hr.

ND-30 - 270 CFH or 3175 1bs/hr or prox. 7.5 gals/hr.

a"MINIMUM TO AN'YCOMBUSTIBLE MATERIAL~r----l&ADJU5T TO ROOt PITCH 'l

I j (IF ANY) _22.":: 1.1I -

(

~ 26H~14f=nT-I7vENTC~1I

Z"i " ABOVERIDGE OR

OBSTRUCTIONWITHIN Z5'FEE

OPEN

I OIl( IS"---"' ••-I'

IMPORTANT!LEAVE OPENFOR AIR FLOW

VARf~S WITHCEILING HEIGHT

jHOOO~ ~ 1£+'

1~ \.. ® ~+aEE "~IDI'E 6-tO f8"

r--~:o;;~::,----,-LI

, ,_ t" (

f~t.R

MATERIALS:16-20GA. GAL\lANIZEDSHE:E:T OR STAINLESSSTEEL

22::--1f 'l I

I~ .•.

IMPORTANT!LEAVE OPENFOR AIR. FLOW

I~ ® ~ISE£ "C"I:"'~

,..--- -----,~ 1.- -,

r---.I'I. -z,.;'/tpuee, 1~SUGGESTED KILN HOOD AND VENT STACK(Not supplied with the kiln as installations vary)

Please check your local building code for conformitybefore using. We assume no responsibility forimproper or illegal venting systems.