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How Safety Limit Controllers Help with Kiln Safety

Safety limit controllers enhance kiln safety by automatically shutting off your kiln if it exceeds a certain temperature.

Kilns get hot! When it comes to kiln safety, using a safety limit controller helps ensure that a kiln automatically shuts off if it exceeds a pre-defined temperature.

Safety Limit Controllers and Safety Redundancy

While advanced process controllers like TAP and TAP II have max temperature safety shutoff, you’re still entrusting the safety of yourself, your household, and your property to a single layer of safety measures.

With proper maintenance, high quality programmable kiln controllers, kiln relays, and thermocouples are extremely reliable. However, they do fail from time to time.

Watch SDS Industries’ President Scott Shannon explain the pros and cons of different types of relays.

Adding a safety limit controller (like TAP Monitor) to your kiln or oven build, adds a layer of safety redundancy. Wiring a safety limit controller to a redundant safety relay ensures that your kiln safely shuts off even if your primary controller or relay fails.

Benefits of Remote Temperature Monitoring

In addition to acting as a safety limit controller, TAP Monitor is also a pyrometric device that adds precise remote temperature monitoring to your kiln or oven build – even if you’re using a manual kiln or an automatic controller from a less advanced temperature controller manufacturer.

With the TAP Kiln Control Mobile App, you can monitor kiln temperature, receive push notifications alerts and alarms, and view real-time firing graphs – even if you have to step away from your project.

This is not only extremely convenient, but it adds an additional layer of kiln safety, keeping you immediately informed of any discrepancies in your firing schedule.

Do I Need a Safety Limit Controller?

Safety limit controllers are much more common in industrial kiln and industrial control system (ICS) applications. Most at home and studio kiln and oven builds don’t include a safety limit controller. And this is usually fine most of the time (especially if you use solid state relays and your primary kiln controller includes max temp safety shutoff).

However, like most safety devices, when you need a safety limit controller, you really need one. A small investment in a safety limit controller potentially protects your property, your health, and will save you massive amounts of money in a worst-case scenario.

If you’re still using a manual kiln or an outdated automatic kiln controller (which includes most kiln controllers currently on the market), we strongly encourage you to invest in a safety limit controller that adds max temperature safety shutoff, precise pyrometric monitoring, and remote kiln monitoring.

Adding TAP Monitor Safety Limit Controller & Pyrometer to Your Kiln or Oven Build

SDS Industries, known for creating the most advanced, easy-to-use automatic kiln controllers, is releasing a safety limit controller and digital pyrometer. TAP Monitor, which is releasing in several months, is already available for pre-order.

TAP Monitor is available as a set of DIY components that can be wired directly to a safety relay (starting at $97.50) to act as a combination safety limit controller and digital pyrometer, or as a plug-and-play standalone remote pyrometer that includes a type K thermocouple and a 2.4” capacitive touchscreen (available for $265).

TAP Monitor is an advanced digital pyrometer that brings precise temperature measuring and remote monitoring to any kiln or heat treat oven.

Both configurations improve kiln safety, but they’re also an affordable way to modernize kiln builds that don’t include precise, remote temperature monitoring. TAP Monitor provides a host of benefits (regardless of the type of kiln control method you currently use):

  • Protect yourself and your family by wiring TAP Monitor to a safety relay to provide redundant safety shutoff.
  • Have peace of mind by knowing the exact temperature of your kiln, oven, or forge every step of the way (via TAP Kiln Control Mobile).
  • Save time and effort by knowing the state of your kiln no matter where you are.
  • Ensure more consistent outcomes and enjoy added convenience by upgrading your existing automatically or manually controlled kiln to include precise, real-time digital temperature readings.


Explore Kiln Control Solutions by SDS Industries

In addition to the TAP Monitor Safety Limit Controller, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.

We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:

CTA for TAP Kiln Controller Shop Pages

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How to Use a Kiln Temperature Monitor

Using a kiln temperature monitor lets you monitor kiln firing temperatures and adds kiln safety.

A kiln temperature monitor is a device that monitors kiln firing temperatures. Typically, when people refer to a kiln temperature monitor, they’re referring to a device specifically dedicated to temperature measurement, such as a pyrometer or a limit controller.

In the next section we’ll explain the difference between limit controllers, pyrometers, and process controllers – because all three devices technically monitor kiln temperature. Then, we’ll explain the benefits and use cases of a dedicated kiln temperature monitor.

Understanding the Difference Between Pyrometers, Limit Controllers, and Process Controllers

Wait, but doesn’t my programmable digital kiln controller already monitor my kiln firing temperatures? Yes, digital kiln controllers (such as TAP Controllers!) receive temperature inputs from the thermocouples and display your kiln’s temperature on the controller interface (or your smartphone with the TAP Kiln Control Mobile App!).

However, digital kiln controllers are process controllers, meaning their primary role isn’t to monitor temperature but rather to adjust kiln firing temperatures according to the programmed firing schedule.

Pyrometers, on the other hand, are devices whose sole function is to monitor kiln temperature. And limit controllers, or high limit controllers or safety limiters, are pyrometers with additional control functions that allow users to pre-program their electric kiln to automatically shut off if the kiln exceeds a specified temperature.

What’s The Point of a Dedicated Kiln Temperature Monitor?

Okay, but if your primary process controller already lets you monitor kiln temperature, then what’s the point of a dedicated kiln temperature monitor? The answer: kiln safety.

More advanced kiln controllers, such as TAP, provide max temperature safety shutoff in case of relay failure. But even then you’re still relying on a single controller, a single relay, and a single thermocouple to ensure the safety of your kiln, yourself, and your property.

When it comes to safety, especially at high kiln firing temperatures, redundancy is key. A dedicated kiln temperature monitor adds an additional level of safety by acting as a safety redundancy device. When installed and wired to a redundant safety relay, TAP Monitor will automatically shut off your kiln if it exceeds a specified temperature – even if your primary relay fails.

TAP Monitor integrates with your kiln to provide remote kiln temperature monitoring to your smartphone.
TAP Monitor integrates with your kiln to provide remote kiln temperature monitoring to your smartphone – when installed with a redundant relay, TAP Monitor also provides additional kiln safety.

Introducing TAP Monitor Digital Pyrometer Limit Controller

While previous kiln temperature monitors only added kiln safety shutoff or a temperature readout, TAP Monitor by SDS Industries adds a whole lot more than that!

TAP Monitor is an advanced, user-friendly kiln temperature monitor that gives kiln operators the ability to precisely monitor kiln firing temperatures – remotely! – regardless of their existing kiln control method.

Available as a plug-and-play standalone pyrometer limit controller or as a set of configurable components for DIY installs and oven builds, TAP Monitor gives ceramicists, potters, glass artists, and bladesmiths the ability to:

  • Precisely monitor the temperature of their kiln, oven, or forge via the TAP Kiln Control Mobile App.
  • View digital pyrometric readouts from any manually controlled kiln, including remote readouts via TAP Kiln Control Mobile when TAP Monitor is connected to a local network.
  • Easily add precise, real-time digital temperature readings to their manual kiln or oven.
  • Pair TAP Monitor with their existing automatically controlled kiln for remote monitoring.
  • For added safety, use TAP Monitor as a standalone or safety relay controller.

Explore Kiln Control Solutions by SDS Industries

In addition to the TAP Monitor Digital Pyrometer, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns – without complicated controls or clumsy user interfaces. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven. We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:

Shop TAP Monitor Digital Pyrometer for kilns

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What Is a Pyrometer? Understanding Pyrometers for Kilns

What is a pyrometer? A pyrometer is a temperature monitoring device for high temperature applications.

What is a pyrometer? A pyrometer is a device that measures high temperatures for applications beyond the range of a mercury thermometer (673° F or 356° C). Pyrometers, also referred to as pyrometric devices, are used to monitor temperature for a wide variety of applications. From kilns, furnaces, heat treat ovens, and industrial processes, to measuring the surface temperatures of distant planets!

Contact vs Non-Contact Pyrometers

Pyrometers can be contact or non-contact. Contact pyrometers, such as pyrometers for kilns, use thermocouples that are in thermal contact with the object or atmosphere. Non-contact pyrometers, on the other hand, use optical systems to measure the radiation of a surface without the need for thermal contact.

Both types of pyrometers have their pros and cons. Contact pyrometers, also known as resistance pyrometers or thermocouple pyrometers, are subject to degradation from heat exposure and are limited by the range of the thermocouple. However, they are highly accurate and usually less expensive.

Non-contact pyrometers, also referred to as optical pyrometers, radiation pyrometers, or infrared pyrometers, have far greater range – both in terms of physical distance as well as maximum temperature. Non-contact pyrometers can measure temperatures exceeding 7232° F or 4000°C – nearly three times higher than most contact pyrometers. Non-contact pyrometers can also measure temperatures of moving objects or objects that cannot be touched. However, they are significantly more expensive and less accurate.

Pyrometers for Kilns

As you can probably imagine from the comparison above, contact pyrometers are generally more suitable for kiln temperature monitoring. Affordability and accuracy, as well as the temperature range of most kiln firing schedules, makes using a thermocouple pyrometer with your kiln a pretty obvious choice!

A Brief History of Pyrometers for Kilns

While the earliest known pyrometer dates back to the “Hindley Pyrometer” in 1732, the first pyrometer for kilns was invented by English potter Josiah Wedgwood in the 1780s. Josiah Wedgwood is an interesting figure in the history of pottery. He was a wildly successful potter, industrialist, and entrepreneur – a savvy marketeer, technological innovator, prominent abolitionist, and fashion tastemaker in 18th century England, possibly the closest thing pottery has had to a ‘rockstar.’

(An interesting aside, the fortune Wedgewood amassed selling his line of pottery to the aristocracy of England and the rest of Europe, including Queen Charlotte of England and Queen Catherine of Russia, helped fund the research of his grandson, Charles Darwin. Yes, that Charles Darwin. Wedgwood was quoted as saying, “Fashion is infinitely superior to merit,” although his pottery was widely considered to possess both due to his dedication to utilizing the latest advancements in technology).

Wedgwood’s pyrometer was an optical pyrometer that was used to visibly compare the color of the clay in the kiln to the color of clay fired at known temperatures (similar in principle to this firing chart!). Later he replaced this early pyrometric technology with using of shrinking clay rings or expanding metal bars to measure the temperature of his kilns.

In 1885, Dr. Herrmann Seger developed the pyrometric cone, another pyrometric device based around a similar principle, which remained the standard in pyrometry for at home kilns all the way up until the invention of digital kiln controllers and digital pyrometers in the 1980s. For industrial kilns and furnaces, the Siemens brothers developed a platinum thermometer that could measure temperatures up to 1832° F or 1000° C in the 1860s through the 1870s.

Alternatively, for higher temperatures, the disappearing filament pyrometer was invented by L. Holborn and F. Kurlbaum in 1901. This was another optical pyrometric device that worked by adjusting current through a filament until it matched the color (and thus temperature) of an incandescent object. Evolutions in disappearing filament and brightness pyrometers continued throughout the 20th century.

Modern Digital Pyrometers for Kilns

In the 1980s, the world became digital, and the modern thermocouple pyrometer was born. Digital pyrometers for kilns use thermocouples that attach to a temperature sensor to precisely monitor kiln temperature.

While digital kiln controllers can be used to monitor kiln temperature, a dedicated digital pyrometer adds additional capabilities. For instance, you can use a digital pyrometer to add digital temperature monitoring to a manual kiln or use it in addition to a programmable digital kiln controller to act as a safety redundancy device to provide automatic safety shutoff in case of relay failure.

TAP Monitor is an advanced digital pyrometer that brings precise temperature measuring and remote monitoring to any kiln or heat treat oven.
TAP Monitor is an advanced digital pyrometer that brings precise temperature measuring, remote monitoring, and safety redundancy to any manual or automatic kiln or heat treat oven.

The TAP Monitor Digital Pyrometer Limit Controller

The latest evolution in digital pyrometers for kilns is the TAP Monitor, which is now available for preorder! The TAP Monitor is an advanced, user-friendly limit controller and digital pyrometer that gives kiln operators the ability to precisely monitor kiln temperature – remotely! – regardless of their existing kiln control method.

Available as a plug-and-play standalone pyrometer limit controller or as a set of configurable components for DIY installs and oven builds, TAP Monitor gives ceramicists, potters, glass artists, and bladesmiths the ability to:

  • Precisely monitor the temperature of their kiln, oven, or forge via the TAP Kiln Control Mobile App.
  • View digital pyrometric readouts from any manually controlled kiln, including remote readouts via TAP Kiln Control Mobile when TAP Monitor is connected to a local network with internet access.
  • Easily add precise, real-time digital temperature readings to their manual kiln or oven.
  • Pair TAP Monitor with their existing automatically controlled kiln for remote monitoring.
  • For added safety, use TAP Monitor as a standalone and safety relay controller. 

Explore Kiln Control Solutions by SDS Industries

In addition to the TAP Monitor Digital Pyrometer, the TAP Ecosystem includes a variety of programmable kiln controllers that give artists complete control of their kilns – without complicated controls or clumsy user interfaces. The TAP and TAP II Controllers by SDS Industries provide users the most advanced, precise, and easy-to-use programmable digital kiln controllers on the market today. With responsive touchscreen controls, an intuitive graphical UI, and integration with the TAP Kiln Control Mobile App, TAP Kiln Controllers can pair with any relay-controlled kiln or oven.

We invite you to explore our selection of programmable kiln controllers, pyrometers, standalones, and conversion kits on our online store. You can also purchase TAP Digital Controllers or TAP Controlled Kilns and Heat Treat Ovens through one of the following distributors:

Shop TAP Monitor Digital Pyrometer for kilns