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Old 12-13-2011, 03:28 PM   #1
Mat
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Kiln Controller Design


Hi All,

I'm currently working on designs for an AC controller which will switch about 220-240V 35-40A on/off to control temperature in the kiln.

the high voltage part will just be the kiln power cord plugged into a socket on the controller wich will have one of the fused hot lines connect to the switching relay. the output of the 3 wires will exit the box, and return to the same type of cable for plugging into the 220-240V wall outlet (still waiting on the spec) (the controller will eseentially be a splice into the power cord of the kiln)

the relay will be controlled by a microcontroller with a thermocouple input.
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the concerns i have so far;

using appropriate AWG wire (with safety margin 125% capacity) with appropriate color coding

fusing the input before the relay

making sure the copper wire is mated to the relay terminals in a way that will not facilitate corosion

weatherproofing the containment box (might be located outside under a carport

heatsink on the relay

case will be plastic and a 12V DC wall/wart will power the microcontroller plugged into a standard 110 wall outlet. the DC voltage will control the relay which is optoisolated within the relay from the AC power.

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Is there anything i might be overlooking from a safety standpoint? anything that i might be concerned about for being compliant with the NEC?


Last edited by Mat; 12-13-2011 at 03:42 PM.
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