ProCheck Instruction Manual
Contents
1. ProCheck User Manual OVERFIRE CW TEMP UNDERFIAE SED LIGHT OVvERFinE aL gt overtine lt SC overtire PREEN IGHT TEMP 7 5 of temperature gt SC underfre ON lt pg Unger Whip Mix Corporation 361 Farmington Ave P O Box 17183 Louisville 40217 0183 USA 502 637 1451 800 626 5651 Fax 502 634 4512 www whipmix com ProCheck Operating Instructions Introduction The Digital ProCheck system consists of a Pro Series firing tray with a K type thermocouple and a precision amplifier discriminator circuit housed in a lightweight plastic enclosure The purpose of the ProCheck system is to provide an accurate repeatable QC reference standard to allow you to verify the temperature stability of your Pro Series furnace week in and week out This can greatly assist Specifications Absolute Accuracy Stability Repeatability 5 0 C 2 0 C at 1200 Status Indications Way Overfire Registration gt 5 5 Mild Overfire Registration 5 5 Calibration OK Registration 4 0 C Solid GREEN LED Mild Underfire Registration 5 5 C Way Underfire Registration gt 5 5 Overview of QC Check Process The periodic temperature QC check procedure is detailed in Section A of the procedures below but here is an overview of the routine QC check process 1 The QC kit firing tra2. If not press the LAST button again dial in a higher temperature press NEXT and so on until the GREEN At Temperature LED IS lit more than 75 Record the temperature this occurs at The Deviation amount is the Instrument Label value minus the Actual GREEN LED value Once you have the deviation values for all 3 QC temperatures add them together algebraically and 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 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 degree Overfire situation the Password 250 mode Remember the Password 250 mode always references back to the factory calibration divide them by 3 then round to the nearest whole number to find the average deviation across the working range Example 850 Deviation 3 overfire 1000 C Deviation 0 1150 C Deviation 1 overfire Algebraically the addition is 3 0 1 2 Now divide 2
3. by 3 get an Average Deviation of 2 3 or 66 Now round up to 1 2 All 3 QC temperatures are greater than 800 which would mean High Fusing territory lt 800 C is Low Fusing territory You also know from Step 1 that you either had to decrease the special Idle setting above the Instrument Label value meaning an Overfire situation OR you had to increase the special Idle setting below the Instrument Label value meaning an Underfire situation You also calculated the amount of Deviation from the Instrument Label value Armed with these three pieces of information you are now ready to adjust the furnace 3 Refer to the next section titled Calibration High Fusing Adjustment or the Pro Series User Manual Section for High Fusing Adjustment There are helpful examples there and a detailed procedure Note The fusing adjustments affect each and every program in the associated range If only one or two programs are yielding mis fires edit just those programs do not use the Fusing Adjustments 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 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 er
4. REEN LED is solidly lit YES NO v v Tip Wait until the afternoon so that the furnace is fully heat soaked Section B Temperature Adjustment Procedure v Determine amount of Overfire Underfire deviation in degrees C and record Deviation Actual GREEN LED temp ProCheck Label Temp if you had to INCREASE special Idle setting to achieve GREEN LED Overfire Deviation ProCheck Actual GREEN LED temp if you had to DECREASE special Idle setting to achieve GREEN LED Underfire Follow High Fusing Adjustment procedure in the back of this manual or the Pro Series User Manual NOTE Do NOT use this instrument in the Cal Low Fusing mode Enter the Amount of Overfire or Deviation Underfire you recorded previously ProCheck Operating Instructions Detailed Directions for Use 6 Insert the notched end of the support arm between the front screw and the triangle plate as shown below IMPORTANT THE FURNACE ANDTHE QC KIT FIRING TRAY MUST BE HEAT SOAKED gt 600 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 red 25 pin connector After the connector is seated turn the AC Line power back on 7 Slide the support arm onto the screw until the arm is up the fur
5. VALUE EQUALS THE TARGET TEMPERATURE VALUE 15 The GREEN LED should now be lighted than 75 of the time ovearme see box below 16 Rotate the Temperature Selector Switch to the next highest QC temperature and repeat steps 13 15 for the second and third QC temperatures Press the LAST button on the furnace then rotate the black knob to enter the next highest QC Temperature value press the NEXT button to enter the value The ProCheck is more stable than virtually any furnace 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 the QC Kit will show a GREEN LED 75 or more of the time and occaisionally blip the Overfire and or Underfire LEDs 13 Enter the same IDLE TEMPERATURE as the TARGET as the furnace oscillates about the hold temperature The TEMP VALUE on the instrument box DON T FORGET GREEN LED indicates the AVERAGE Temperature within this TO PRESS THE NEXT button ON THE FURNACE TO oscillation ENTER YOUR IDLE TEMP SELECTION Repeat this procedure regularly at a frequency determined by you The BLUE Underfire LED vear will be blinki
6. Yes and press NEXT button PRO 100 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 IT IS IRRELEVANT THE ONLY THING THAT MATTERS 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 You can even immediately turn the furnace off back on again dial up the fusing adjust overfire question again say Yes to Overfiring and there is your 5 degree value That is how it will stay as long as you do not press the NEXT button with any other value displayed in the window 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 Now the next time you run a normal firing program with a hold temperature above 800 C the furnace will automatically deduct 5 degrees from the programmed hold temperature and the actual temperature will be right on the money 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 kn
7. and subtract 850 from the recorded temperature and know the furnace is overfiring by 13 C in the High Fusing range since it is above 800 You would press the SPECIAL FUNCTIONS button rotate the knob to Cal High Fusing and follow the directions in the Calibration High Fusing section of this manual or the Pro Series User Manual regarding an Overfire in the High Fusing range During that process it will ask you to input the number of degrees of overfiring temperature this would be where you d enter the 13 C from the example above All programs in the Low Fusing porcelain range below 800 C will now fire 13 cooler than before the adjustment rocedure will NOT affect the displayed parameters of your programs whatsoever they will all be exactly as you entered them The furnace has been effectively adjusted to the programs so that you don t have to adjust the programs to match the furnace NOTE Do NOT use this instrument the Cal Low Fusing mode Here is a simplified process diagram of the intended QC Kit usage Section A QC Check v Place QC firing tray on table and soak both furnace and tray for at least one hour at a temperature above 600 C Enter Special Functions Calibrate Furnace Password 250 and input the special idle temperature which is the temperature labeled on the QC Instrument box Wait til QC Instrument beeps then observe temperature stable and G
8. ases all previously stored correction values and 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 ProCheck Operating Instructions 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 ProCheck 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 ProCheck if you routinely and regularly get consistent indications to base that confidence on Another way the ProCheck 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 Calibratio
9. heck 5 To exit the QC check mode entirely and return to your standard idle temperature simply press the SPECIAL FUNCTIONS button one time ProCheck Operating Instructions Overview of Temperature Adjustment Process In the event that the QC instrument indicates a significant deviation from the desired special idle temperature and you want to adjust the furnace so that your firing program temperature is valid again you would use the special idle temperature setting control to locate the temperature where the GREEN LED comes on solid Then note the number of degrees above or below the QC instrument s labeled temperature record it and use the built in High Fusing Adjust 800 C or higher to effectively adjust the temperature of the furnace for all firing programs in each category The description of the High Fusing Adjustment procedures is well documented within your Pro Series User Manual as well as in the Calibration High Fusing section later in this manual For instance if the QC Instrument labeled temperature was 850 C and you discovered when you set the special idle temperature to 850 C that the RED Overfire LED was blinking when the furnace display said the furnace was stable at 850 C you would lower the special idle temperature setting in small increments until the GREEN LED is on and stable then record the displayed furnace Actual Temperature Let s say it indicates 863 degrees Write this down
10. n High Fusing Adjustment from Section Step 3 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 and Idle temperature of 850 C the furnace takes the muffle to the temperature corresponding to the value it saw when it was calibrated at 850 C at the factory Lets say for the sake of discussion that the ProCheck GREEN LED is on 100 of the time at 855 C or 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 850 C or effectively spot on 1 You would press SPECIAL FUNCTIONS rotate the knob to Calibration High Fusing and press the NEXT button PAO 100 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 ProCheck Operating Instructions 2 In this example we were Overfiring by 5 degrees so we answer
11. nace against the table arm Wiggle the support arm slightly until the notch in the support arm engages the table arm then seat it fully into the notch 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 connector noting it will only plug in one way and attach the instrument box to the support arm by mating up the Velcro square on the arm with the one on the instrument box 4 Raise table to close muffle Allow the white cable to exit out the front of the muffle 9 BLUE Underfire LED should blink 5 Locate the aluminum ovesriag support arm The yellow as soon as TC plugged in as long triangle hot surface warning as furnace is under temperature over sticker and the Velcro patch should be turned upwards dt _ toward the top of the muffle ProCheck Operating Instructions 10 Press SPECIAL FUNCTIONS button on Pro 100 Furnace When the furnace is approximately 5 degrees below the target temperature the BLUE Underfire LED will be constantly lit a beeper will sound to alert you to observe the arrival at the target temperature 14 IMPORTANT WAIT FOR FURNACE TO STABILIZE AT SELECTED VALUE FOR 5 MINUTES BEFORE PASSING JUDGEMENT ON FURNACE CALIBRATION FOR MOST REPEATABLE RESULTS USE A STOPWATCH OR A DIGITAL TIMER TO MEASURE THE TIME AFTER THE ACTUAL TEMPERATURE
12. ng as the furnace temperature begins to climb Cal tea towards the first temperature check point Limited ME ProCheck Operating Instructions Section B User Adjustment Only When Needed 1 Do steps 1 16 If the GREEN LED is not on solid most gt 75 of the time do the following If the RED Overfire LED is on more than 25 of the time or all the time press the LAST button on the furnace then rotate the knob until the new special Idle temperature selection is a couple degrees lower than the Instrument box Label value and press the NEXT button Allow the furnace a couple of minutes to re stabilize at this new special Idle temperature and see if the GREEN At Temperature LED is now on more than 75 of the time If not press the LAST button again dial in a lower temperature press NEXT and so on until the GREEN At Temperature LED IS lit more than 75 Record the temperature this occurs at The Deviation amount is the Actual GREEN LED value the Instrument Label value If the BLUE Underfire LED is on more than 25 of the time or all the time press the LAST button on the furnace then rotate the knob until the new special Idle temperature selection is a couple degrees higher than the Instrument box Label value and press the NEXT button Allow the furnace a couple of minutes to re stabilize at this new special Idle temperature and see if the GREEN At Temperature LED is now on more than 75 of the time
13. ob Clockwise the sequence of selections is shown below from top to bottom Special Functions Menu 1 Night Mode Change Idle Temp Set Vacuum Level Temp in C or F Prog Start Delay Night Mode Temperature Constant vc Pump Sp Cool Position Capital Letters Cw m eS gt Porcelain Names Cal Low Fusing 12 13 14 19 16 17 18 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 Print Form Set Time amp Date Programs gt Box Programs gt Box Test Furnace 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 IT11462 10 08
14. y is placed on the lift table in place of your normal firing tray 2 Both the furnace and the QC tray are heat soaked at the desired temperature 3 Under the SPECIAL FUNCTIONS button section of the furnace software a special idle mode temperature is entered which will hold a given commanded temperature for an extended period of time This does NOT affect the normal porcelain idle temperature your furnace is set at so when you exit this special mode the furnace idle temperature will be right where it was originally you in determining the root cause of porcelain firing inconsistencies which can be challenging since so many variables ranging from excessive moisture blotting technique thickness of buildup and furnace accuracy can affect the outcome Just knowing if and when your furnace is deviating from the program temperatures can be a powerful tool in assuring consistent firing quality Blinking RED Overfire LED Solid RED Overfire LED Solid BLUE Underfire LED with Beeper Blinking BLUE Underfire LED 4 You simply enter the QC temperature labeled on the QC instrument box and walk away until the instrument beeps signifying the furnace is getting close to the QC check temperature You ll want to return to the furnace and observe that the furnace ideally stabilizes at the special idle set temperature and the GREEN LED comes on signifying the furnace is stable at the same temperature it was the last time you performed the QC c
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