There's a sinking feeling that I get in my
gut when one of my kilns behaves oddly. It's akin to the car making weird
noises as you are driving down the highway. Thoughts of dread begin to fill
your mind and you start to concoct scenarios of doom. Mainly, "ON NO, I
HAVE TO OPEN THE CONTROLLER BOX!"
Anyway, if you feel the same way too, know
you are not alone. The inside of the "box" is intimidating. Although
it's pretty simple once you know what all of the wires are for and how the
electricity needs to move, it's still a little daunting. So here's my story of
the week regarding my kiln surgery.

There are only a few reasons why a kiln
won't heat; dead or stuck relay(s), broken or fried element, not enough
current/volts getting to the kiln, etc. The thermocouple was telling me the
correct temps, so we could rule that out easily. I'm not as religious about
changing relays as I should be on this kiln. I changed them all out exactly 3
years ago. So, it clearly was time! Luckily, I'm not a hypocrite! I did have a
stash of relays that was reserved for this event, so I was ready when the time
came. (I might be lazy, but I'm not a hypocrite!) So I set aside yesterday
afternoon for this planned outpatient kiln surgery!
I took out my drill with the 1/4" nut
driver attachment, my phillips head bit, and my long nose pliers. I unplugged
the kiln and set a small bowl next to my chair. The bowl is for all the screw,
nuts, and parts that come off, and will need to go back onto the kiln. It just
helps keep things in one place and makes sure things don't roll away and escape
from you. (I learned this from experience of not doing the bowl thing and being
on my hands and knee on the floor looking for a damn screw.) I pull up a comfy
low chair and found a stool to rest the box on since It was still going to be
attached to the kiln. NOW I AM READY FOR SURGERY! All I needed was the trippy
Grey's Anatomy music and someone telling me, go for it!

Each relay is held in place by 2 bolts, each with their corresponding nut. That's a challenge, removing the relay from its spot, then disconnecting all of the crimped connections, then attaching all the connections correctly to the new relay, and then bolting the new relay back in place securely. That's what you do, just four times, in a small space, bent over, with reading glasses on, while you struggle to hold the long nosed pliers that are wiggling the tightly crime connectors on and off. See.... it's simple... a breeze.. ARE YOU KIDDING ME?
The TRUTH is that none
of this in mentally taxing. I didn't need special knowledge, JUST NERVE! I had
to remember that this was just a giant toaster, and I am a resourceful girl! Yes,
I started out intimidated, but that soon gave way to a wave of confidence and
accomplishment. My last step was to take a picture of the inside of the box and
send it to the folks that built the kiln to assure I hadn't missed anything.
They got back to me quickly and pointed out one mistake, which was easily fixed
in 15 seconds. The kiln companies are there to help, so utilize that
help. NOW I AM READY TO GO!
HERE'S WHAT I LEARED,
THAT YOU CAN LEARN FROM TOO...
- Fear is the enemy, not the relays!
- Have the right tools and get them together in one place.
- Get a stash of relays so that you will be ready when the time comes.
- Schedule a quiet, uninterrupted "appointment" time with yourself to do this task.
- Go slowly and take a break if you need it.
- DO NOT wait until the kiln doesn't fire, or do this the night before a show.
- Ask for help from your kiln manufacturer.
- Reward yourself for job well done!
Good luck! If I can do
it, you can too!
Your Kiln Gal,
Gail