ProCal ™ User Manual Whip Mix Corporation • 361 Farmington Ave. • P.O. Box 17183 • Louisville, KY 40217-0183 USA 502-637-1451 • 800-626-5651 • Fax 502-634-4512 • www.whipmix.com 16911_ProCal_Manual.
ProCal Operating Instructions Product Overview in some cases, chemically react with the noble metals, thereby affecting the temperature sensed. The Pro Cal Calibration Kit is a professional grade instrumentation system designed to rapidly monitor the calibration status of your furnace, and automatically recalibrate the furnace to factory specifications.
ProCal Operating Instructions Kit Contents • Instrument Case • Special Firing Tray • Data Cable • Operator Manual Important Notes / Reminders The Special Firing Tray and the Instrument box form a MATCHED SET. These two components are calibrated together at the factory and the overall system accuracy depends upon these two components always being used together.
ProCal Operating Instructions Setup for Either Quick Check or Full Calibration Turn the Furnace Power to the OFF position. Use the Furnace Up Arrow button to raise the table until it is fully closed and the wire umbilical is protruding out of the front/center of the muffle. This is required to prevent electrical surges which could damage the sensitive electronics in the Instrument Box. Remove the two small thumbscrews on the right side of the furnace chassis to expose the calibration ports.
ProCal Operating Instructions Quick Check Survey (Assumes the Physical Setup Step is Complete) Procedure for Pro 200 Series Only Allow Stabilization Time Navigating to the Pro Cal Menu It is suggested that a period of at least 15 – 20 minutes is allowed for stabilization time before manually recording the value on the Instrument box LCD display to insure a stable reading. From the Pro 200 Main Menu Select Special Functions.
ProCal Operating Instructions Furnace Display You can still address a deviation from nominal in a single range by going into each program that has a Hold Temperature in that range and use the Program Level Fusing Adjustment.
ProCal Operating Instructions How to Enter An Overfire Correction Using The Program Level Fusing Adjust Affects This One User Firing Program ONLY) 1. 2. Main Menu Run Program Change Program >Special Functions Roll Selector Knob to item, push Knob to select Special Functions Select Language Cal Low Fusing > Cal High Fusing Roll Knob to item, push Knob to select High OverFire? >Yes Roll Knob to Program #, push Knob to select 3. 4. High Temp Adjustment 8. 6.
ProCal Operating Instructions Full Calibration Run How to Keep Tabs on the Calibration Run IMPORTANT NOTE: When the Full Calibration Run finishes successfully, the Pro Cal software will automatically zero out any previously entered High Fusing Adjustments and Low Fusing Adjustments as the newly minted Full Calibration cancels the need for such entries. The Program Level Fusing edits will, however remain in effect until User modifies them again.
ProCal Operating Instructions Inspecting the Results SOAKED MUFFLE TIMELINE Pro Cal Furnace Quick QC Check Pro Cal – Cool Muffle >Pro Cal – Soaked Muffle Pro Cal Furnace Calibration 1150 C 1:05:00 Pro Cal Furnace Pro Cal Furnace Open Cool 0:50:00 Connect Instrument Box • Within 40 Minutes of Completion The three calibration results for 850°C, 1000°C, and 1150°C are on the confirmation screen shown above.
ProCal Operating Instructions Detailed Directions for Use with the Pro 100 Series Furnaces 6. Press SPECIAL FUNCTIONS button on Pro 100 Furnace. 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.
ProCal Operating Instructions 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.
ProCal Operating Instructions Section B — High Fusing Adjustments 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. 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.
ProCal Operating Instructions Appendix – Special Functions Mode Menu Selections 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.
ProCal Operating Instructions Troubleshooting • Possible Error Conditions & What to Do Error Number Displayed Problem What to Do About It 100 Pro Cal reading exceeds upper limit This could be a bad furnace thermocouple, causing the furnace temperature to go very high. Remove the Pro Cal Kit and verify the furnace Actual Temperature is tracking the furnace Target Temperature. If the furnace itself is not the issue, contact Whip Mix Customer Service.
ProCal Operating Instructions Troubleshooting The following three Error Codes 108, 109 and 110 have multiple possibilities. First, verify all the Pro Cal Kit electrical connections are tightly connected, especially if Error 108 is displayed (the first temperature to be checked). Re-start the Pro Cal cycle afterwards. Second, if the furnace has been idle for a while or at low heat with the Lift Table open, moisture may have accumulated in the white muffle insulation.
ProCal Operating Instructions Technical Support For additional support please contact us at (800)626-5651. Specifications • Special Firing Tray – Type K Thermocouple with ceramic support, ceramic fiber sheath in hot zone. Maximum Temperature: 1200 Degrees Celcius. • Instrument Box – ABS plastic enclosure with 2 line by 8 character LCD Display. Maximum Temperature: 125 Degrees F Power: +5 VDC +/- .1% @ .030 Amps, furnished by Furnace under test via Data Cable.
