So, I opened the box and I see a small area that looks burned. It's a connector that attaches the kiln element to the electrical feed that runs to the relay. (In case you didn't know... the element isn't directly connected to the relay.) There's also a ceramic insulator that looks like it's seem better days, and a dead bug.
To make a short story short...the bug wiggled in, couldn't get out, and in it's frenzy, wiggled around the wire and caused a short when the wire touched the side of the box. This action killed the bug, and fried the connection. (I know what you are all thinking... and, yes... we have big bugs here in Texas.) This is not common, but it can happen.
Thankfully, kilns these days are made pretty "smart" so the controllers sense when a problem arises and shut the program down. With that said, all I needed now was a new ground connector and a new ceramic insulator. I went to my local hardware supply and picked up some hot tub ground connectors as a temporary measure and found some unglazed bisque beads to serve as my insulator. A few moments later I was up and running again. (I know... who the heck has unglazed bisque beads?)
Here's the lesson learned; Just like with a car, occasionally your kiln will hit a bump, or a bug in the road, and need a minor repair. You CAN do it, if you have some spare parts available.
Here's what I recommend having on hand:
An Extra Set of Relays - call the manufacturer of your kiln and ask them to send you a full set of relays for you kiln. They're cheap. They usually run about $15 each and are worth their weight in gold. They do have a lifespan rated in "clicks." So age is less of a factor than usage. You just can't run your kiln with them.
Ceramic Insulators - since you're asking for the relays
Thermocouple - This is truly for the die hards! These run somewhere around $45 dollars depending on the company. Again, your kiln won't run without it.
Electrical Tape - Duh!
Pliers, a Phillips head and a Flat head Screwdriver, Wire Strippers, Set of Nut Drivers, Flush Cutters - These are basic tools you should have in your kiln survival kit. Pack these along with some tranquilizers and a shot of tequila for calm steady hands!
The phone number of someone who knows what their doing....if you don't. - When you call them they'll tell you to get all this stuff, and you'll look like a genius because you have it.
Your Brain - Always unplug the kiln before you start unscrewing things. Do not fire the kiln unattended.
Call your kiln company today and practice safe kiln forming! Your mother will be proud of you!
Your Kiln Gal - Gail