Whip Mix P.D.Q. User manual

115 and 230-volt Models
P. D . Q .
Automatic Burnout Furnaces
OPERATOR’S MANUAL

2
Introduction ............................................................3
Warranty ..............................................................3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications ...........................................................4
Key Parts Identification & Explanation ..........................................5
Installation .............................................................8
Operation..............................................................9
Program and Operate .......................................................9
Review a Program ........................................................... 9
Edit While a Program is Running.................................................9
Sample Programs ..........................................................10
Error Codes ...........................................................11
Service ...............................................................12
Field Service ...........................................................14
Replacement of Heating Plates .................................................14
Replacement of Main PC Board ................................................16
Replacement of Thermocouple Assembly ..........................................18
Replacement of the Relay .....................................................19
Spare Parts List .........................................................21
TABLE OF CONTENTS

Thank you for purchasing an PDQ-D Burnout Furnace.
We have designed and manufactured this furnace using the latest in microcomputer technology to give you many
years of dependable service. The controls on your new PDQ-D are different from those you may be used to on an
ordinary burnout furnace. To ensure that your PDQ-D Burnout Furnace gives you the highest level of service,
review and follow the guidelines outlined in this Operator’s Manual.
INTRODUCTION
3
Do Not Attempt Internal Service
The interior of the Main Assembly is only accessible by removing hardware with tools and should only be opened
and serviced by qualified technicians. Since the interior of the unit may contain high voltage and dangerous
components, failure to heed this warning may result in equipment damage, personal injury and/or death.
Please call Whip Mix between 8:00 a.m. and 5:00 p.m. (EST) for service information toll free 800-626-5651.
Use of the PDQ furnace not in conformance with the instructions specified in this manual may result
in premature failure of the unit.
WARNING: To prevent fire or electrical shock, do not expose this appliance to rain or moisture.
ATTENTION USERS:
SAFETY INSTRUCTIONS
This Whip Mix equipment is warranted to be free from defects in material and workmanship from the date
of installation for a period of 24 months.
Any item returned to Whip Mix will be repaired or replaced at our option at no charge provided that our
inspection shall indicate it to have been defective. Dealer charges are not covered by this warranty.
This warranty does not apply to damage due to shipping, misuse, careless handling or repairs by other
than authorized service personnel. Whip Mix is not liable for indirect or consequential damage or loss
of any nature in connection with this equipment.
This warranty is in lieu of all other warranties expressed or implied. No representative or person is authorized
to assume for us any liability in connection with the sale of our equipment.
WARRANTY
This symbol alerts the user that important
Operating and Maintenance instructions
have been included with the unit. Read
carefully to avoid any problems.
This symbol warns the user to use
caution surface is hot.

SPECIFICATIONS
HEAT RATE*a) 1 –30°F/min. (1 –17°C/min.)
b) “FULL” Stage heats at the maximum rate attainable.
TEMPERATURE 150°F – 2012°F (66°C –1100°C)
HOLD TIME 0–4 hours
*Programmable heat rates. Actual heat rate at high temperatures may be lower depending upon
furnace load and electrical voltage.
4
ENVIRONMENTAL CONDITIONS
• Indoor use
• Altitude up to 2000 m
• Temperature 5°C to 40°C
• Maximum relative humidity 80% for temperatures up to 31°C decreasing linearly
to 50% relative humidity at 40°C
• Mains supply voltage fluctuations not to exceed +/– 10% of the nominal voltage
• Pollution Degree 2, Installation Category II
• Protection Degree IP20 – protected against objects greater than 12.5mm, no liquid protection
PDQ-D Medium PDQ-D Large
Electrical 115V 50/60Hz 1075W
230V 50/60Hz 1280W
115V 50/60Hz 1392W
230V 50/60Hz 1890W
Capacity 8–1 3/4” rings or 2–3” rings 15–1 3/4” rings or
5–1 3/4” rings and 3–3” rings
Overall
Dimensions
10.7”W x 10.6”D x 15.0”H
(27.2cm x 26.9cm x 38.1cm)
14.4”W x 11.0”D x 15.0”H
(36.6cm x 28.0cm x 38.1cm)
Heating
Chamber
Dimensions
5-1/2”W x 5-1/4”D x 5-1/8”H
(14.0cm x 13.3cm x 13.0cm)
9-1/8”W x 5-1/4”D x 5-1/8”H
(23.2cm x 13.3cm x 13.0cm)

DISPLAY DESCRIPTION
1. START / STOP Press to start or stop a program.
2. Press to increase a number. The longer the button is pressed,
the faster the numbers change.
3. Press to decrease a number. The longer the button is pressed,
the faster the numbers change.
4. ENTER / REVIEW When programming or reviewing a program in process,
press to advance to the next parameter.
5. °F and °C Identifies the temperature scale.
6. °/ MIN Identifies the heat rate.
7. HH : MM Indicates time. When flashing it indicates that a power failure
has occurred.
8. Main Display A. The 4 digit display indicates the chamber temperature.
B. When programming or reviewing, indicates (time to completion),
HEAT RATE, TEMP and HOLD TIME.
C. Displays special words and error codes.
9. Program Status Graph Indicates status of the burnout process.
10. Door Interlock Shuts off electrical power from the heating plates
Safety Switch when the furnace door is opened.
FRONT PANEL (Figure 1)
5
KEY PARTS IDENTIFICATION AND EXPLANATION
á
á

POWER
TEMPHEAT RATE HOLD TIME READY
ENTER
REVIEW
START
STOP
°F
°C
°/MIN
HH:MM
PDQ DIGITAL
6
Figure 1
PDQ DIGITAL IDENTIFICATION
10
7
86
5
9
2
4
1
Front
Panel
Heating
Chamber
Vent
Tube
KEY PARTS IDENTIFICATION AND EXPLANATION
3
Keep clear 6” zone
around Vent Tube

KEY PARTS IDENTIFICATION AND EXPLANATION
LOWER BACK PANEL (Figure 2)
DISPLAY DESCRIPTION
1. Power Cord AC power cords are provided to correspond to receptacles that are available
in a specific country.
2. Circuit Breaker Protects circuitry from electrical overload.
• Black button will “pop out” if overload is present.
• To reset, wait one minute and push black button into body of circuit breaker.
Figure 2
PDQ-D LOWER BACK PANEL (MEDIUM)
7
PDQ-D LOWER BACK PANEL (LARGE)
2
2
IEC RECEPTACLE
IEC RECEPTACLE

1. Unpack the contents of the box. Remove the following materials:
A. Vent Tube – Remove from bubble wrap and insert in hole on top of furnace.
B. Calibration Table Kit – Remove plastic bag containing two tablets and save for future use.
C. Burnout Tray – Remove tray(s) from bubble wrap and install on the floor of the chamber.
2. Place the furnace in position allowing a minimum of 10 inches (25.4 cm) of air space on all sides.
Do not place the unit so as to block access to the power outlet.
3. Plug the power cord into a grounded AC electrical outlet. First connect the power cord located
in the rear of the furnace. A dedicated circuit is required.
4. The furnace is now ready for operation.
CAUTIONS:
DO NOT BLOCK VENT HOLE ON TOP OF THE FURNACE. Hot gases are vented through this hole.
TO SET TEMPERATURE SCALE (Figure 1)
115V furnace is pre-set in degrees Fahrenheit.
230V furnace is pre-set in degrees Celsius.
1. Turn the power switch on. (If the furnace is already on, be sure it is in the idle mode – no program
is running.) The chamber temperature appears on the Main Display and the °C or °F light goes on.
2. Press at the same time. The degree light switches to the opposite temperature scale.
UNPACK AND SET-UP
INSTALLATION
8
When a program is completed, 20 “beeps” sound every 15 minutes to remind the operator
that the material is ready to cast.
1. Be sure the PDQ-D is in the idle mode – no program is running.
2. Press and (while holding) press START / STOP to display the status of the “beep.”
“ON” indicates the beep is active. “OFF” indicates the beep is inactive.
3. Use either of the to turn the “beeps” on or off.
4. To return to the idle mode, wait 7 seconds or press START / STOP twice.
(If START / STOP is pressed once, cycle starts.)
TO TURN THE “BEEP” ON AND OFF (Figure 1)
VENTING INSTRUCTIONS
Vent fans must have a minimum capacity of 100 cubic feet per minute for each burn out furnace.
If a common hood is used for more than one burn out furnace, fan capacity must be 100 cubic feet per minute
for each square foot of hood opening.
All hoods, vent pipe and ducting components must be constructed of non-combustible materials
and be installed in accordance with local building codes.
Maximum expected exhaust temperature is 1800°F (980°C).
Maximum expected exhaust waste heat is 5,100 BTU’S / Hour or 1,500 Watts.

1. Turn the power switch on.
2. Press ENTER / REVIEW. HEAT RATE light turns on. Enter to select the heat rate required from
1°F – 30°F / min (1°C – 17°C / min) or “FULL” for the maximum heat rate.
3. Press ENTER / REVIEW. STAGE 1 light remains on, HEAT RATE light turns off and TEMP light turns on.
Enter to select the temperature required up to the maximum of 2012°F (1100°C).
4. Press ENTER / REVIEW. TEMP light turns off and HOLD TIME light turns on.
Enter to program the time needed to hold at above temperature. (0 – 4hrs).
5. All necessary information for this program is now entered.
6. To run the program immediately, press START / STOP.
PROGRAM AND OPERATE (Figure 1)
OPERATION
1. Turn the power switch on.
2. Press ENTER / REVIEW. HEAT RATE light turns on. If 7 seconds has elapsed and the furnace temperature
appears on the Main Display, press ENTER / REVIEW. When the HEAT RATE light is on, the programmed
heat rate appears on the Main Display.
3. Press ENTER / REVIEW and the TEMP light turns on.
4. Press ENTER / REVIEW and the HOLD TIME light turns on. The programmed HOLD TIME
appears on the Main Display in HH : MM.
REVIEW A PROGRAM (Figure 1)
1. Any individual parameter can be increased or decreased during the actual running of the program.
2. To change a parameter while a program is running, press ENTER / REVIEW to advance to the desired
parameter (i.e. TEMP or HOLD TIME). Initially, Heat Rate will appear. Any parameter can be increased
or decreased by pressing or .
3. Any program can be stopped or started by pressing the START / STOP button.
EDIT WHILE A PROGRAM IS RUNNING (Figure 1)
9

10
OPERATION
SAMPLE PROGRAM
HEAT RATE TEMP HOLD TIME
10°F (6°C) 1600°F (871°C) 1:00
To start immediately, press START / STOP.

SHORTED
THERMOCOUPLE
OR DEFECTIVE
HEATER PLATES
11
ERROR CODES
NOTE: “Beeps” occur when the Error Code appears on the Main Display
ERROR
CODE DESCRIPTION PROBABLE CAUSE
Occurs when the temperature on the display is outside the allowable range
at the time the user pressed the ENTER / REVIEW keys simultaneously to set
the PDQ calibration temperature to 1500°F. If this occurs and is not an
operator error, it indicates that there is a problem with the thermocouple or
the PC board. Press ENTER / REVIEW to turn off the error indication and
continue with the program. Press START / STOP to end the program.
TABLET
TEMPERATURE
CALIBRATION
ERROR
Er 2
ELECTRONICS
MALFUNCTION
Er 3 Occurs when PC board hardware malfunctions.
OPEN
THERMOCOUPLE
Occurs if the thermocouple is open or the connecting wire(s) are broken
or disconnected from the terminal board.
Er-1
REVERSED
THERMOCOUPLE
OR
NO HEAT
Occurs if the thermocouple extension wires have been connected backwards
to the terminals on the printed circuit board. The error will be detected 5
minutes after heating program started. This error will also occur if the
program is started and the chamber door is kept open for 5 minutes or the
relay is defective, the heater plates are defective or there is a problem with
the main PC board.
Er 5
Occurs if the thermocouple wires are shorted or the heater plates are
defective causing Infinity to achieve a HEAT RATE of less than 6% of the
maximum attainable HEAT RATE with full power applied to the heater
plates for 5 minutes. This error will also occur if a program is running
and the door is kept open for more than 5 minutes or the relay or the
Main PC board developed a problem during a burnout process.
Er 6

12
CAUTION: The PDQ-D should be serviced only by qualified service technicians. Be sure
to unplug the power cord and wait for the furnace to cool before performing any service
operation. For help with operating or servicing your Jelrus equipment, please call
Whip Mix any time between 8:00am and 5:00pm Eastern time.
Toll Free: 1–800–626–5651
1–502–637–1451
FAX [phone]
TEMPERATURE CALIBRATION
PDQ-D Burnout Furnaces come complete with temperature Calibration Tablets (2) which accurately melt at 1500°F
(816°C). (Re-Order Calibration Tablet Kit –PN 15291).
Your PDQ-D is factory calibrated. It is not necessary to re-calibrate on installation. If it becomes necessary
to re-calibrate in the future, use the following calibration procedure.
Temperature Calibration with Calibration Tablets (Figure 3)
1. Place a short metal casting ring towards the front center of the chamber.
2. Place a ceramic tray or a small piece of casting ring lining material on top of the ring.
Place a tablet in the center of the tray.
3. Program the PDQ-D as follows:
HEAT RATE TEMP HOLD TIME
25°F (14°C) 1700°F (927°C) 0:00
4. When the furnace temperature attains 1400°F (760°C) as indicated on the Main display, open the
furnace door slightly and begin to check for the melting of the of the tablet. Continue to do this at each
25°F (14°C) interval, opening the furnace door just enough to determine at a quick glance if the
tablet has begun to liquefy at the edges.
SERVICE
CLEANING INSTRUCTIONS
Clean exterior of furnace only by wiping unit with a damp cloth coated with a mild non abrasive cleaner.

13
1. If a power failure occurs, the PDQ memorizes the conditions prior to the loss of power.
When the power returns, the PDQ returns to the proper point in the program.
2. When power is returned, the HH : MM light flashes indicating that a power failure has occurred.
It continues to flash until START / STOP is pressed.
NOTE: The HH : MM light flashes if the power switch is turned off and on while
a program is running and START / STOP was not pressed. It will not flash
if the power switch was turned off or a power failure occurred when the
PROGRAM READY light was on.
REPLACEMENT OF DOOR INSULATION AND SPRINGS
1. Open, locate and remove the two screws on the door closest to the door hinges which hold
the retainer strip in place. Remove the retainer strip.
2. Remove the one piece door insulation by sliding it toward the rear of the furnace and slightly lifting.
3. To replace the springs, remove each spring from the hook which holds it in place.
Remove both the hook and spring.
4. To reinstall the new door insulation or springs and hooks, reverse the above procedure. If installing
springs and hooks, add grease to junction of spring and hook and spring and hinge junction.
POWER FAILURE
SERVICE
5. When the tablet begins to melt or liquefy at the edges, immediately press and hold.
Then press ENTER / REVIEW. Your PDQ is now calibrated. Three “beeps” sound and
“CAL” appears on the main display.

14
Turn off the power to the oven, unplug the power cord,
remove trays from the muffle chamber and insure that
the oven is cool.
Remove the upper back cover.
On the rear of the unit remove the nuts that hold the
heater plate wires to the ceramic terminals. Remove all
hardware and wires from the terminals. Discard any
burnt hardware and replace with hardware pieces
shipped with the heater plates. Retain hardware for
later use. Straighten the wires for smoother removal
of the plates.
Straighten thermocouple at the bend and remove
bushings from heater plate wires.
Move heater wires and thermocouple out of the
upper housing to allow insulation to slide out
the back of the unit.
From the front of the muffle chamber with the door open
push the entire insulation chamber out the back of unit
and place on a table.
Remove ceramic front plates from muffle insulation
and place aside.
From here the plates can be removed by pulling them
out the front of the insulation. The Large models have
back plates and side plates, while the Medium model
has only side plates.
Place the new plates in the chamber, if back plates are
being replaced as well they must be installed first, also
insure that the wires are bent up so they will slide into
the back.
If the back plates are being replaced the filler strip
should be replaced as well. A new strip was shipped
with the plates.
Once the plates are installed place the insulation chamber
back inside the oven and wire the terminals according to
the model and voltage in the pictures on the next page:
When wiring the plates insure that between each wire
a flat washer is placed. See picture below.
Note: Place flat washer between each wire.
After the heater plates are wired, replace the upper back
cover and bottom cover. Insure that the oven heats by
running a program.
FIELD SERVICE
REPLACEMENT OF HEATING PLATES
Heater Jumper
Ceramic Fronts
Flat Washer
Flat Washer
Side Heating
Plate Assembly
(2)
Ceramic Insulating Bushings
Insulating Strip
Rear Heating
Plate Leads
Rear Heating
Plate Leads
Lock Washer
Lock Washer
Nut
Nut

15
Figure 4
PDQ-D WITH UPPER REAR PANEL REMOVED
PDQ-D Medium (all voltage models)
PDQ-D Large 115V
PDQ-D Large 230V
Figure 4
PDQ-D WITH UPPER REAR PANEL REMOVED
Rear Insulating Panel
Rear Insulating Panel
Thermocouple
Thermocouple
Ceramic Insulating
Bushing
Ceramic Insulating
Bushing
Heating Plate Wire
Heating Plate Wire
Power Terminal
Power Terminal
Heater (Power) Leads
Heater (Power) Leads
Jumper
Heating Plate Wire
Power Terminal
Heater (Power) Leads
Jumper
Ceramic Insulating
Bushing
Thermocouple
Rear Insulating Panel

16
Part numbers can be found on last page(s) of Manual.
1. Remove the bottom panel.
2. Note and record the color and location of each wire on the thermocouple
terminals located on the Main PC Board. Remove both wires.
3. Tag or label the electrical connectors on the Main PC Board before removal
so that you know where to reconnect each one. Create a sketch showing the
locations and referencing the tag or labeling. Pull straight out on the connector.
DO NOT PULL ON THE WIRES.
4. Remove the nuts and lock washers that hold the Main PC Board to the front panel and lift
straight away from the front panel to remove board.
5. Align the holes in the new board with the standoffs on the front panel, reinstall the fasteners
and screws.
6. Reconnect the electrical connectors by referring to the tags and your sketch.
7. Reconnect the two thermocouple wires to the thermocouple terminals observing the color coding
noted in Step 2. If thermocouple wires are reversed, 5 minutes after heating program is started,
"Er 5" will appear on the Main Display.
8. Replace the bottom panel.
REPLACEMENT OF THE MAIN PC BOARD
FIELD SERVICE

17
Figure 5
PDQ-D WIRING DIAGRAM

18
CAUTION!
TO PREVENT INJURY, ALWAYS TURN POWER OFF AND DISCONNECT THE OVEN’S POWER
CORD BEFORE PERFORMING SERVICE. VERIFY THAT UNIT IS COOL TO THE TOUCH.
Unplug oven, remove trays from inside, then lay oven on its side and remove screws from bottom and back covers.
Disconnect heater wires to pull thermocouple out from the muffle, then through the grommet into lower housing.
Disconnect thermocouple from the main board.
Note: Thermocouple should be wired as shown above. Heater wire must rest over ceramic
sheath not to come in contact with bare wire or fiber sleeve.
Front View Large
Rear Back View Medium
Rear View Medium
Rear Back View Large
Rear View Large
10
Screws
6 Screws Bottom Cover
Note: make sure to run thermocouple wire through loop
to hold wire stable before pulling into upper housing.
4 Screws Bottom Cover
FIELD SERVICE
For assistance call 1-800-626-5651 or write to: [email protected]
REPLACEMENT INSTRUCTIONS: 15295 JELRUS THERMOCOUPLE

FIELD SERVICE
REPLACEMENT OF THE SSR (Solid State Relay) (PN 96225)
19
1. Remove the lower bottom panel (Figure 2, Page 7).
2. Note and record the color and location of each of the four wires on the SSR terminals (Figure 5, Page 17).
Remove each of the four wires by pulling straight up on the connecter. DO NOT PULL ON THE WIRES.
3. Remove the two nuts and screws that hold SSR in place. Lift SSR off the chassis (Figure 5, Page 17).
4. Put the new SSR in place on the rear panel. Locate the SSR so that the center terminal will face downward
when the bottom panel is in place.
5. Replace the four wires on the SSR (Figure 5, Page 17).
6. Replace the lower bottom panel (Figure 2, Page 7).

20
SPARE PARTS LIST
PARTS FOR PDQ-D Medium
Description
Part No.
115V 230V
Power Cord Kit-Japan & U.S. 26202 N/A
Power Cord Kit-Europe N/A 23203
Power Cord Kit-UK N/A 23202
Power Cord Kit-Italy N/A 23205
NEW-Main PC Board 15298 15299
Heater Jumper 33130 33130
Ceramic Front Section 15292 15292
Door Assembly 15284 15284
Door Insulation 15722 15722
NEW-Heating Plate Assembly Side (Set of 2) 33915 33916
Ceramic Terminal Block w/Terminals 33935 33935
Door Handle Kit 15279 15279
NEW-Thermocouple Assembly Kit 15295 15295
NEW-Solid State Relay (SSR) 25 amp 96225 96225
Tray for Heating Chamber 33256 33256
Power Switch 15684 15684
Calibration Table Kit 1500°F (816°C) 15291 15291
NEW-Door Switch Kit 15294 15294
Vent Tube 15729 15729
Ceramic Insulating Bushings (Pkg. of 4) 33958 33958
NEW-Rubber Feet (Set of 4) 96011 96011
Door Spring Hook Assembly Kit 33997 33997
Door Hinges (Set of 2) 33998 33998
Circuit Breaker 117046 117047
Heater wire assembly 15312 15312