Paragon Caldera & FireFly Instruction &Service Manual Recommended books at Free video training! Watch www.paragonweb.com kiln videos at www.paragonweb.com Click “Products” near the top of the home page. Then click Click the “Audio & Videos” link “Books & DVDs” from the near the top drop menu. of the home page. Printed in USA Safety. 3 Introduction The Optional Glass Window. 3 Thank you for choosing a Paragon kiln! We have designed it to give Setting Up the Kiln . 4 you many years of reliable service. Electrical Installation . 4 The Caldera Kiln Stand . 4 It will help you gain the most enjoy- Seating the Elements . 4 ment from your kiln. It will show you how to avoid damaging the Where to Locate the Kiln . 4 kiln and will answer many questions. If your kiln is digital, your in- Installing the FireFly Thermocouple . 4 struction packet will include a separate digital controller manual. Basic Operation . 5 Please save both manuals and write your kiln’s serial number on Accessories . 5 the inside cover of both manuals. Important Guidelines . 5 Loading the Kiln. 6 At www.paragonweb.com select Venting the Kiln . 7 “Products,” then “Books & DVDs” from the drop menu. The books we recommend will enhance your kiln experi- Glass Fusing & Slumping . 7 How to Cut Glass. 7 ence. You can also email or phone us with questions. We Fusing Compatibility of Glass . 8 are glad to help. The Annealing Range . 8 Cleaning and Gluing the Glass . 8 Load Glass Into the Kiln . 8 At www.paragonweb.com you will find online Firing the Glass . 8 videos for many of the procedures shown in this manual. Annealing Flame-Worked Glass Beads As you read each section, you can go online to watch an (in the Caldera with Bead Collar) . 9 actual demonstration on your computer. Check the videos before performing kiln maintenance procedures. Enameling in the Caldera . 10 How to Load the Caldera . 10 Preparation of the Copper. 10 When you receive your kiln, check the carton Decorating the Copper . 10 for damage. Check the kiln for both interior and exterior damage. Firing Enamel . 11 If the kiln is damaged, you can refuse the shipment and have it re- turned, or accept the shipment after having the driver note the Ceramics . 11 damage on the Bill of Lading. Then call Paragon at 800-876-4328 Pyrometric Cones . 11 Viewing the Cones During Firing . 11 or 972-288-7557 (open Monday to Thursday, 7 a.m. to 5:30 p.m. Firing Overglaze . 12 Central). If there were no signs of visible kiln damage and you dis- Firing Low Fire Greenware . 12 cover it after the driver has left, notify the shipper immediately. Firing Low Fire Glaze. 13 Firing Porcelain Greenware. 13 Firing Porcelain Glaze . 13 Save the packing materials. Use them to pack the kiln when you Firing Stoneware Greenware or Glaze . 13 take it with you to seminars or on vacation. Glaze Testing. 13 Tremendous stresses are generated within Silver & Gold Clay . 14 the kiln. The insulating firebricks actually expand and contract Drying Time . 14 Loading the Kiln. 14 with each firing. Do not be concerned if small cracks appear in the Venting the Kiln . 14 bricks. This is normal. These are surface cracks that close tightly Rate, Temperature and Hold. 14 when the heated brick expands. Cooling Time . 15 Combining Silver Clay with Other Materials . 15 During firing, you will hear an intermittent, distinct clicking. In a digital kiln, this is the sound of the relay sending power to the heat- Firing Mistakes . 15 Silver Clay . 15 ing elements. In a manual kiln, it is the infinite control switch cy- Glass . 15 cling on and off. Do not be concerned with this sound. Ceramics . 16 Im- Kiln Maintenance . 16 portant information about your Trouble-Shooter. 16 kiln is recorded on its electrical Replacing the Thermocouple . 17 Replacing a Relay or Transformer. 17 data plate. Please include this in- Replacing a Switch or Caldera-S Pyrometer. 18 formation when ordering parts or Replacing the Temperature Controller . 18 calling your dealer or the factory Reseating a Bulging Element . 18 Replacing an Element . 19 about your kiln. 2/ Monitor the kiln during operation. © 2013, by Paragon Industries, L.P. IM-211/8-13 Important Safety Rules An electric kiln is extremely safe to operate provided you Safety follow these basic safety rules: Overfiring G Unplug kiln when not in use. The warranty on your Paragon kiln does not G cover damage from overfiring, regardless of Do not touch hot sides. the circumstances. It is the operator’s G Keep unsupervised children away. responsibility to make sure the kiln turns off G at the proper time. Place the Caldera kiln, with its separate steel stand, or the FireFly on a non-combustible sur- Read the Manual! face. In the photo below, the kiln has been Read each page of this manual in detail placed on a large kiln shelf. (The FireFly stand before operating your kiln. Warranty does is built into the kiln.) not cover damage caused by failure to follow instructions. Food or Drink Surfaces Some decorative materials may be unsafe and toxic when used for surfaces that will be in contact with food or drink. When you make food or drink containers, select a glaze or glass that has been formulated, tested and labeled as approved for surfaces that will be in contact with food or drink. Follow the glaze or glass manufacturer’s instructions exactly, without any variations. Mastering Cone 6 Glazes, by John Hesselberth and Ron Roy, covers food safe stoneware glazes in great detail. We recommend this book to every potter. G Do not install closer than 12” (304 mm) from any wall or combustible surface. The Optional G The Caldera kiln top and bottom must be in place before firing the kiln. (The top and bot- Glass Window tom are attached to the FireFly.) The glass window on the kiln top is rated to 2300°F / G 1260°C, so it can easily withstand glass fusing temperatures. Fire only in a well ventilated, covered and pro- Please note, however, that the window reduces the kiln’s tected area. maximum temperature to approximately 2100°F / 1148°C G Keep cordset away from hot sides of kiln. and is meant for glass fusing. G DANGEROUS VOLTAGE: Do not touch heat- You can still fire porcelain and stoneware even with the ing elements with anything. window, but you will need G to plug the window with Disconnect kiln before servicing. ceramic fiber. The ce- G Do not leave kiln unattended while firing. ramic fiber should fill the G Wear safety glasses when cutting glass. entire window cavity in the G firebrick top. Insert the fi- Wear green #3 firing safety glasses when look- ber plug so that it fits se- ing into a hot kiln. curely against the view G Keep food away from your work area. port. Friction will hold the G fiber plug in place. Never fire tempered glass inside a kiln. It could explode. You can also temporarily plug the glass view port to re- G duce heat loss when firing silver clay and other materials that Avoid firing toxic materials inside the kiln, such do not need visual inspection. If you ever need to order a re- as styrofoam (used as a core for silver clay hol- placement fiber plug, please specify view port size (2” x 2” or low beads). 50mm x 50mm). Note: Always wear green #3 firing safety glasses when looking through the view port into the hot fir- ing chamber. To find the glasses, enter firing safety glasses in the search line at www.paragonweb.com. Fire in a well ventilated area. /3 groove, you needn’t be concerned as long as the element fits all the Setting Up the Kiln way back into each corner and doesn’t bulge outside the groove. Electrical Installation Before the kiln is fired there is You must plug your kiln into a cir- minimal danger of breaking the cuit that no other appliance uses elements. After firing, however, while the kiln is firing. Turn off the the elements must be reseated if circuit breaker or unscrew the fuse they bulge out of the groove. See for the circuit that your kiln will be “Reseating a Bulging Element,” page 18. plugged into. Check to see if other appliances shut off too. If that circuit powers appliances that must remain Where to Locate the Kiln on while the kiln is firing, plug your Place your kiln in a well ventilated, covered and pro- kiln into a different circuit. tected area such as the garage, basement, utility or hobby room. Some people keep their kiln outside on Note: 120 volt kilns: avoid extension cords if possi- a covered patio. This is okay as long as the kiln is not ble. If you must use one, never use one smaller than subjected to excessive humidity or rain. 12 gauge and longer than 20 feet (6.09 m). Never plug it into a ceiling outlet! Remove gasoline, paint, and other flammable materials from the kiln room. Voltage fluctuation can vary firing time from as little as half to more than twice the average time. If the voltage is too Never allow the room temperature of your firing low, the kiln may never reach full temperature. room to exceed 100 - 110° F / 37 - 43° C. Measure the The receptacle must have a separate safety grounding temperature about 3 feet (91 cm) from the kiln. If wire. This protects you from serious electrical shock.