Whip Mix ProCal-Pro 100 Plus User manual

ProCal-Pro 100 Operating Instructions
6. Press SPECIAL FUNCTIONS button on Pro 100
Furnace.
7. Rotate counter clockwise to CALIBRATE OVEN.
8. Enter PASSWORD = 250, then press NEXT button.
9. Enter the same IDLE TEMPERATURE as the
TARGET QC temperature, don’t forget to press
the NEXT button on the furnace to enter your idle
temp selection.
10. Important, wait for furnace to stabilize at selected
value for 15-20 minutes before passing judgement
on furnace calibration.
IMPORTANT: THE FURNACE AND THE PROCAL KIT FIRING
TRAY MUST BE HEAT SOAKED AT >=600ºC FOR AT LEAST
AN HOUR TO GET CONSISTENT, REPEATABLE RESULTS.
Section A — Routine Quality
Control Checking
1. Remove the two thumbscrews on the right side of the
furnace chassis, exposing the 25 pin connector.
2. Turn off the AC Line power to the furnace before
inserting the 25 pin adaptor then plug the 9 pin
ProCal cable into the adaptor. After the connector is
seated, turn the AC Line power back on the furnace.
3. The table will drop automatically after the Power On
Self Test has completed. Place firing tray on table
after using centering pin to locate its position.
4. Raise table to close muffle. Allow the white cable to
exit out the front of the muffle.
5. Connect instrument box to the green thermocouple
connector, noting it will only plug in one way.
Detailed Directions for Use with the Pro 100 Series Furnaces
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ProCal-Pro 100 Operating Instructions
11. After the stabilization time record the “actual temp”
on the furnace display and the temperature on the
ProCal display on a piece of paper.
*** The ProCal is more stable than virtually any
furnace it is present in. All furnaces turn the
heater on until the target temperature is reached
then switches it off and coasts downward until
the thermocouple senses the temperature is
just below the target, then repeats the cycle.
This means there will be a slight oscillation of
temperature a degree or two above the target and
a degree or two below the target;
12. If the ProCal display value is higher than the furnace
display the furnace is overfiring.
EXAMPLE: Idle temp 850°C
Furnace actual temp=850°C
ProCal display remp=855°C
The furnace is overfiring by 5°C at this temperature.
13. Repeat above procedure at 1000°C idle and again at
1150°C idle setting.
Example of results:
Furnace ProCal
850°C 850°C 855°C
1000°C 1000°C 1003°C
1150°C 1150°C 1152°C
14. Since all 3 QC checks show readings higher on the
ProCal than on the furnace the furnace is overfiring.
Use the ‘high fusing’ adjust feature to dial in
compensation.
Since the high fusing adjust affects all programs over
800°C equally you may want to use a high fusing
Adjustment valve of 3 degrees. (See section B to find
procedure on entering high fusing adjustments.)
Important Note
The Fusing Adjustment function will render correction in
the normal User Program firing mode ONLY. If you’ve
got active Fusing Adjustments from previous QC Checks
they will not correct the Special Functions \ Calibrate
Oven \ Password = 250 \ Idle temperatures. You ALWAYS
get the temperature based on the most recent factory
calibration in the Password = 250 mode.
OK, what does that mean?
Here is an example:
You noted a 2 degree Overfire on a previous QC check
and entered a 2 degree Overfire into the High Fusing
Adjustment and all has been well for the last few months.
Today you ran your next QC Check and this time you note
a 3 degree Overfire situation in the Password = 250 mode.
[Remember, the Password = 250 mode always references
back to the factory calibration] You go to the Calibration–
High Fusing adjustment, answer YES for overfire, but
do you enter 2 degrees from the first correction plus
3degrees from today’s QC check?
THE ANSWER IS DEFINITELY NO! If the needed
correction in the current QC check indicates a 3 degree
Overfire, just enter the 3 degrees and press the Next
button. The corrections are not cumulative. Every time
you press the Next button the furnace first erases
all previously stored correction values, it effectively
restores the factory calibration for that temperature.
In other words it always wipes the slate clean, so any
correction value you determine is needed during QC
Checks in the Password = 250 mode is exactly the value
you should enter in the Calibration - High Fusing mode.
Interpretation of Results
Consistency is more important than absolute accuracy
for pure porcelain work. Notable exceptions to this are
the CapTek process which depends on absolute accuracy
for optimum infiltration. Once you have a furnace setup
and programmed to your liking, this is the BEST TIME
torun a QC check as described in Section A to serve as
a benchmark reference in case something goes astray
in the future.
The primary advantage of the ProCal is the ability to
register temperature calibration data AFTER a problem
has crept into the overall build-up and firing process,
and immediately tell you whether the problem is with the
porcelain mixture itself, the furnace, or a combination
of both. You can only have confidence in the data
obtained from the ProCal if you routinely and regularly
get consistent indications to base that confidence on.
Another way the ProCal can benefit you is by providing
comparison data on all your Pro Series furnaces to ensure
that every Pro Series furnace matches the results from all
others with matched program parameters.
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ProCal-Pro 100 Operating Instructions
Section B — High Fusing Adjustments
Calibration – High Fusing Adjustment
Both the Password = 250 Idle temperature AND the High
and Low Fusing Adjustments always reference back to the
stored Factory Calibration point, not the previously stored
adjustment.
What this means is that when you set the Idle Temperature
in the Password = 250 mode to an Idle temperature of
850ºC the furnace takes the muffle to the temperature
corresponding to the value it saw when it was calibrated
at 850ºC at the factory.
Lets say that the ProCal reads 855ºC when furnace
reads 850, a 5 degree overfire (relative to the last factory
calibration point).
You need to go into the Special Functions \ Calibration-
High Fusing Temperature Fusing adjustment and dial
in anoffset which will result in User Programs firing
5degrees lower at 850ºC.
1. You would press Special Functions, rotate the knob
to Calibration–High Fusing, and press the Next
button.
Press Special Functions Button
Rotate Knob to “Cal – High Fusing”, Press Next The
furnace would display “High Fusing – Overfires?” on
the top line and Yes or No on the second line.
If we answer yes, we can input an Overfire value, if we
answer No, we're actually saying that the furnace was
Underfiring, not Overfiring.
2. In this example we were Overfiring by 5 degrees, so
we answer Yes and press Next button.
3. The furnace will now display the last known Overfiring
fusing adjust entry value; it might be 0, it might be 50,
IT DOES NOT MATTER WHAT IT SAYS. THE ONLY
THING THAT IS IMPORTANT IS THE AMOUNT OF
OVERFIRING YOU HAVE RIGHT NOW.
Spin the dial to the desired value of 5 degrees of
Overfire adjustment and press Next button. As
soon as you press the Next button the CURRENT
fusing offset value is stored to non-volatile memory
(after erasing all previous values, either Overfire or
Underfire).
If you are curious about what was previously stored
you can go into the Fusing Adjust mode, inspect the
stored value and back out without altering the value
by pressing the Special Functions button [not the
Next button].
4. The next time you run a normal firing program with
a hold temperature above 800ºC the furnace will
automatically deduct 5 degrees from the programmed
hold temperature and the actual temperature will be
accurate.
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ProCal-Pro 100 Operating Instructions
Appendix – Special Functions Mode Menu Selections
(Pro 100 only)
When you press the Special Functions button the first
menu selections appear at the top below. As you rotate
theknob Clockwise, the sequence of selections is shown
below, from top to bottom:
Special Functions Menu
1. Night Mode
2. Change Idle Temp
3. Set Vacuum Level
4. Temp in C or F?
5. Prog Start Delay
6. Night Mode Temperature
7. Constant vc Pump
8. Sp Cool Position
9. Capital Letters?
10. Porcelain Names:
11. Cal Low Fusing
12. Cal High Fusing
High Overfires (Yes/No)?
Overfires – confirm Yes with Next button, enter
amount, press Next button.
Underfires – rotate knob to No, confirm with
Next button, enter amount, press Next button.
13. Print Form
14. Set Time & Date
15. Programs > Box
16. Programs > Box
17. Test Furnace
18. Calibrate Oven
Password – [rotate knob to 250], press Next button
Change Idle Temp
New Idle - xxx [enter temperature, press Next
button]
Last button gives chance to change temperature
again, press Next after.
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