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Apollo Dual Channel Temperature Controller User`s Manual

1. 31 WARN IN G Adhere to the restrictions of SECTION 3 2 Failure to do so may create a significant safety hazard and will void the warranty Section 1 Quick Operating Instructions The four steps below are the basics of using your temperature controller The User s Manual is a reference that explains the controller more fully as well as some of its more sophisticated features It s recommended that new users unfamiliar with process controllers read the entire manual carefully The controller is preprogrammed for use with heating mantles fitted to round bottomed flasks running typical organic reactions i e non polymeric reactions in solvents such as THF toluene DMF etc If the controller is used with this type of reaction the 3 steps below will help you get started To use heaters other than heating mantles See Section 2 Do not use the controller to heat oil baths See Section 3 2 amp Appendix I For polymer synthesis atypical expensive or safety critical reactions See Appendix II NOTE The Apollo has 2 completely separate temperature controller in a single cabinet labeled Channel 1 and Channel 2 Any change or adjustment made to Channel 1 will have no affect on Channel 2 and visa versa The instructions below apply to each channel individually Place the thermocouple in the solution being heated Place at least the first 1 4 of the thermocouple directly in l the sol
2. key then while holding in the key press the V or A key until the value 10 appears in the display then let go of all the keys 4 Press the A key once and the word dEr t will appear in the display First hold in the key then while holding in the key press the V or A key until the value 50 appears in the display then let go of all the keys oa Press the A key once and the word dAC will appear in the display First hold in the key then while holding in the key press the V or A key until the value 5 0 appears in the display then let go of all the keys Press the A key once and the word CyC t will appear in the display First hold in the key then while holding in the key press the V or A key until the value 30 appears in the display then let go of all the keys Press and hold in both the V and A keys until the temperature appears in the display then release both keys 3 10 Changing the Temperature Display Resolution The controller is programmed to display temperature resolution within 0 1 C The controller can be changed to 1 C resolution if by following the procedure below the display can also be changed to read in F call for information There are two reasons to change the display resolution 1 To enter a setpoint faster the display scrolls 10X faster in 1 mode than in 0 1 mode 2 To display temperatures above 999 9 Press and hold
3. At any time the timer program can be aborted by holding in the timer knob for 1 second When this is done the display changes to toFF To turn on heating push the timer knob twice until the display reads On 16 ON at Zero Push to Select g ON at Zero OFF at Zero Push to Turn to Select Set Time ON at Zero Momentarily push knob to lock in minutes OFF at Zero Turn to EA Set Time ON at Zero OFF at Zero Push to Turn to Select a Set Time tua ON at Zero OFF at Zero Push to Select g Turn to gt Set Time Push to Select 4 S ON at Zero Hold in the timer knob for 1 second Push to Turn to Set Time OFF at Zero Turn to Select ho Set Time OFF at Zero Rotate knob to enter minutes Push to i Select gi OFF at Zero Rotate knob to enter hours ON at Zero Hold in timer knob for 1 second to store time and start timer Push to Select ON at Zero Push to Select T Turn to ap Set Time E OFF at Zero Turn to _ Set Time OFF at Zero Turn to Set Time 3 6 Delay Heating for a Set Period of Time In this mode the user enters an amount of time to delay before turning on power to the heater This is useful to start heating a reaction or piece of equipment automatically at a specific time While at this setting and while entering a time into the timer no power is applied to the heater Step 1 Whe
4. tei Yellow type K toi Black type J to i First hold in the key then while holding in the key press the A key until the value from the table above appears in the display Let go of all the keys NOTE Many of the patterns for this parameter look similar be careful to select the exact pattern shown above Press the A key once and unit will appear in the display Next hold in the key then while holding in the key press the A key until the value O C appears in the display Let go of all the keys Press the A key once and the word SP1 d appears in the display Next hold in the key then while holding in the key press the A key until the value SSd appears in the display Let go of all the keys 7 Press and hold in both the V and A keys on the front of the temperature meter for the channel you want to change until the word tunE appears in the display then release both keys Press the A key once and the word bAnd will appear in the display Next hold in the key then while holding in the key press the A key until the value 10 appears in the display Let go of all the keys Press the A key once and the word int t will appear in the display Next hold in the key then while holding in the key press the A key until the value 10 appears in the display Let go of all the keys Press the A key once and t
5. until the range coil cooled down This problem of overshooting the set point during initial warm up is the major difficulty with process 25 4 2 controllers Overshooting the set point is minimized in two ways by your J KEM controller but first let s finish the range analogy If you had turned the range off just as the water temperature reached 80 C the final temperature probably would not exceed 82 C by the time the range coil cooled down because the volume of water is so large In most situations a 2 C overshoot is acceptable But what if you were heating 3 tablespoons 45 mL of water and turned the stove off just as the temperature reached 80 C In this case the final temperature would probably approach 100 C before the range cooled down A 20 C overshoot is no longer acceptable Unfortunately this is the situation in most research heating applications That is small volumes lt 2 L heated by very high efficiency heating mantles that contain large amounts of heat even after the power is turned off Your controller handles the problem of latent heat in the heating mantle in two ways 1 The controller measures the rate of temperature rise during the initial stages of heating It then uses this information to determine the temperature at which heating should be stopped to avoid exceeding the set point Using the range analogy this might mean turning the power off when the water temperature reached 60 C and allowin
6. Hold 3 in the button and simultaneously press the A key to increase or the W key to decrease the setpoint The setpoint can be seen at anytime by holding in the button the setpoint appears as a blinking number in the display To turn power On to the heater briefly push in on Set the timer 4 the round timer knob and the display changes to ON When power is applied to the to show that power to the heater is ON For controller by default rusni tm complete instructions on the user of the timer see the Pushto _Turnto the timer turns power section titled Timer Controls E ee OFF to the heater as a a If the display does not change when the timer knob safety precaution is pressed make sure that the Power Level Switch is not set to the Heat Off position KEM Net Data Logging and Control Software At the beginning of 2008 J KEM implemented a redesign of it s research grade temperature and vacuum controllers The redesign involved both the hardware running your controller and software for remote control and data logging Hardware The controller may look the same but inside is our 3 generation microcontroller This controller is FLASH programmable and capable of downloading program modules software from our web site at no charge Several program modules are in development but the most exciting is a module that automatically reports exothermic reactions even during the heating phase of a reaction when an
7. can be controlled 2 Temperature control is independent of the properties of the material being heated e g viscosity solid liquid etc 3 Air and water sensitive reactions can be more effectively sealed from the atmosphere The temperature controller must be programmed for use with an external thermocouple before this procedure is used see following procedure The following step by step procedure programs the controller to regulate heating mantle temperature If you switch back and use the controller with the thermocouple in solution Procedure 1 in Section 3 9 will program the controller for heating mantles For all other heaters see tuning instructions in Section 2 26 After the controller is reprogrammed place a fine gage wire thermocouple Heating Power 7x 1 3 the size of kite string available from J KEM in the bottom third of Beery ei a the heating mantle and fit the flask snugly on top so that the thermocouple 25 ml 10 100 ml is in intimate contact with the heating mantle Set the power reduction ee o circuit to the power level shown in the table at the right Turn the For temperatures over 120 C the controller on and enter the set point next higher power level may be necessary Procedure to Load Tuning Parameters for External Thermocouples Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the A
8. does not heat incorrectly Section 3 5 The heater is broken To verify that the controller is functioning properly place the power level switch on the gt 2L setting and enter a set point of 100 C Plug a light into the outlet of the controller then wait 1 minute If the light comes on the controller is working properly Controller blinks The temperature sensor is inPt FAIL unplugged excessively corroded or Clean or replace broken sensor broken AL The process temperature is hotter Correct the over temperature condition than the alarm temperature See Section 3 13 PArk Controller has been placed in 1 Hold in both the A and V keys on the front of the J KEM Park mode temperature meter until tunE appears in the display 2 First hold in the key then while holding in the oa key press the V key until oFF appears 3 Hold in the A and V keys until the temperature appears in the display tunE FAIL Displayed temperature is The controller has not warmed up The display temperature reads low when the controller is first incorrect turned on but will self correct as it warms up The controller can be used immediately since it will warm up during the initial stages Note Types K amp J of heating Thermocouples display Wrong type of thermocouple is Thermocouples are color coded Thermocouple plug and negative temperatures but are plugged into controller
9. 3 2 4 9 Press and hold both the A and V buttons 3 seconds until the temperature appears in the display The controller is now in its autotune mode While in autotune the display alternates between tunE for autotune and the process temperature When the autotune sequence is done this may take in excess of an hour the controller stops displaying tunE and only displays the process temperature To abort autotune manually repeat steps 3 8 and 9 except in step 8 press the V button until off is displayed Autotune Errors The autotune routine can fail for several reasons If it fails the controller displays the error message tunE FAIL To remove this message turn the controller off for 10 seconds Try the procedure titled Autotuning the Controller for Very Fine Control above If autotune fails again call and discuss your application with one of our engineers A common problem when tuning at high temperatures or with large volumes is for the heater to be underpowered A more powerful heater may be needed contact J KEM for assistance Tuning for Heating Mantles A Special Case This section gives special consideration to heating mantles since they re the most commonly used heaters in research Every heating mantle size has its own optimum set of tuning parameters and if you wanted the controller could be tuned or autotuned every time a different size was used However this is cumbersome and is also unn
10. 3 5 The display can show On meaning that the circuit will allow power to be applied to the heater Off meaning that the circuit will not allow power to be applied to the heater or it will show a time when power will be applied or removed from the heater depending on the settings in the timer Timer Function Knob Multi function knob that selects timer function push knob in and enters the amount of time in the timer rotate See Section 3 5 Timer State LED s Timer status LED s indicate whether power will be applied or removed from the heater when the time in the timer goes to 0 See Section 3 5 Heater Status LED This small LED is On when power is being applied to the heater and Off when power is not applied to the heater Power Reduction Circuit This switch is the interface to J KEM s patented power control computer that limits the maximum power delivered to the heater See Sections 3 6 and 4 1 Optional 9 pin serial connector For controllers equipped for serial communications this RS232 port connects to a PC for remote control and data acquisition For units set up for multi controller operation a RJ 11 phone connector may also be on the back of the controller See supplemental Serial Communications Manual 32 Heater Restrictions The controller delivers 10 amps of current at 120 VAC from the outlets on Channel 1 and Channel 2 into resistive loads heating mantles hot plates ovens etc The controller is limit
11. THE PURCHASE PRICE PAID BY THE PURCHASER TO J KEM SCIENTIFIC INC FOR THE UNIT OR UNITS OF EQUIPMENT DIRECTLY AFFECTED BY SUCH BREACH Service J KEM Scientific maintains its own service facility and technical staff to service all parts of the controller usually in 24 hours For service contact J KEM Scientific Inc 6970 Olive Blvd St Louis MO 63130 314 863 5536 FAX 314 863 6070 E Mail JKEM911 jkem com Internet on line catalog http www jkem com This manual contains parameters specific to temperature controller Serial When calling with a technical question please have the controller serial number available You ve purchased the most versatile controller available to the research community We re confident it can regulate ANY heating cooling situation you ll ever encounter If the information in this manual isn t adequate to make your application work call our Engineering Department for assistance With J KEM s patented Microtune circuitry INDEX SECTION PAGE 1 QUICK OPERATING INSTRUCTIONS 4 KEM NET DATA LOGGING AND CONTROL SOFTWARE 5 2 ADJUSTING THE CONTROLLER FOR STABLE CONTROL WITH DIFFERENT HEATERS 6 2A Whatis TUNN 14 4222 u oe0hodeodedsoaeoeddhedeedsdeeees 6 22 Aulum Procedure ics sic cee sewebeenseeraya savers 7 2 3 Tuning for Heating Mantles A Special Case 9 ZA Sensor Placement i5c 4o odes eas E
12. controller stops heating 13 3 5 Timer Controls The timer circuit works in conjunction with the digital meter to determine when power is applied to the heater The digital meter is the actual temperature controller the timer circuit only acts as a gatekeeper to determine 1f the digital meter temperature controller is allowed to apply power to the heater or not By inserting the timer between the digital meter and the heater the timer can turn heater power On or Off based on a user entered time The timers on channel 1 and 2 work exactly the same way but are completely independent of each other So the explanation of the timer on channel 1 equally applies to the timer on channel 2 When power to the controller is turned on the timer defaults to the Power Off state as is indicated by the word Off in the display In this state no power is applied to the heater This is a safety feature that insures that power is not applied to a heater following recovery from a power failure The timer has 4 ON at Zero OFF at Zero ON at Zero OFF at Zero ON at Zero OFF at Zero OFF at Zero states The timer cycles between the 4 States by pushing in Pushto Turn to Push to i Turn to Pushto Turn to Pushto Turn to Select Set Time Select Set Time Select 4 Set Time Select Set Time on the silver timer eC eC knob momentarily SL gt L f For example push l the timer knob once Push and the timer changes NOTE Pushin
13. in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the W key once and LEVL appears in the display First hold in the key then while holding in the key press the A key until 2 appears in the display then let go of all the keys Press the A key repeatedly until the word diSP appears in the display First hold in the key then while holding in the key press the V or A key until the value 1 not 0 1 appears in the display then let go of all the keys Press and hold in both the V and A keys until the temperature appears in the display then release both keys 3 11 Changing Between PID and ON OFF Operating Modes The controller can heat in either of 2 operating modes PID Proportional Integral Derivative or ON OFF mode The difference between them is the way they supply power to the heater In ON OFF mode the simplest heating mode the controller is ON when it s below the set point Tereeratyp spees ON OFF Mode and OFF when above The disadvantage of this Temp SOSOM a PE mode is a large over shoot of the set point 5 X 30 on initial warm up and oscillation of temperature around the set point thereafter The reason for the overshoot is because the heater turns off only after crossing the set point and until the heater cools down the temperature continues to rise This method wo
14. key once and the word bAnd will appear in the display While holding in the key press the V or A key until the value 5 appears in the display then release all keys Press the A key once and the word int t will appear in the display While holding in the key press the V or A key until the value 2 appears in the display then release all keys Press the A key once and the word dEr t will appear in the display While holding in the key press the V or A key until the value 5 appears in the display then release all keys Press the A key once and the word dAC will appear in the display While holding in the key press the V or A key until the value 5 0 appears in the display then release all keys Press the A key once and the word CyC t will appear in the display While holding in the key press the V or A key until the value 5 0 appears in the display then release all keys Press and hold in both the V and A keys until the temperature appears in the display then release both keys To return to using thermocouples in solution perform Procedure 1 in Section 3 9 4 3 Automatic Storage of Min Max Temperatures The controller will automatically record the minimum and maximum temperatures of a process by following the procedure below These temperatures are updated continuously after the routine is started and cleared by turning the controller off This pr
15. mode The Ramp to Setpoint feature remains activated even if power is turned off to the controller Activating amp Programming the Ramp to Setpoint Feature I Press and hold in both the A and V keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the A key 8 times until the word SPrr appears in the display This is where you set the ramp rate in units of degrees hour First hold in the key then while holding in the key press the V or A key until the desired ramp rate appears in the display then let go of all the keys Units are in degrees hour Press the A key once and the word SPrn will appear in the display This function turns the ramping feature ON OFF or to Hold First hold in the key then while holding in the key press the V or A key until the desired setting appears in the display then let go of all the keys Press the A key once and the word SoaK will appear in the display This is where the soak time is set in units of Minutes A soak time of means to soak forever this setting is one below 0 First hold in the key then while holding in the key press the V or A key until the desired time appears in the display then let go of all the keys If a soak time is set the controller display will alternate between showing the current reaction temperature and the word StoP when the soa
16. results indicating a large volume is being heated the controller sets internal parameters appropriate for heating large volumes If a large rise in temperature results the controller responds by loading a set of parameters appropriate for heating small volumes For the controller to work ideally information needs to travel instantaneously around the feedback loop That means that any power the controller applies to the heating mantle must reflect itself in an instantaneous temperature rise of the solution and the thermocouple Unfortunately this type of instantaneous heat transfer from the heating mantle to the solution to the thermocouple just doesn t occur The delay time between when power is applied to the heating mantle and when the solution rises in temperature and also the converse when power is removed from the heating mantle and the solution temperature stops rising is the source of most controller errors The reason for this can be seen in a simple example Imagine heating a gallon of water to 80 C in a 5 quart pan on an electric range Placing the pan on the range and turning the heat to high you d observe a delay in heating while the range coil warmed up This delay might be a little annoying but it s really no problem The real problem comes as the water temperature approaches 80 C If you turned the range off just as the water reached 80 C the temperature would continue to rise even though all power had been disconnected
17. the Ramp to Setpoint feature in activated the display alternates between the current reaction temperature and the word SPr to indicate that a SetPoint Ramp is active 2 This controller is equipped with a digital 100 hour timer the digital timer and the Ramp to Setpoint feature are completely independent of each other For example if the digital timer is set to turn heating OFF after 5 hours heating is turned off even if a ramp step is in progress Likewise if a Soak time turns heating off after 3 hours and the digital timer is set to turn heating off after 10 hours the digital timer has no effect since the expired Soak time already has turned heating off To avoid confusion and conflicts between the meters Hold feature and the front panel digital timer it s recommended that the Soak Time feature be set to in the meters setup menu and not changed 12 3 Setting a ramp rate will not guarantee that the reaction temperature is at the specified ramp temperature since heating is dependent on the power of the heater For example if a ramp rate of 1200 deg Hr e 20 deg min is set unless the heater is powerful enough to impart heat at such a high rate the reaction temperature will not track the ramp temperature Likewise a reaction can t cool faster than natural cooling by ambient air 4 Once the Ramp to Setpoint feature is activated in programming mode it remains on until it s deactivated in programming
18. the keys Press the A key until Lo SC appears in the display Next hold in the key then while holding in the key hold in the V key until the number in the display stops changing this will be 0 or 50 or 199 9 depending on thermocouple type Let go of all the keys First hold in the key then while holding in the key press the A key until 3 appears in the display Let go of all the keys Press the A key until ZEro appears in the display Next hold in the key then while holding in the key press the V or A key until the correct value see below appears in the display Let go of all the keys O N If the TOP meter is being reset enter the value __ If the BOTTOM meter is being reset enter the value 22 Press the V key until the word LEVL appears in the display First hold in the key then while holding in the key press the V key until 1 appears in the display Let go of all the keys Press the A key until SEt 2 appears in the display Next hold in the key then while holding in the key press the A key until NO Uo the value 5 0 appears in the display Let go of all the keys Press and hold in both the V and A keys until the temperature appears in the display then release both keys If PArk appears in the display it will be replaced by the temperature when a setpoint is entere
19. thermocouple receptacle must be the same color see Section 3 4 not calibrated for them connections sandpaper or steel wool discard thermocouple To enter a controller display offset Turn on controller Allow unit to warm up for 30 minutes Temperature display offset needed Record displayed temperature Press both the V and A keys on the front of the temperature meter until tunE appears then let go of the keys Press the V key until LEVL appears First hold in the key then while holding in the ee key press the A key until 3 is showing in the display then let go of all keys Press the A key until ZEro is showing in the display Note the current display offset this is the number blinking in the display Calculate the new offset temperature using the equation New Current Display display offset Displayed Correct Offset blinking in display temperature temperature First hold in the key then while holding in the ae key press the V or A keys until the new offset temperature is showing then let go of all the keys Press the V and A keys until the temperature is displayed 23 3 13 Over Temperature Protection Circuit The temperature controller is equipped with an over temperature protection circuit that turns off heating any time the temperature of the reaction goes 10 C above the entered setpoint When the temperature of the reaction cools to 10 C above the setpoint the c
20. 0 ml flask a point 45 C the next higher power setting 500 ml heating mantle re 28 power on might be needed to supply the J heater with additional power l l l l l l l 0 10 20 30 40 50 60 70 Time min The power reduction circuit limits the total amount of power delivered to the heater In this sense it works like a variac and can be used like one If the heater isn t getting enough power turn the power level up one notch if it is getting too much power then turn the level down one Do s and Don ts When Using Your Controller The controller heater and thermocouple form a closed loop feedback system see Fig 2 in Section 4 1 When the controller is connected to a heater the feedback loop should not be broken at any point remove either the thermocouple or heater from the solution without setting the power level to the Heat Off With the thermocouple or heater separated from the solution as the thermocouple cools the controller turns the heater on Since this heat is never fed back to the controller it heats continuously use the controller to regulate an exothermic process The controller has no capacity for cooling If an exotherm is expected it must be controlled in another way use an appropriate size flask and heater for the volume being heated Use the smallest flask and heating mantle that accommodates the reaction This ensures that the heating power of the heating mantle closely matches the volume being heated This also
21. FIKE SERTER 9 3 OPERATIONS GUIDE 0 eee 10 Sl Pront Panel Description serere ea twa sees eae ee 10 22 seater RESUICIONS sicret Suk aod Sata ae hee See eee ae aes 11 3 3 Ramp to Setpoint amp Soak Feature 20 0 0 11 3 4 Temperature Sensor Input 0 0 0 0 ccc eee eee 13 2 AMC OMLIOUS nasties acto a E eae eu Goes 14 30 Power Reductiom Circuit 22444 e 4beetuewsdeuiweie ssaces 17 3 7 Affect of Power Setting on Heating Profile 19 3 8 Do s and Don ts When Using Your Controller 20 3 9 Resetting the Controller for Use With Heating Mantles 21 3 10 Changing the Temperature Display Resolution 21 3 11 Changing between PID and ON OFF Operating Modes 21 S12 Troubleshooting 222 i4t att2tarecaantebadtabrenteehee ee 23 S213 Over Femperdtire Alarm 2 4 420 80 ced bbek oes dee Beebe eek os 24 a APPLICA TION NOTES iwi0e beedwindceedwewstauiwa was sates 25 4 1 Theory of How the Controller Works Simply 25 4 2 Controlling the Heating Mantle Temperature Directly 26 4 3 Automatic Storage of Min Max Temperatures 27 TABLET oeenn EE RI O AERE ER OR E T 28 APPENDIX oeer rer eE ere IAE uate ae TTET 29 I Using the Controller With an Oil Bath Application Note 1 29 II Safety Considerations and Accurate Temperature Control 30 Il Resetting the Controller to Original Factory Settings
22. L capacity of water is twice that of a typical organic solvent 100 ml heating mantle 50 power 1 cal g K a higher power setting can be used to compensate SP 80 C for the higher heat capacity 125 ml toluene When the heating mantle size is substantially larger 2 5X 1 L flask 10 100 ml than the volume being heated i e the heating mantle has 1 L heating mantle 10 power excess heating capacity for the volume being heated a lower SP 80 C power setting gives better control 150 ml toluene Even though the solvent volume isn t included in this power 250 ml flask 10 100 ml setting it should be used because low temperatures are better 250 ml heating mantle 10 power regulated with less power SP 35 C 22L 100 Avoid switching between the different power levels while the controller is heating Specifically do not initially set the controller on a high power level to rapidly heat the solution and decrease the power level to the correct setting as the solution approaches the set point Changing power levels doesn t damage the controller but it will reduce its heating performance Heating Equipment Two factors need to be considered when heating equipment ovens hot plates furnaces HPLC columns etc 1 placement of the temperature sensor Section 2 4 and 2 the appropriate power setting The best guide to the correct power setting for various pieces of equipment is the researcher s experience If your best gue
23. Temperature Control for Research and Industry Apollo Dual Channel Temperature Controller User s Manual KEM Scientific mc Instruments for Science from Scientists Warranty J KEM Scientific Inc warrants this unit to be free of defects in materials and workmanship and to give satisfactory service for a period of 12 months from date of purchase If the unit should malfunction it must be returned to the factory for evaluation If the unit is found to be defective upon examination by J KEM it will be repaired or replaced at no charge However this WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of being damaged as a result of excessive current heat moisture vibration corrosive materials or misuse This WARRANTY is VOID if devices other than those specified in Section 3 2 are powered by the controller Components which wear or are damaged by misuse are not warranted This includes contact points fuses and solid state relays THERE ARE NO WARRANTIES EXCEPT AS STATED HEREIN THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL J KEM SCIENTIFIC INC BE LIABLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES THE BUYER S SOLE REMEDY FOR ANY BREACH OF THIS AGREEMENT BY J KEM SCIENTIFIC INC OR ANY BREACH OF ANY WARRANTY BY J KEM SCIENTIFIC INC SHALL NOT EXCEED
24. al purposes turn the over temperature circuit off since with this setting the reaction must exceed the set point by 999 9 C before the alarm would come on Procedure to DEACTIVATE Over Temp Alarm Procedure to RE ACTIVATE Over Temp Alarm 1 Press and hold in both the V and A keys on the front of the Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display temperature meter until the word tunE appears in the display then release both keys This places the controller in programming then release both keys This places the controller in programming mode Press the A key until SEt 2 appears in the display then release Press the A key until SEt 2 appears in the display and release all keys all keys Press and hold in the key When the key is held in the display Press and hold in the key While holding in the i key press the shows the number of degrees that the set point must be exceeded by V or A keys until the display shows 10 0 then release both keys to cause the over temperature alarm to activate To effectively disable the over temperature alarm press the A key while holding in the key until a very high value is entered such as 900 degrees When you re done let go of all the keys Whatever number you entered at this point is the number of degrees that the reaction temperature must exceed the set point before the alarm comes on T
25. allows the solution to radiate excess heat to minimize temperature overshoots place the thermocouple directly in the solution Place at least the first 1 4 of the thermocouple directly into the solution If a corrosive mixture is heated use a Teflon coated thermocouple or use the external thermocouple method Section 4 2 avoid exposure of the controller to corrosive gases and liquids The atmosphere of a research hood is corrosive to all electronics Place the controller outside the hood away from corrosive gases 20 3 9 Resetting the Controller for Use With Heating Mantles If you want to use your controller with heating mantles after it s been tuned for a different style heater rather than autotuning the controller with the heating mantle J KEM recommends that the controller be manually tuned by following the procedure below Procedure 1 Perform when using heating mantles with round bottom flasks This procedure takes about 2 minutes to perform Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the A key once and the word bAnd will appear in the display First hold in the key then while holding in the key press the V or A key until the value 10 appears in the display then let go of all the keys Press the A key once and the word int t will appear in the display First hold in the
26. aneously In contrast a hot plate may take several minutes to begin heating when electricity is applied and even longer to start cooling when electricity is turned off Your controller can regulate both a heat lamp and a hot plate to 0 1 C But to do this it must be programmed with the time constants describing how fast the heater heats when electricity is turned on and how fast it begins to cool when it s turned off These time constants are called the tuning parameters Every type of heater has its own unique set of tuning parameters For the controller to heat with stability it must have programmed with the tuning parameters for the heater currently being used Prior to shipment tuning parameters were programmed into the controller that maximize heating performance for laboratory heating mantles since these are the most common heaters used in research Tuning is regulated by 5 of the temperature meter s user programmable functions The correct value for these 5 functions can be calculated and loaded by the user manually or the controller can do it automatically with its autotune feature When Should the Controller be Tuned Ifthe controller is tuned to one type of heater heating mantles for example any size heating mantle can be used without the need to retune When changing from heating mantles to a different type of heater an oven for example the controller should be tuned with values describing the oven s heating characteristics The effe
27. ct of tuning is seen below When the controller is tuned for heating mantles using it with any size heating mantle yields stable temperature control Plot 1 but poor control results when the same tuning parameters are used with an oven Plot 2 Curve 1 However after tuning the controller to the oven stable temperature control results Plot 2 Curve 2 Plot 2 Plot 1 80 105 l Curve 2 Controller loaded with 60 tuning parameters for 60 Temp i Temp 7 drying oven C al 50 Conditions 100 ml Toluene 30 Curve 1 Controller loaded with 50 ml Round bottomed flask tuning parameters for 250 ml Heating mantle heating mantles Power Setting 50 500 ml 40 40 mi 30 20 He A ae se oe te See ee l l 0 10 20 30 40 50 60 Time min Time min 2 2 It s important to understand that this controller isn t a simple ON OFF type controller 1 e ON when below the set point OFF when above though it can be made to work this way see Section 3 11 Rather it s a predictive controller Based on the shape slope of the heating curve the controller predicts calculates the percent of power to apply to the heater now to control the shape of the heating curve minutes in advance The importance of the tuning parameters is that they are constants in the equation the temperature meter uses to perform its predictive calculations If the temperature meter is programmed with tuning parameters that incorrect
28. d N Nn N N 31
29. ecessary Factory tests show that there s one set of tuning parameters that delivers good performance for all heating mantle sizes These tuning parameters were loaded into the controller at the factory prior to your receiving it If you re using a heating mantle and none of the parameters have been changed or the controller hasn t been autotuned since you ve received it you re ready to go If the tuning parameters have been changed or the controller has been autotuned and you want to go back to using heating mantles J KEM recommends that the tuning parameters for heating mantles be loaded manually 1 e don t autotune to the heating mantle by following the step by step instructions given in Procedure 1 of Section 3 9 Sensor Placement Placement of the sensor is basically common sense The sensor should be positioned to sense the average temperature of the medium being heated That means the thermocouple should be shielded from direct exposure to the heater but not so distant that rise in temperature isn t sensed by the controller within a reasonable period of time Several examples follow that show the type of consideration that should be given to sensor placement Use With Place the sensor in the solution Stir vigorously so that heat is homogeneously mixed Solutions throughout the solution Tape a thin wire thermocouple directly to the HPLC column Place several layers of HPLC column heated paper over the thermocouple to insulate i
30. ed to a total of 15 amps output current for the sum of the current from Channel 1 and Channel 2 Use only resistive loads that are safely operated at 120 VAC and require less than 10 amps or damage to the controller and a safety hazard may result Do not plug oil baths into your controller Oil baths are not 120 VAC devices and become a fire hazard unless properly connected to the controller See Appendix for an application note describing the use of oil baths with this controller Devices other than resistive loads can be used with your controller but certain restrictions apply Device Type Incandescent lamps lt 700 watts Set the power reduction circuit Infrared heaters to the gt 2 L setting Inductive loads lt 4 amps 480 watts The controller must be solenoids programmed for this use transformers Request application note ANS motors 3 3 Ramp to Setpoint amp Soak Feature A new feature of J KEM s controllers called Ramp To Setpoint allows you to enter a specific heating rate e g heat to 120 C at a rate of 5 C Hour a second feature called Soak then lets you specify how long to stay at that temperature before turning off 11 Examples of Program Ramps YN O ssf 2 2 Temperature Power Off q4 Nn O ssf 2 5 e Power Off Temperature Time The controller is shipped with the Ramp to Setpoint feature OFF the user must specifically turn Ramp to Setpoin
31. eing controlled The controller uses a PID Proportional Integral Derivative algorithm to regulate heating Each of the terms in the PID equation has a constant that scales the equation to the process being heating These constants plus two other related terms are collectively known as the tuning constants and for the most part they are expressed in units of time since they represent delay times rate of heat transfer times and rate of error accumulation The relative value of each constant depends on the physical characteristics of the process being heated For example for the same amount of input power the rate of heat transfer is twice as high for hexane as compared to water since the coefficient of heat for hexane is 0 54 calories g C and water is 1 0 calorie gram C That means that 1000 watt seconds of input power will raise the temperature of 10 g of hexane 44 C while the same amount of power causes a 24 C rise in water In theory the tuning constants needed to heat hexane are different from those to heat water Fortunately your J KEM controller is self adaptive and is able to adapt its heating characteristics for different solvents such as hexane and water Even with the controller s self adaptive algorithms the tuning constants have to be reasonably close to a proper set or the controller will not produce stable temperature control see Section 2 1 When a controller is shipped the default set of tuning constants loaded
32. exotherm would normally be undetectable Software Your controller is equipped with a USB port to allow remote control and data logging J KEM is currently developing a complementary software package KEM Net that remotely controls and data logs up to 16 controllers simultaneously Until KEM Net is available J KEM is offering KEM Log at no charge KEM Log provides remote E KEM Scientific AutoKem Software control and data logging for bees one IKEM controller J KEM Scientific KEM Net Software KEM Log implements Data logging directly to Excel or a text file Active Step 1 M Data Logging us Ramping Ramp TimeRemaining 1 11 09 Setpoint 25 1 Hold Time Remaining 0 30 00 MV LogtoExcelFile D Log to Test File x A 1 6 step Ramp Hol i temperature ramp gt 2 an 40 NormalLoggi that S constructed in 45 1000 Log Interval 15 Seconds Minutes an Excel like table Data To Log V Time V Temperature l SetPoint Easy entry of the setpoint KEM Log is free of charge To load KEM Log to your PC follow these steps 1 Enter this link in your web browser _ http www jkem com kemnetzip exe A popup window appears presenting the options of RUN SAVE and CANCEL Selecting the SAVE option brings up a Save File Dialog window Save the file kemnetzip exe to your C drive then exit your web browser 2 Kemnetzip exe is a self extracting zip file Double click on its icon to expand it Once expanded ke
33. ff indefenently Push to Turn to Select ME A SetTime Fi ay Function Push knob for Change 1 4 second OFF at Zero ON at Zero When the timer counts to 00 00 power is turned On indefenently Push to _ Turn to Select SetTime j a To immediately exit a timed run hold in the timer knob for 1 second Function Change Push knob for 1 4 second F BRONCO at OFFatZero ON at Zero OFF at aa 6 9 1 1c ummm E pa g z m ON at Zero ON at Zero OFF at Zero n N m 7em ma OFF at Zero n D x fea Mesa Push knob for Hold in knob LHS secon a second ie 1 second Loic Q O 9 Push to Turn to Push to pan Turn to Ey Push to Turn to E Push to Turn to 5 Select 4 x Set Time Od ar Vale Select 4 gt Set Time Ey SR 7 m N Set Time Change aia i i Set Time D q f i a Vy Dj s d T then ae Enter Minutes gt Enter Hours unction Push knob for Change 1 4 second ON at Zero OFF at TON at Zero OF Fat Zero ON at Zero OFF at Zero l ON at Zero OFF at Zero _ ON at Zero OFF at Zero Hold fis knob Eo o 1 second Push knob for Hold in knob me Secon second for 1 second i om Push to Turn to z r 3 unction Push to Turn to Push to Turn to ee 10 g pra Change Select KON Set Time Ch Select a Set Time Program Select M Set Time Select 4 Set Time Selec 4 Change s then Enter Minutes gt En
34. g tunE and only displays the process temperature To abort autotune manually repeat steps 3 8 and 9 except in step 8 press the V button until off is displayed New tuning I ae values loaded into memory Set Point Heat to set point ferenering The autotune sequence nemParem During autotune the controller heats to 75 of 0S2 x 75 of the setpoint temperature set point where it oscillates for several cycles before loading the new tuning parameters After the tuning parameters are loaded it heats to the Start Way T2 hg TA set point temperature Tuning below During T1 4 the controll AT measles heating delays and Quarter cycle times the set point prevents any damage that rales OL ngatng alia googling might occur from overheating Time Autotuning the Controller for Very Fine Control This procedure is not recommended for heating mantles see Section 2 3 In the majority of cases the procedure above results in stable temperature control with any heater A second version of the autotune routine is available and can be used when the heater is already at or close to the set point is being tuned at a temperature close to room temperature or for very fine control in demanding situations If stable temperature control doesn t result after performing the first autotune routine the procedure below should be performed Before performing the fine tune autotune procedure the regular autotune procedure that
35. g in on the timer knob quickly for about 1 4 second causes it to advance to the next from the Off state to state Holding in the knob for 1 second changes to the mode where time is entered into the timer the On state push it again and it changes to the toFF state Repeatedly pushing the knob cause the time to cycle between its three normal states of On toFF and t on If the Power Reduction Circuit Section 3 6 is set to the Heat Off position the timer window always displays oFF The four states of the timer circuit are explained below Axe In the off state no power is applied to the heater even if the temperature meter calls for power to be applied The controller always enters the off state when power is turned on or following recovery Pushto c Tumo from a power failure The controller also enters the off state when the power reduction Select 4 Set Time circuit is set to the Heat Off position see Section 3 6 xo In the on state the timer circuit applies power to the heater when the temperature meter nem calls for power to be applied Whenever power is applied to the heater the small LED dot on the left of the timer window is lit Depending on the power needs of the heater this Select Set Time dot may blink rapidly The toFF state standing for Time Off allows the user to enter the amount of time the controller should heat until heating is automatically turned off While time is present in the timer power is ap
36. g the latent heat of the burner to raise the water temperature from 60 to 80 C This calculation is done by the controller and is independent of the operator The next feature of the controller is directly under operator control and has a major impact on the amount of overshoot on initial warm up 2 Again referring to the range analogy you d obtain better control when heating small volumes if the range had more than two power settings Off and High J KEM s patented power reduction circuit 12 serves just this function It allows the researcher to reduce the power of the controller depending on the amount of heat needed This circuit can be thought of as determining whether the heating power is Very low 0 mL Low 10 100 mL Intermediate 50 500 mL Medium 300 mL 2 L or High gt 2 L The proper power setting becomes instinctive after you ve used your controller for a while For additional information see Section 3 6 Controlling the Heating Mantle Temperature Directly In a normal heating setup the thermocouple is placed in the solution being heated The controller then regulates the temperature of the solution directly The thermocouple could alternately be placed between the heating mantle and the flask so that the controller regulates the temperature of the heating mantle directly which indirectly regulates the temperature of the solution Advantages to this method include 1 The temperature of any volume microliters to liters
37. ginal factory settings If you still have difficulty with your controller our Engineering department is available to help resolve any problem The factory settings of a J KEM controller are 0 1 C resolution PID control with tuning parameters for a heating mantle thermocouple type to match the thermocouple originally installed on the controller high temperature alarm turned on and a thermocouple offset entered at the time of original calibration This procedure should be followed for each of the two independent meters in this dual channel controller Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the Wkey until LEVL appears in the display Next hold in the key then while holding in the key press the A key until 3 appears in the display Let go of all the keys Press the A key until rSEt appears in the display Next hold in the key then while holding in the key press the A key until the word All appears in the display Let go of all the keys Press and hold in both the V and A keys until the word inPt appears in the display then release both keys The value that needs to be entered depends of the type of thermocouple receptacle your controller was shipped with Determine the thermocouple type below Color of thermocouple receptacle Fig 1 7 Value to enter Blue type T
38. he word dEr t will appear in the display Next hold in the key while holding in the key press the A key until the value 50 appears in the display Let go of all the keys Press the A key once and the word dAC will appear in the display Next hold in the key then while holding in the key press the A key until the value 3 0 appears in the display Let go of all the keys Press the A key once and the word CyC t will appear in the display Next hold in the key then while holding in the key press the A key until the value 30 appears in the display Let go of all the keys Press the A key until the word SPrn appears in the display Next hold in the key then while holding in the key press the Aor V key until the word OFF is displayed Let go of all the keys 15 First hold in the key then while holding in the key press the A key until 2 appears in the display Let go of all the keys Press the A key until SP2 A appears in the display Next hold in the key then while holding in the key press the A key until the word Dvhi appears in the display Let go of all the keys Press the A key until diSP appears in the display Next hold in the key then while holding in the key press the Aor V key ioe until the value 0 19 appears in the display Let go of all
39. ime Select A ON at Zero OFF at Zero Push to Turn to Select fo Set Time Momentarily push knob to lock in minutes ON at Zero OFF at Zero Push to i Turn to Select Set Time Cy Push to Hold in knob Turn to Select 4 Aa SetTime ON at Zero OFF at Zero Rotate knob to enter minutes Turn to a Set Time Push to Select ME Rotate knob to enter hours ON at Zero OFF at Zero Hold in timer knob for 1 second to store time and start timer Push to Turn to Select 4 Set Time 7 ta Cy F ON at Zero OFF at Zero for 1 second Pushto _ Turn to Select KN Set Time j This switch 12 is the user s interface with J KEM s patented power control computer that limits the maximum output power delivered by the controller It determines whether the controller heats at a very low 1 10 mL low 10 100 mL intermediate 50 500 mL medium 300 mL 2 L or high gt 2 L power level The power reduction circuit acts as a solid state variac This circuit has an additional setting Heat Off which when selected turn heating off and allows the controller to act as a digital thermometer The table to the right shows the maximum output power from the controller to the heater depending on the position of the power switch The correct setting for this switch is the setting that supplies adequate power for the heater to heat to the set point in a reasonable period of time
40. into the controller are those appropriate for heating typical organic reactions 1 e small molecule chemistry in low boiling lt 160 C organic solvents using heating mantles since this is the most common application for J KEM controllers Since it s impossible for J KEM to predict the application the controller will be used for the researcher must be aware of the possibility that the tuning constants loaded into the controller may not be a set that results in stable temperature control It s the researcher s responsibility to monitor the temperature regulation of a reaction If you encounter a process that your J KEM controller does not heat with stability you have two resources Autotune Feature Your controller has and autotune feature that when turned on see Sections 2 1 amp 2 2 automatically determines the proper tuning constants for your application and then loads them into memory for future use J KEM Technical Assistance If you have an application you wish to discuss call us we re always anxious to help our users For an additional description of the PID algorithm and the concept of tuning see Sections 2 and 4 1 30 III Resetting the Controller to Original Factory Settings J KEM manufactures the most technically advanced temperature controller available and should give you consistently flawless control If you have difficulty with your controller a good place to start to correct the problem is by loading the ori
41. ircuit is reset and the controller begins to operate normally An over temperature condition is indicated by the display blinking the message AL This over temperature feature acts to prevent accidents from reactions where something significant has gone wrong since no application with J KEM s controllers should over shoot the setpoint by more than 2 C For applications requiring more versatile and accurate over temperature protection circuits the user is refereed to J KEM s Model 260 and Model 270 controllers There may be situations where it s desirable to disable the over temperature protection circuit for example if the controller is often used as a digital thermometer The two procedures below give directions on disabling and re enabling the over temperature circuit In reality the over temperature alarm can t be turned off because it s hard wired in the controller but what you can do is program an over temperature condition so high 1 e 999 9 C that it has the effect of disabling the alarm What you ll do in the procedure to deactivate the over temperature circuit is enter the number of degrees that the reaction temperature must exceed the set point to cause the over temperature circuit to come on If you enter a small number such as 10 C which is the factory default the alarm will turn off heating when the reaction exceeds the set point by 10 C If you enter a large number such as 999 9 C you ll for all practic
42. k time has expired to indicate that power has been turned off 3 To exit programming mode press and hold in both the V and A keys until the temperature appears in the display then release both keys Deactivating the Ramp to Setpoint Feature L Press and hold in both the A and V keys on the front of the temperature meter until the word tunE appears in the display then release both keys 2 Press the A key 9 times until the word SPrn appears in the display This function turns the ramping feature ON and OFF First hold in the key then while holding in the key press the V or A key until OFF appears in the display then let go of all the keys 3 To exit programming mode press and hold in both the A and WV keys until the temperature appears in the display then release both keys 3 4 Temperature Sensor Input Every controller is fitted with a specific type of thermocouple input and can only be used with a thermocouple of the same type For the correct temperature to be displayed the thermocouple type must match the receptacle type on the front of the controller Figure 1 7 All thermocouples are color coded to show their type Blue type T Yellow type K Black type J The color of the thermocouple plug must match the color of the receptacle on the front of the controller If the thermocouple is broken or becomes unplugged the error message inPt FAIL blinks in the temperature meter display and the
43. ly describe the heater being used poor temperature control will result But when the correct values are loaded temperature regulation of 0 1 1s typically achieved Manual Tuning Manual tuning is when the values of the 5 tuning parameters are determined manually then entered into the temperature meter via the push buttons on the front of the controller Experienced users might prefer to manually tune the controller since this allows customization of the heating process Autotune Autotune is a feature built into the temperature meter that automatically calculates the tuning parameters i e delay times heating efficiency etc for any type of heater After the autotune procedure is complete and the tuning parameters are determined the controller loads them into its memory for current and future use Heating mantles are a special case and are covered in a separate paragraph Section 2 3 Autotuning Procedure This procedure is not recommended for heating mantles see Section 2 3 1 Set the equipment up in the exact configuration it will be used For example to tune to a vacuum oven place the thermocouple in the room temperature oven and plug the oven into the controller If the oven or heater has its own thermostat or power control turn both as high as they ll go 2 Set the controller to the appropriate power level see Section 3 6 Make sure timer circuit is set to ON e the timer window displays On see Section 3 5 Tur
44. mall volume heating mantles and micro thermocouples Call if you have any concerns or would like to discuss your application with a technical representative Accessories for Heating Small Volumes Available From J KEM Heating Mantles All sizes from 5 ml to 50 L Teflon Coated Microscale Thermocouples See Catalog Thermocouples hermetically sealed in See Catalog various size hypodermic needles 29 IT Safety Considerations and Accurate Temperature Control For safety critical and non typical organic reactions especially polymeric reactions or for use with heaters other than heating mantles the user must either 1 monitor the reaction closely to verify the tuning parameters are appropriate for the current application or 2 autotune the controller for the application For any safety critical or high value reaction call J KEM to discuss your application with an engineer prior to beginning Your J KEM controller is capable of regulating virtually any application to 0 1 C if the controller is tuned to the application being heated Since it s possible that the tuning parameters are not set correctly for your application the user must monitor a new reaction to verify the controllers operation A short primmer on tuning is presented below a more detailed explanation is presented in Sections 2 1 and 4 1 Tuning is the process that matches the control characteristics of the controller to the heating characteristics of the process b
45. mnetzip exe creates a new folder on your C drive titled JKEM which contains the KEM Net Installation Project and copies of user s manuals and USB drivers 3 Print the document titled PrintWMe_Now pdf for instruction on how to install the USB drivers and the KEM Net software Section 2 Adjusting The Controller For 2 1 Stable Control With Different Heaters It s important to remember that this controller has two completely independent controllers in a single cabinet The description of the operating characteristics of one channel are identical to those of the second channel No setting on Channel 1 affects Channel 2 and visa versa What is Tuning The controller s most powerful feature is its ability to regulate virtually any heater with stable temperature control For stable control the controller requires two things 1 the controller must be set to the correct power level see Section 3 6 and 2 that it be tuned to the heater being used Tuning is the process that matches the control characteristics of the controller to the heating characteristics of the heater The controller is said to be tuned to the heater when its memory is programmed with values telling it how fast the heater warms up cools off and how efficiently it transfers heat For example consider the difference between a heat lamp and a hot plate When electricity is applied to a heat lamp it begins to heat instantaneously and when it s turned off it stops heating instant
46. n the controller and heater on and enter the desired set point temperature If the set point isn t at least 30 C above ambient skip this procedure and go to the next procedure Autotuning the Controller for Very Fine Control 3 Press and hold in both the A and V buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons 4 Press the A button 5 times until CyC t appears in the display if you go past this setting press the V button until you get back to it 5 First hold in the button while holding in the button press the V button Continue to hold both buttons in until the display reads A or A where HF is some number Release the button and press the V button until tunE once again appears in the display 7 Press and hold the button and tunE will change to off to indicate that autotune is currently off 8 While holding in the button press the A button to change the display to on then release both buttons 9 Press and hold both the A and V buttons for 3 seconds until the temperature appears in the display The controller is now in its autotune mode While in autotune the display alternates between tunE for autotune and the process temperature When the autotune sequence is done this may take in excess of an hour the controller stops displayin
47. n the timer displays t on holding the timer knob in for 1 second causes the display to change to a clock that shows 00 00 The left 2 digits are hours and the right 2 digits are minutes The minutes digits are blinking which indicates that their value can be changed Step 2 To increase the number of minutes rotate the timer knob to the right To decrease the number of minutes rotate the timer knob to the left Step 3 To change the number of hours in the display momentarily press the timer knob 1 4 second and the hours digits begin to blink To increase the number of hours rotate the timer knob to the right To decrease the number of hours rotate the timer knob to the left Step 4 When the desired time is displayed hold in the timer knob for 1 second to enter the time and start the timer When the timer starts the LED under the label ON at Zero lights This indicates that power to the heater will turn ON when the timer counts down to zero At any time the timer program can be aborted by holding in the timer knob for 1 second When this is done the display changes to t on To turn on heating push the timer knob until the display reads On Power Reduction Circuit ON at Zero Push to Turn to Select Set Time OFF at Zero mom ON at Zero OFF ae Zero mu Push to Turn to Select A Set Time ON at Zero OFF at Zero Hold in the timer knob for 1 second Push to Turn to A Set T
48. ned for use with oil baths rated for any voltage and is recommended for this application The 200 Series controller can be used with an oil bath rated for 120 volt operation without any special setup Simply place the flask and the thermocouple directly in the oil set the appropriate power setting and enter the reaction setpoint temperature If you need to use an oil bath with you J KEM controller J KEM recommends the Ace Glass Instatherm oil baths The two largest baths Catalog s 9602 15 and 9602 17 are both rated for use with 120vac controllers and provide good temperature regulation If you frequently heat reactions using oil baths we recommend J KEM s 400 Series oil bath controller If the reason for using an oil bath is that a small volume is being heated and you want to use your 200 Series controller for the job you have a second option J KEM sells heating mantles for small volumes 5 10 25 50 ml which can be plugged directly into the temperature controller Your controller regulates volumes as small as 1 ml in a 5 ml flask using a 5 ml heating mantle If you need to heat even smaller volumes your User s Manual describes a technique for heating microliters Controlling the Heating Mantle Temperature Directly in Section 4 The advantage of this option is that it eliminates the mess and safety hazards associated with oil baths Accessories for regulating the temperature of small volumes are available from J KEM including s
49. o return to normal temperature display press and hold in both the To return to normal temperature display press and hold in both the V and A keys about 3 seconds until the temperature appears in V and A keys about 3 seconds until the temperature appears in the display 24 Section 4 Application Notes Supplemental application notes on the following topics are available by contacting J KEM Application Note Subject How to heat oil baths with your controller Included in Appendix AN2 Changing the controller s thermocouple type AN3 Changing the heating outlet into a cooling outlet AN2 AN3 Using the controller with inductive motors valves loads 4 1 Theory of How the Controller Works Simply For the purpose of explaining how the controller works the example of a solution heated with a heating mantle is used The principles are the same for all heater types Thermocouple J KEM Scientific 10 100nl 50 5001 InstrumentsforScience 1 10ml T 7 300ml 2L Heat Output Power Level 120 vac Power to heater Model 210 120 Vac 840watts Temperature of process Heating mantle from the thermocouple Figure 2 The controller the heating mantle and the thermocouple form a closed loop feedback system If the process temperature is below the set point the controller turns the heating mantle on and then monitors the temperature rise of the solution If a small rise
50. ocedure must be started every time you want to record temperatures Procedure to Start Temperature Logging 1 Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the V key once and the word LEUL appears in the display While holding in the key press the A key until the value 3 appears in the display then release all keys Press the A key until the word ChEy appears in the display While holding in the key press the A key until on appears in the display then release all keys Hold in both the V and A keys until the temperature appears in the display and release both keys Automatic temperature logging is now on and will remain on until the controller is turned off or logging is turned off manually by repeating this procedure except in Step 3 pressing the A key until the word off appears Procedure to Read Minimum and Maximum Temperatures both keys Press the V key once and the word LEUL appears in the display While holding in the key press the A key until the value 3 appears in the display then release all keys Press the A key until the word rEAd appears in the display The rEAd screen displays 3 parameters Variance the difference between the highest and lowest logged temperatures hold in the key and the display will alternate between UAr and n
51. plied to the heater when the time counts down to 0 heating is turned off See the section below titled Heating for a Set Period of Time nmr The t on state standing for Time On allows the user to enter an amount of time to delay before applying power to the heater While time is present in the timer no power is applied to the heater even if the temperature meter calls for power to be applied but when time counts down to 0 heat is turned on indefinitely See the section below titled Delay Heating for a Set Period of Time 14 Over View of the Timer Functions The timer knob is a multi function knob When it s pushed in for 1 4 second it causes the timer to advance to the next function When it s pushed in for 1 second it enters programming mode In programming mode the user enters time into the timer or locks the entered time into the timer which starts the program running a running program can be aborted by holding in the timer knob for second When in programming mode rotating the knob in a clockwise direction increases the amount of time entered into the timer Rotating the knob in a counter clockwise direction decrease the amount of time when rotating in a counter clockwise direction the timer rolls over from OO to 59 minutes when entering minutes or from 00 to 99 hours when entering hours ON at Zero OFF at Zero When the timer counts to 00 00 power is turned O
52. precedes this should normally be performed l Set the equipment up in the exact configuration it will be used If the heater has its own thermostat or power controls turn both as high as they Il go With this procedure it s not necessary for the equipment to start at room temperature This procedure can be performed at any time and any temperature Set the controller to the appropriate power level see Section 3 6 Make sure timer circuit is set to ON i e the timer window displays On see Section 3 5 Turn the controller and heater on then enter the desired set point temperature Press and hold in both the A and V buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons Press the A button 5 times until CyC t appears in the display if you go past this setting press the V button until you get back to it First hold in the button while holding in the button press the V button Continue to hold both buttons in until the display reads A or A where HP is some number Release the button and press the V button until tunE once again appears in the display Press and hold the button and tunE will change to off to indicate that autotune is currently off While holding in the button press the A button to change the display to At SP and release both buttons 2
53. rks well for heaters that transfer heat rapidly such as heat lamps it s acceptable for heaters such as heating mantles 5 overshoot but it s terrible for heaters that transfer heat slowly vacuum ovens heating blocks etc Power q to heater Time 21 In PID mode the controller monitors the shape of PID Mode the heating curve during initial warm up and A ee decreases power to the heater before the set point aot 3 is reached so that the solution reaches the set point with minimal over shoot Notice that the heater turns off for varying periods of time before Power the set point temperature 1S reached The second 7 3 feature of PID mode is that it adjusts the percent on of time the heater is on so that the set point is E maintained precisely The advantage of PID Time mode is that it delivers stable temperature control with any heater from heat lamps to vacuum oven The disadvantage is that the controller must be properly tuned to the heater being used whereas ON OFF mode requires no tuning Since both heating modes have their advantages simplicity vs accuracy instructions to change the controller to ON OFF mode are given below though PID mode will probably give better results 95 of the time The controller can be set back to PID mode by following Procedure 1 in Section 3 9 1 Press and hold in both the V and A keys on the front of the temperature Procedure to change meter until the word
54. settings demonstrating use of the power reduction circuit 19 Graph 1 This graph shows typical heating profiles for a laboratory oven and an HPLC column In the example of the oven the heating curves for 2 different power levels are shown The 50 500 ml setting is the appropriate amount of power to heat to 75 C and thus results in a smooth heating curve The gt 2L power setting is too much power and results in oscillation around the set point Graph 2 This graph shows the affect of different power settings when heating liquids with heating mantles The 10 100 ml setting 10 power is underpowered and results in slow heating The 300 ml 2 L setting 50 power is too much power and results in sporadic control The controller adapts to a wide range of power settings In this example the power is varied by a factor of 5X nevertheless reasonable control is maintained in each case 170 145 120 Temp 3 8 95 70 45 20 Set point 155 C Graph 3 Pa Power gt 2L 0 100 power Another factor affecting the 2 choice of power setting is the set point temperature For set points Set point 100 C near room temperature a low Power 300 ml 2L power level is adequate For Ps 50 power average temperatures 50 100 the volumes are printed on the front of the controller are a good guide For high temperatures A Conditions 300ml collidine EEE l 50
55. ss is that the equipment needs 1 3 full power to heat to the set point set the power switch on the 300 ml 2 L setting 1 e 50 power it s usually better to have too much power rather than too little If the heater heats too slow increase the power to the gt 2 L setting if it heats too fast or has excessive overshoot decrease the power to the 50 500 ml setting If the amount of power seems to be adequate but the heater doesn t heat with stability the controller probably needs to be tuned see Section 2 Section 3 7 shows the type of performance you should expect from the controller with different pieces of equipment 18 3 7 Temp oC Temp C 80 SO a E Sn 70 7 Conditions Set point 75 C Laboratory oven 60 Power Setting 50 500 ml Power Setting gt 2L 5 40 Conditions Set point 45 C HPLC Column wrapped with heating tape 30 Power Setting 50 500 ml 20 i i i i i i 0 10 20 30 40 50 60 10 Time min 80 70 60 Conditions Set point 70 C 50 50 ml Toluene 100 ml Round bottomed flask 40 Power Setting 10 100 ml i e 10 power 30 Power Setting 50 500 ml i e 25 power pies Power Setting 300 ml 2 L i e 50 power 20 0 10 20 30 40 50 60 70 Time min Affect of Power Setting on Heating Profile The following graphs show the affect of selected power levels on heating performance in a variety of situations Each example contains 1 optimal and 1 or 2 less optimal
56. t ON When Ramp to Setpoint is OFF the controller heats to the entered setpoint at the fastest rate possible When Ramp to Setpoint is ON the controller heats at the user entered ramp rate The Ramp to Setpoint feature and its associated parameters are turned on and set in the controller s programming mode The parameters of importance are SPrr SetPoint Ramp Rate Allowable Values 0 to 9990 deg Hr This specifies the desired rate of heating cooling Note this parameter specifies the desired rate of heating cooling but in cases of extremely high ramp rates the reaction will not actually heat faster than the power of the heater will allow SPrn SetPoint Ramp Run Allowable Values ON OFF Hold This parameter turns the Ramp to Setpoint feature ON or OFF During an active run if this parameter is set to Hold the setpoint ramp stops and holds at its current value This continues until the parameter is set to ON or OFF When set to OFF the values in SetPoint Ramp Rate and Soak Time are ignored SOAK Soak Time Allowable Values 0 to 1440 min This specifies the amount of time to soak at the setpoint after the setpoint temperature ramp is complete A setting of causes the controller to remain at the final setpoint indefinitely A numeric value causes the controller to stay at the setpoint for the entered time and then turn power to the heater off after the time expires Important Points to Know 1 While
57. t from the heating tape the thermocouple with a heating tape should sense the column temperature not the heater temperature Wrap the HPLC column completely with heating tape The thermocouple needs to be shielded from transient hot and cold air currents Don t Oven place the thermocouple near the heating coil or an air vent A small thermocouple 1 16 or 1 8 thermocouple that responds rapidly to changes in air temperature is better than a larger one Section 3 Operations Guide 3 1 Front Panel Description It s important to remember that this controller has two completely independent controllers in a single cabinet The description of the operating characteristics of one channel are identical to those of the second channel No setting on Channel 1 affects Channel 2 and visa versa 13 Serial connection on back 8 5 12 9 m 6 2 3 j Push to Turn to Channel 2 Select M Set Time T d J KEM scientific MODEL APOLLO 11 Figure 1 NOTE The controls for Channel 1 and Channel 2 are independent of each other The description of the controls for Channel 2 are identical to the description of those for Channel 1 presented below 1 Temperature Display Shows temperature of the process as the default display Shows set point temperature i e desired temperature when button is pressed 2 Control Key When pressed the display shows the set point temperature To decrease or increase the set point press
58. ter Hours To immediately exit a timed run hold in the timer knob for 1 second 15 Heating for a Set Period of Time In this mode the user enters the amount of time to heat before turning heating off permanently This is useful to heat a reaction or other lab instrument for a ON at Zero OFF at Zero set period of time and then have the reaction stop heating automatically While at this setting and while entering a time into the timer no power is applied to the heater Step 1 When the timer displays toFF holding in the timer knob causes the display to change to a clock showing 00 00 The left 2 digits are hours and the right 2 digits are minutes The minutes digits are blinking which indicates that their value can be changed Step 2 To increase the number of minutes rotate the timer knob to the right To decrease the number of minutes rotate the timer knob to the left Step 3 To change the number of hours in the display momentarily press the timer knob 1 4 second and the hours digits begin to blink To increase the number of hours rotate the timer knob to the right To decrease the number of hours rotate the timer knob to the left Step 4 When the desired time is displayed hold in the timer knob for 1 second to enter the time and start the timer When the timer starts the LED under the label OFF at Zero lights This indicates that power to the heater will turn OFF when the timer counts down to zero
59. the V key 3 or A key 4 while simultaneously pressing the control key The set point appears as a blinking number in the display 3 Lowers set point when x button 2 is simultaneously pressed 4 Raises set point when x button 2 is simultaneously pressed 5 Controller On Off switch For maximum accuracy of the displayed temperature turn on controller 30 minutes prior to use WARNING Due to the nature of solid state relays a small amount of output power 7 5 mA 120 VAC 0 9 watts is present at outlet 6 even when the controller is turned off Take appropriate precautions to avoid electrical shock 10 10 11 12 13 Power Outlet Plug only 120 VAC devices into this outlet see Section 3 2 7 Temperature Sensor Input Use the same type of sensor probe as the sensor plug installed on the controller see Section 3 4 The correct sensor type will have the same color plug as the receptacle 7 on the front of the controller Thermocouple Input The temperature sensor for the process plugs in here The thermocouple of the correct type must be used or incorrect temperatures will be displayed Thermocouples are color coded so the male plug on the end of the thermocouple must be the same color as the receptacle on the front of the controller Type V thermocouples are blue type J are black and type K are yellow Timer Display The timer display always shows the status of the timer circuit see Section
60. tunE appears in the display then let go of the buttons controller to ON OFF mode While holding in the key press the V key until the word on of appears The controller can be set back in the display NOTE if the display shows the letter A when the keys is to PID control by following held in press the A key until on of is in the display then let go of all the Procedure 1 in Section 3 9 To keys completely reset the controller Press the A key until the word bAnd appears in the display While holding to original factory settings in the key press the V key until the value 0 1 appears in the display follow the procedure in the then let go of all the keys Appendix Section II 5 Press and hold in both the V and A keys on the front of the controller until the temperature is displayed then release both keys 22 3 12 Troubleshooting Corrective Action Large over shoot of the set Output power level is set too high Set the output power level to a lower setting see Section 3 6 point gt 39 during initial warm up or unstable temperature control Controller is not tuned for process Tune the controller as outlined in Section 2 3 6 power KEM on Circuit breaker on back has tripped Allow unit to cool and reset circuit breaker The controller comes on but The timer controls are set Change the position of switch 8 or enter a time into the timer See
61. umber of degrees of variance High Temperature the highest temperature since the logging option was turned on While holding in the key press the A key once and the display will alternate between hi and the highest recorded temperature Low Temperature While holding in the key press the A key once and the display will alternate between Lo and the lowest recorded temperature The High and Lo temperatures can be examined as often as you like since updating and monitoring continues until the monitor is stopped by turning the controller off 4 Press and hold in both the V and A keys until the temperature appears in the display then release both keys a Press and hold in both the V and A keys on the front of the temperature meter until the word tunE appears in the display then release es a 21 Table 1 Tuning Parameters for Various Heaters Fill in values determined for your equipment for quick reference Proportional Integral Time Derivative Time Derivative Band Reset Rate Approach Cont Cycle Time Instrument bAnd int t dEr t dAC CyC t Heating Mantles Factory Default 10 10 50 5 30 pom voommovn d pom 28 Appendix I Using the Controller With an Oil Bath Application Note 1 Using your 200 Series controller with oil baths rated for less than 120 volt operation is not recommended J KEM manufactures a 400 Series controller desig
62. ution being heated Thermocouples can be bent without harming them If you re heating a corrosive liquid use Teflon coated thermocouples If you are heating a sealed reaction see Section 4 2 Set the power level switch to the volume of 10 100mi 50 500ml TIP Because the power switch acts 2 solution being heated 10m 5300mb2L like a variac if the reaction is heating not the size of the flask being used The Heat i g too slowly or you need more power power level switch can be thought of as a off gt 2L e g heating to high temperatures solid state variac Volume ranges are printed give the heater more power by above this switch as a guide to select the Mea turning the power level up one correct power level since it s easier to guess setting If the reaction needs less the volume being heated than the appropriate power than normal e g heating to percent power to apply to a heater Heat Off turns off the heater so the controller A power is equivalent to setting of a variac setting of low temperatures lt 60 C or the l temperature overshoots the set point displays temperature only All new users 1 10 ml T aE tas O a should read Section 3 5 nae 7 eae HONOIe Geass 300 ml i a 50 switch on a setting too high initially SIL 100 to heat the reaction quickly and then lower it to the correct setting this degrades heating performance Enter the setpoint i e the desired temperature
63. while at the same time not overpowering it 17 Heating Liquids Each power level is associated with a Front Panel Approx of volume range that acts as a guide when heating solutions Volume Range Full Power with heating mantles When solutions are heated with 1 10 mL 3 heating mantles set the power switch to the range that 10 100 mL 10 includes the volume of solution being heated Note this 50 500 mL 25 switch is set to the volume of solution not the size of the 300 ml 2L 5 flask For example to heat 250 ml of toluene to 80 C in a 1 L round bottomed flask choose the third power setting 50 500 ml since the solution volume falls within this range There are situations when a power level other than that indicated on the front panel should be used Power Setting Explanation 80 ml toluene 50 500 ml Organic solvents heated to 50 110 C are set to the volume 100 ml flask 25 power range on the front panel When choosing between 2 power 100 ml heating mantle settings i e 80 ml also falls within both the 10 100 ml range SP 80 C and the 50 500 ml range choose the higher setting 80 ml collidine Even though the solvent volume is less than the range of this 100 ml flask 300 ml 2 L power setting it should be used because high temperatures 100 ml heating mantle 50 power require additional power SP 170 C 80 ml water While the setting 50 500 ml would work since the heat 100 ml flask 300 ml 2

Apollo Dual Channel Temperature Controller User`s Manual

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