KISS (Kiln Interface Software System) is a computer program designed to allow users of ceramic kilns to access their ***Bartlett Instrument*** kiln controller through use of a personal computer. In addition to the ability to remotely access the existing functions of the controller, KISS also includes the capability to collect and store data from the firing process, which will allow for detailed evaluation of the kiln's actual temperatures during a firing. KISS will also allow the user to monitor, at a glance, a maximum of ten kilns simultaneously, by providing a display of all ten kilns' current status and current temperature.

     In order to take advantage of the Kiln Interface Software System, there is certain equipment that you must have. The following link will give you a detailed description of what is required to get you up and running.

Software

Installation

The first steps in getting a KISS network setup are installing the software on your computer and checking the COM port settings.

Running Setup

1. Close all other programs. If using 3.5" disks, place disc 1 in drive "A". If using a CD, place in CD drive.

   Using your mouse -

2. Click on the "Windows" Start button.
3. Click on "RUN"
4. If using 3.5" disks, type "A:\SETUP". If using CD, type "D:\SETUP" (If your CD drive has a different drive designation use it instead of "D".
5. Click "OK"
6. Follow the on-screen instructions
7. After installation is complete, click "START", "PROGRAMS", "KILNKISS" to start the program.

User Manual

Contents

• Main Display

• Status

• Installation

• Programming

  • Cone Fire

  • Ramp/Hold

• Data Collection
• Error Messages

Main Display

     When KISS is first started, the user will see the main display, as shown in Diagram 1. This contains ten boxes, one for each kiln which can be connected into the system, as well as the menu bar across the top of the screen. The menu bar allows the user to access all the functions for the selected kiln. Each menu bar item indicates a set of kiln functions which have been grouped together on another display screen. For example, all options for storing and collecting data during a firing process are shown on the screen for the "Collect Data" menu bar item.

     Each kiln's box on the main screen contains a name for the kiln, initially set to be "Kiln 1", "Kiln 2", etc. This can be changed to a more descriptive name for each kiln, as desired by the user, in the installation screen. Along with the name of the kiln, each kiln's box will contain the current status, such as "Not Connected", "On", "Off", "Idle" or the current temperature in the middle zone of that kiln, if the kiln is connected. When the program first begins, "Kiln 1" is always the currently selected kiln. The term "currently selected kiln" means that when the user clicks on any of the items in the menu bar, the operations performed will be applied to that kiln which is the currently selected kiln. The user can change which kiln is selected by positioning the cursor anywhere in the box for that kiln and clicking there. That kiln's box will then change colors, from gray to blue, indicating it is the currently selected kiln. And, when the user clicks on the menu bar, the other screens will display the kiln name of the currently selected kiln in the status bar at the top of the screen. Notice in Diagram 1 that the box for kiln 7 is blue, indicating it is the currently selected kiln.

     The user can access any of the functions for the controller by selecting other display screens using the menu bar of the main display. Once the correct kiln has been selected, the user uses the mouse to click on the appropriate item on the menu bar. Then, the menu bar item's screen will be displayed with the information for that category of functions. Following is a list of the functions and information included under each of those menu items:

STATUS

• start and stop a firing
• access more detailed information:
  • current program parameters: rates, temperatures and hold times
  • current segment and set point
  • current temperatures in all three zones
  • information indicating whether the kiln was programmed as a ramp/hold program or as a cone fire program
  • for cone fire programs, which cone number and speed were used
  • for cone fire programs, preheat time and hold time
  • firing time and remaining time
  • temperature scale (OF or OC)
  • information indicating if a data collection is in progress
  • errors on or off indicator
  • lag temperature
  • cone offset temperature

INSTALL

• assign a descriptive name for the kiln
• set up the correct communications port for the hardware going to the kilns
• select temperature scale (OF or OC)
• set the errors function to be on or off
• assign cone offset temperatures for each valid cone number
• Echo Test

PROGRAM

• define up to six user programs for ramp/hold firings
• select cone number and speed for a cone firing
• set preheat and hold times for a cone firing
• set an alarm temperature for either ramp/hold or cone firings

COLLECT DATA

• enter a filename and frequency (in minutes) for collecting firing data
• start and stop the process of collecting data

     The menu bar also uses shortcut keys for these other screens, which are indicated by the underlined letter in each menu bar item. A shortcut key will allow the user to use the combination of the <ALT> key with the appropriate shortcut key to access any of those screens, rather than using the mouse. For example, once the desired kiln has been selected, the user can hold down the <ALT> key and hit "P", to get the programming screen displayed for that kiln.

     The user can also display the "Status" screen for any kiln from this main display by simply double-clicking in the box for that kiln. This creates an easy-to-use method to get to the screen which gives more detailed information regarding the current status of any of the kilns.

Status

     Diagram 2 demonstrates an example of the status screen. The status screen is designed to give the user detailed information regarding the kiln as it is being used. This screen is also where the user will actually start and stop the firings, once a program has been selected using the programming screen. The starting and stopping of the kiln is, in fact, the only input the user is able to give at this screen, as the rest of the screen is strictly informational. The status bar will display "Kiln Status - ", then the kiln name and its current status, which is also the status given in that kiln's box on the main display screen.

     The status screen will be very important in tracking each of the users' kilns. The user can very quickly obtain information about the currently selected kiln. The information displayed on this screen is listed below:

(Please refer to Diagram 2 for the layout and location of each piece of data on the status screen)

• The current program information in the controller, including:
  • Identification of whether a cone fire or ramp/hold program was used
  • Cone number and speed (if in cone fire program)
  • Preheat and hold times (if in cone fire program)
  • Segment information for eight possible segments in the program
    • rate for each segment
    • final temperature for each segment
    • hold time
• Information regarding a firing in progress, including:
  • Name of the current segment (Ramp 1, Hold 1, etc)
  • Set point.
  • Temperatures for each zone
  • Status of the kiln (firing, In Delay, etc. or a stop sign if the kiln is not connected or firing.
  • Firing time
  • If a kiln is in a hold or delay, it shows the remaining time of each function
• Function settings:
  • Temperature scale (Fahrenheit or Celsius)
  • Status of errors (ON/OFF)
  • Lag temperature
  • Cone offset temperature
• Other information:
  • Data collection (if collecting data, the filename will be displayed)

     As mentioned previously, the only input allowed from this screen is starting and stopping a firing. To do that, the user selects the appropriate option and then clicks on the "GO" box to actually initiate the action. Note that the "Start Firing Now", "Stop Firing" and "Delay Start Firing" buttons are mutually exclusive to one another - that is, when one is clicked, the other will automatically be turned off.

Installation

    Diagram 3 shows what the installation screen looks like. The user-defined kiln name for each kiln is the first field that can be entered in this screen. This will make it easier for the user to distinguish how each kiln is interfaced with the computer program. These names will be saved for each kiln, so the user-assigned kiln names will stay a part of the program until changed by the user again. The names may not begin with a blank, but otherwise may contain any character. There is not a maximum number of characters which can be used in the kiln name, but the display of the kiln name on the main display will be truncated. However, the display on the status bar of the other screens will allow for display of more lengthy kiln names.

     The next field to be entered in this screen is where the user may select the serial port in which the hardware interfacing to the kilns has been plugged. COM1, COM2, COM3 AND COM4 are the choices available in the dropdown box.

     The user may select Fahrenheit or Celsius in the framed area for temperature scale. Similar to the "Start Firing" and "Stop Firing" buttons on the status screen, the "Fahrenheit" and "Celsius" buttons are mutually exclusive option buttons. When the "GO" box in that frame is selected, the program will check to see if the kiln is already currently using that temperature scale. If that is the case, no message will be sent. Otherwise, a message is sent and KISS verifies that the controller has changed the temperature scale. The watch icon will be removed when the message has been sent and the verification process is complete.

     The user may select whether the errors are used by the kiln with the errors on/off options box on this screen. This function, however, may not be changed during a firing. These options are, obviously, mutually exclusive, like the temperature option buttons. As with the temperature scale options, when the "GO" box in the framed area is selected, the program checks to see if the user's choice is already in effect. If so, no message is sent. Otherwise, a message is sent and KISS verifies that the errors are set appropriately. The watch icon will be removed when the message has been sent and the verification process is complete.

     The user may enter a cone offset temperature for all valid cone numbers by entering the cone number in that field or selecting one from the dropdown box selections. Once a valid cone number is in the field, the program checks the current cone offset temperature being used for that cone and displays it in the offset temperature field. Then, the user may enter a new temperature and select the "OK" box, at which time KISS will display the watch icon while it is sending the message to the kiln. If, at any time, the user decides to not change the cone offset temperature, the "CANCEL" box is available to discontinue the operation. It will not, however, cancel the operation once the "OK" box has been selected and the watch icon is displayed on the screen. Its purpose is only for when the user has called up a cone number, entered a new offset temperature and then decided to not change the offset, after all.

Programming

     An example of the programming screen is shown in Diagram 4. If the user chooses to enter or modify a ramp/hold program, there is another screen which will displayed for each program segment. This screen is shown in Diagram 5 and will be discussed later. The programming screen is divided into three sections, one for entering ramp/hold firing programs, one for entering cone firings and one for entering other information which may apply to either type of firing, such as an alarm temperature. The default section with which the user begins this screen is the same type currently programmed into the kiln. For instance, if the current program was created as a cone firing, the user will begin this screen in the cone fire section. At any time, the user is allowed to access either the ramp/hold section or the cone fire section, but not both of those. To enter information for either type of firing, the user just needs to position the cursor anywhere within that type of firings box and press the left mouse button. This enables the entry of information for that type of firing, beginning with the first box of information at the top of the box, whether it be program number for a ramp/hold firing or cone number for a cone firing.

Cone Fire

     For a cone firing, the user chooses from valid cone numbers by choosing one from the dropdown box or entering a valid cone number. The default which will appear in the box is the cone number currently programmed into the kiln.

     The next field to be entered for a cone fire program is the preheat time, in hours and minutes. This indicates how long the kiln will hold at the first segment's temperature. The two left digits in this field contain the hours portion of the preheat time and the two right digits contain the minutes portion of the preheat time. For example, a preheat time entered by the user of "0210" indicates a hold time in the first segment of two hours and ten minutes.

     The third field to be entered for a cone fire program is the desired firing speed - fast, medium or slow. Similar to the "Start Firing" and "Stop Firing" buttons on the status screen, these firing speed buttons are mutually exclusive so that only one speed can be selected at a time. When the user chooses one speed, the program automatically unselects the other two speeds.

     The last field which applies only to cone fire programs is the hold time. This indicates how long the kiln should hold at the final segment's temperature. The time entered into this field is entered identically to the time in the preheat field, where the two left digits are hours and the two right digits are minutes.

     When the user has finished entering the hold time, the cursor will automatically advance to the field for alarm temperature, giving the user the opportunity to enter a different alarm temperature or to use the <TAB> key to advance the "OK" option button. Clicking the "OK" button will actually initiate communication with the controller to send the new program, which is indicated by the display of the watch icon. When the cone fire program has been successfully transferred to the controller, the message, "Programming completed successfully.", will be displayed.

Ramp/Hold

     

For a ramp/hold program, the first field to be entered is the user program number. It must be a number from one to six. Once the user has entered a valid user program number, KISS will read that user program from the controller and display it on this screen. Only segments which contain information will be displayed. The cursor will also advance to the field for the first segment. The user cannot change the segment number, but can either hit <TAB> to indicate no changes are to be made to that segment or hit <ENTER> to bring up the segment programming screen, as shown in Diagram 5. If the user <TABS> through the segment numbers, that action is indicating each segment being tabbed through is satisfactory. However, by hitting <ENTER>, the segment programming screen is displayed for that segment and the cursor is positioned in the rate field. The user can <TAB> through each of these fields in the segment screen or enter new values for the parameters of this segment. As the cursor moves from field to field in this screen, the values will be checked for validitiy. For example, the final temperature parameter must be greater than 70OF and less than 2400OF. If any of the fields contain inappropriate values, a message will be displayed telling the correct range of values and the user will need to enter a new parameter.

     The three control buttons on the segment programming screen allow for three different actions by the user. The "Segment Complete" button will store the current values for this segment as part of the program to be sent to the controller and will also assume the user wants to enter another segment of a program. This segment programming screen will be redisplayed with the next segment of the program, as identified in the status line at the top of the screen. The "Delete Segment" button will erase this segment as part of the program to be sent to the controller and, if any information is contained in following segments, those segments will each be moved up to get rid of the empty spot created here, creating one less segment in the program overall. The "End Programming" button will not store anything for this segment as the user has entered information and will return the user to the regular programming screen.

     After all information for either type of firing has been entered, the user clicks on the "OK" box to indicate that the program has been entered correctly and should be sent to the controller. If the kiln would be running when the user tries to send a new program to the controller, this message will appear, "Programming not allowed while kiln is running. Do you want to stop <kilnname> kiln?". There are two options to choose from in response to this situation. The user can choose "Yes", which will stop the kiln and ready it for the user to enter the "OK" box again to continue programming. Or, the user can choose "No" which will allow the current program in process to continue.

     If the kiln is not running when the "OK" box is clicked, the computer will send the program to the controller. KISS will also continue to check the status of the controller and wait until it is satisfied that the program as the user entered it was received by the controller. When that has been verified, a message will be displayed to indicate that information to the user, "***".

Data Collection

      

Diagram 6 shows an example of the data collection screen.  Data collection can only be done on a kiln that is running, or KISS will ask the user if the kiln should be started.  Data collection will continue until it is MANUALLY stopped by the user. This allows for collection of data during a cooldown segment, if desired by the user.

• Starting Data Collection
  1. After selecting kiln on main display screen, click Collect Data in the main menu tool bar.
  2. Enter the filename that you want the data to be stored in. This is entered into a standard Windows file selection screen, where the user can move up or down directory levels, choose a different device available on the computer, pick a file currently on disk or enter a new filename.
  3. Enter the interval at which the data should be stored in the file, in increments of minutes.  The default is every 2 minutes, with a maximum of 30 minutes.
  4. An optional field for the data collection is the header information, where the user is free to enter any text which will be inserted into the file prior to the first record of data from this collection procedure.
  5. Click Start.
     
• Stopping Data Collection 
  1. Click Stop.

The data collection file is opened as a shared file, which allows the user to access the information in the file even before the firing is completed.  There are more details about the layout of this data collection file in the Quick Start section.

Error Messages

Enter the default COM port.
The box containing this error message should be labled "NEW Installation". This situation occurs when KISS is initially loaded on a computer and the program is trying to assign a default serial port where the kilns will be connected. This port can be reassigned, if necessary, by using the Installation menu.

Parameter file has been corrupted. A new one will be created for you.
A problem has occurred with the initialization file which contains the name of the communication port to which the kiln hardware is connected, as well as the user-defined kiln names. A new file is created, with the communication port as specified by the user after this error message. The kiln names will be returned to the initial names of "Kiln 1", "Kiln 2", etc. This file will always be created in the default directory for this application. If this error continues to occur, this file "kiss.ini" is getting deleted or modified so it is not usuable by this application.

Cannot program disconnected kiln
If the user tries to program a kiln while it is not connected, KISS will display this message instead of the programming screen. The hardware problem to the selected kiln needs correcting before programming can be done. If the hardware has been corrected and the main display is not recognizing the kiln, display the status menu of this kiln to get more detailed information.

Cannot program kiln while running
If the user tries to program a kiln while it is already firing, KISS will display this message instead of the programming screen. The user should go to the status screen and stop the current firing before trying to program the kiln.


Any error message displaying " 'some event' not successful - Please try again"
Examples: Programming not successful - Please try again
Echo test not successful - Please try again
This means that for some reason KISS and the kiln are no longer communicating. Please check your connections and try it again.

Invalid Port Number
The user entered a COM port that is either not on the computer or already in use.


File already in use for another kiln
Data collection filename given is already being used to collect data from another file.

Information Not Entered for this Segment
When user is entering information for a ramp/hold program, they have tried to save a segment without entering all of the necessary data.


buffercount < 2 or invalid string
You will get these messages for one of 2 reasons. One is that you are trying to send invalid data to the controller. An example would be trying to not properly change a cone offset value. The other reason you would get these errors is that data is being sent to the controller is getting changed due to noise on the lines. You may have to check to see if you are using shielded or unshielded wire. If you are using unshielded wire and the problem consists you might have to change to a shielded wire. Also, if the end of the wire on the very last connection is not terminated correctly using a resistor, could cause noise on the lines.

Hardware

Computer

     The first step in connecting the hardware is to insert the RS232/RS485 connector into the COM port on the computer, usually COM 1 or COM 2, whichever is not being used for other devices. Insert the end of the 25 ft. phone cord into the connector on the RS232/RS485 converter. Plug in the power supply for the converter to a standard 120 volt outlet.

     At this point you should have the software loaded on the computer and be able to open the Kiln KISS program. The PC Kiln Control window should show that all the kilns are "not connected" at this time. The power supply should be plugged into a 120 volt outlet and the RS232/RS485 converter should be attached to the COM port on the computer. The phone cord should be connected to the RS232/RS485 converter.

     This completes the computer portion of the starter kit installation and you are now ready to connect the individual kilns to the system.

Kiln

     Once the computer portion of the installation has been completed, you are ready to install the hardware on the kiln and connect each kiln to the system.

Note: You should first disconnect the electric power or unplug the kiln.

      Remove the controller by unscrewing the 4 screws at the corners of the controller. Once the screws are removed pull out the controller toward you. Install the RS485 communications chip (labeled Maxim MAX487 on the drawing) in the socket on the controller circuit board. This diagram SMT 600 CIRCUIT BOARD CONNECTION DIAGRAM shows the location and orientation of the chip. The notch in the chip should be toward the right; this is the same orientation as the chip to its right. Check to make sure that the pins and chip are fully inserted.

      Next, attach the surface mount modular jack to the kiln's control box. Drill a 3/8" hole in the side of the control box. Locate the hole so the receptacle does not interfere with other wiring and so the wires on the receptacle will reach the controller circuit board. Insert the wires through the 3/8" hole and use the foam tape to fasten the receptacle in place. Instead of using the foam tape, the two screws provided can be used as an alternative method of attaching the modular wall jack. Next, insert the red and green signal wires with the 2 pin housing onto the locking header on the controller circuit board; the locking header is located just below the RS485 chip which you inserted earlier. The red wire should connect on the left and the green wire on the right. Next, remove the wire connected to the Center Tap. This is the second quick-on connector from the bottom of the circuit board and there may be two wires connected to this connector tab. Attach the male/female quick-on connector, with the green and black wires attached, to this connector and reattach the removed wire or wires to the male connector. You should now have the original wires plus the green and black wires attached to the center tap connector on the circuit board. Connect the green wire with the U-connector to a safety ground screw on the control box. Re-install your controller to the kiln with the 4 screws.

      Restore power to the kiln.

      Connect the 25 ft. modular (phone) cable from the RS232/RS485 converter (on the computer) to the surface mount connector on the kiln.

KISS installation is now complete.

Help

Q.  How do I put in a program and start my kiln?

A.  Follow these steps.

1. Make sure the status of the kiln you want to start does not show up as "Not Connected" on the main display screen.
2. Select the kiln you want to start.
3. Click Program in the main menu tool bar.
4. Enter the appropriate information into the program menu.
5. Hit OK to load the program into the controller. Make sure you receive the message "Programming completed successfully."
6. Close the Programming screen.
7. Click Status in the main menu tool bar.
8. Click Start.

Q.  How do I see what program is loaded into the kiln controller?

A.  Click Status from the main menu tool bar.  

Q.  What information gets put in the data collection file?

A.  These fields will be stored in the data collection file, one record per frequency of collection, with the fields being delimited by commas.

• an asterisk for valid data collection records
• current system date, in MM/DD/YY format
• current system time, in HH:MM:SS AM format
• Set point temperature
• Zone 1 temperature
• Zone 2 temperature
• Zone 3 temperature
• Segment Name
• Kiln Status

Each of the temperature fields are written to the file as four-digit numbers, with leading zeroes padding on the left side of the field, if necessary.

Diagram 1

Diagram 2

Diagram 3

Diagram 4

Diagram 5

Diagram 6

Items included in KISS Starter Kit: