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Model 270 Manual - J

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1. Temp oC 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 soren Power Setting 300 ml 2 L i e 50 power 20 0 10 20 30 40 50 60 70 Time min Set point 155 C 170 Power gt 2L y SSES ie 100 power 145 ih Set point 100 C 7 Power 300 ml 2 L oc a ca 50 power 95 70 Conditions H m ae Set point 45 Power 50 500m 500 ml heating mantle 25 power M 25 power 20 0 10 20 30 40 50 60 70 Time min Graph 2 This graph shows the affect of different power settings when heating liquids with heating mantles The 10 100 ml setting 10 power 1s under powered 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 Graph 3 Another factor affecting the choice of power setting is the set point temperature For set points near room temperature a low power level is adequate For average temperatures 50 100 the volumes printed on the front of the controller is a good guide For high temperatures the next higher power setting might be needed to supply the heater with additional power The power reduction circuit limits the total amo
2. StoP when the soak time has expired to indicate that power has been turned off To exit programming mode press and hold in both the W and keys until the temperature appears in the display then release both keys Deactivating the Ramp to Setpoint Feature Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys l 2 Press the 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 Y or M 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 W and 4S keys until the temperature appears in the display then release both keys 13 3 4 3 5 Temperature Sensor Input Each controller is fitted with a specific type of temperature sensor input and can only be used with a temperature sensor of the same type thermocouple or RTD 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 The thermocouple plug on the left is connected to the
3. se Ramp to Setpoint amp Soak Feature A new feature of J KEM s controllers called Ramp To Setpoint allows the controller to heat at a specific heating rate e g heat to 120 C at a rate of 5 C Hour a second feature called Soak allows the controller to be programmed to stay at that temperature for a user specified period of time before turning off NOTE This feature is functional on the Setpoint Controller only not on the Limit Controller Examples of Program Ramps Ramp Temperature Power Off eh NY Q ao 2 5 Power Off Temperature Time Time The controller is shipped with the Ramp to Setpoint feature OFF the user must specifically turn Ramp to Setpoint 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
4. easier to guess the volume being heated than the appropriate percent power to A power is equivalent to or the temperature overshoots the set apply to a heater Heat Off turns off S tms oh avariac setting of point excessively turn the power down the heater so the controller displays 1 10 ml 3 one setting DO NOT set the power temperature only All new users should 10 100 ml 10 switch on a setting too high initially to read Section 3 5 50 500 ml 25 heat the reaction quickly and then lower 300ml 2L 50 it to the correct setting this degrades gt 2L 100 heating performance 4 Enter the setpoint i c the desired temperature Hold in the button and simultaneously press the X key to increase or the W key to decrease the setpoint The setpoint can be seen at anytime by holding in the i j button the setpoint appears as a blinking number in the t display KEM Net Data Logging and Control Software The USB port on the back panel of the controller is an interface to J KEM s KEM Net Software KEM Net is free and can be downloaded from J KEM s web site at www jkem com KEM Net provides remote control of up to 8 controllers graphical presentations of each digital meter and time amp temperature plots Highlights of KEM Net include GLP and GMP compliant data logging Runs a 12 step temperature ramp Eh J KEM Scettific KEM Net Logging of Time and Temperature Logging of Power for Exo a
5. see Section 3 5 Turn the controller and heater on and then enter the desired set point temperature Enter a temperature in the Limit Controller meter about 25 C higher than the set point entered into the Setpoint Controller meter Press and hold in both the 8 and Y 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 button 5 times until CyC t appears in the display if you go past this setting press the W button until you get back to it First hold in the button while holding in the button press the button Continue to hold both buttons in until the display reads A or A where HE is some number Release the button and press the Y 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 button to change the display to At SP and release both buttons Press and hold both the 4X and Y 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
6. First hold in the key then while holding in the key press the W or key until the value 30 appears in the display then let go of all the keys Press and hold in both the W and keys until the temperature appears in the display then release both keys 4 Press the 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 W or key until the value 50 appears in the display then let go of Heater Restrictions The controller delivers 15 amps of current at 120 VAC into resistive loads heating mantles hot plates ovens etc Use only resistive loads that are safely operated at 120 VAC and require less than 15 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 1200 watts Set the power reduction circuit Infrared heaters to the gt 2 L position The controller must be programmed for this use Request application note AN5 Inductive loads 6 amps 720 watts solenoids transformers motors 1 3 horsepower Fusing The contro
7. Saletan iaa 6 2 Autotuning Procedure ww eee R E 7 2 3 Tuning for Heating Mantles A Special Case 9 2 4 Sensor Placement isere eir E See eee Bolte E 9 3 OPERATIONS GUIDE 3 24 23 2254 es the heat coh eee aah 10 3 1 Front Panel DesctipUon sins oy dared noes 6 eee at e E 10 32 Setting the Controller for Safe Operation 11 3 3 Ramp to Setpoint amp Soak Feature ccc cee eee 12 3 4 Temperature Sensor Input 244 2 44wees eeu Cad heh eae Pee wes 14 3 5 Power ReducuomCucutl a 0 3 2404cadsauos oeoenbacwe dese kvaen 14 3 6 Affect of Power Setting on Heating Profile 15 aa Do s and Don t s When Using Your Controller 17 3 8 Changing the Temperature Display Resolution 17 3 9 Resetting the Controller for Use With Heating Mantles 18 S10 Heater ReSmicuOns sitius de ecdaucdeeedeus ducoaldaiseceteuaas 18 Sula FUSING todace ddan Ak ieu ae eens wee eee oo a oe e 18 3 12 Changing between PID and ON OFF Operating Modes 19 19 6 TrowbleshOOUne ssrersre Servnn aos eae he ae GAS SON we eee eas 20 a APPLICATION NOTES s44640052 4864c0s25ueu wen tebe toe nehoou aes 21 4 1 Theory of How the Controller Works Simply 21 4 2 Controlling the Heating Mantle Temperature Directly 22 4 3 Automatic Storage of Min Max Temperatures 05 23 4 4 How to Set Up a Reaction With Your Temperature Con
8. both keys 17 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 W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys 3 10 3 11 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 W or key until the value 10 appears in the display then let go of all the keys Press the key once and the word int t will appear in the display First hold in the key then while holding in the key press the W or key until the value 10 appears in the display then let go of all the keys all the keys Press the key once and the word dAC will appear in the display First hold in the key then while holding in the key press the W or key until the value 3 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
9. heaters such as heating mantles 5 overshoot but it s terrible for heaters that transfer heat slowly vacuum ovens heating blocks etc In PID mode the controller monitors the shape of the PID Mode heating curve during initial warm up and decreases a mere power to the heater before the set point is reached so eas that the solution reaches the set point with minimal P 3 over shoot Notice that the heater turns off for varying periods of time before the set point temperature is reached The second feature of PID mode is that it adjusts the percent of time the heater is on so that the set point is maintained precisely The advantage of PID mode is that it delivers stable t Time temperature control with any heater from heat lamps to vacuum ovens 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 the procedure in Section 3 9 Temp Set Paint Power f to heater 1 Press and hold in both the and keys on the front of the temperature Procedure to change ia until the word tunE appears in the display then let go of the controller to ON OFF mode uttons 3 Whi
10. over temperature meter should never be changed changing the parameters of the over temperature meter will compromise the safety features of your controller This procedure should only be performed on the setpoint meter Do not change the parameters in the over temperature meter Press and hold in both the W and keys on the front of the setpoint temperature meter until the word tunE appears in the display then release both keys Press the Y key until LEVL appears in the display Next hold in the key then while holding in the key press the key until 3 appears in the display Let go of all the keys Press the key until rSEt appears in the display Next hold in the key then while holding in the key press the 8 key until the word All appears in the display Let go of all the keys Press and hold in both the W and 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 ie Yellow type K tee Black type J te 1 First hold in the key then while holding in the key press the key until the value from the table above appears in the display Let go of all the keys NOTE Many of the patterns for t
11. 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 12 Important Points to Know 1 While 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 Setting a ramp rate doesn t 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 3 Once the Ramp to Setpoint feature is activated in programming mode it remains on until it s de
12. 1 8 thermocouple that responds rapidly to changes in air temperature 1s better than a larger one Section 3 Operations Guide 3 1 Front Panel Description 1 10 9 12 Serial Comm Port on back J KEM Scientific inc sa 50 5000 3 gt rae 10min 300 m 2 Ln __Instruments for Scientists from Scientists ne 3 7 D E Heat mf 3 or ES y i LU Anniversary LU Anniversary E s gt A 8 2 Edition Edition Ram p To Setpoin Ramp Tt Setpoint Limit Clontrollerg a Figure 1 J KEM highly recommends that all users read Section 4 4 How to Set Up a Reaction with J KEM Scientific s Digital Temperature Controller prior to using the controller for the first time 1 Temperature Display Shows temperature of the process as the default display Shows set point temperature i e desired temperature when button is pressed PA Control Key When pressed the display shows the set point temperature To decrease or increase the set point press the W key 3 or key 4 while simultaneously depressing the control key The set point appears as a blinking number in the display 3 Lowers the set point when button 2 is simultaneously pressed 4 Raises the set point when x button 2 is simultaneously pressed 5 Limit Controller sets the temperature that causes the over temperature circuit to activate disconnecting power from outlets 8 see Section 3 2 Indicates an over temperature condition wh
13. 5 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 allowing 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 11 serves just this function It allows the researcher to reduce the power of the controller depe
14. Controller loaded with tuning parameters for heating mantles 40 30 20 0 10 20 30 40 50 60 Time min 2 2 It s important to understand that this controller isn t a simple ON OFF type controller i e ON when below the set point OFF when above though it can be made to work this way see Section 3 12 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 incorrectly describe the heater being used poor temperature control will result But when the correct values are loaded temperature regulation of 0 1 is 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 procedu
15. Next hold in the key then while holding in the key press the Y or A key until the value 9600 appears in the display Let go of all the keys Press the 8 key and dAtA will appear in the display Next hold in the key then while holding in the key press the W or key until the value 18n1 appears in the display Let go of all the keys Press and hold in both the W and M keys until the temperature appears in the display then release both keys The word PArk in the display will go away when a set point is entered 31
16. 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 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 314 863 5536 FAX 314 863 6070 E Mail jkem911 jkem com Internet Catalog http www jkem com This manual contains parameters specific to temperature controller Serial When calling with a technical question please have the controller s 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 Il ever encounter If the information in this User s 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 2 1 Wats TUNDE sis deter apes today dodo Satis vb ec Geos bhi ddan
17. Setpoint Controller and that on the right to the Limit Controller If the thermocouple to either unit becomes broken or disconnected the controller displays an error message and stops heating Rather than using one dual element thermocouple 2 single element thermocouples can be used if desired Power Reduction Circuit This circuit 11 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 The table to the right shows the maximum output power from the Front Panel Approx of controller to the heater depending on the position of the power Volume Range Full Power switch A new power setting was added to this circuit that is not Tey setting to the left labeled on the front of the cabinet The new setting is 1 click grine 1 10 ml setting 0 to the left of the 1 10 ml setting and is power off In this 1 10 mL 3 position the controller doesn t heat but acts as a digital 10 100 mL 10 thermometer The correct setting for this switch 1s the setting 50 500 mL 25 that supplies adequate power for the heater to heat to the set point in a reasonable period of time while at the same time not 3 Er L overpowering it See Section 4 4 for a detailed explanation of how to correctly set up a rea
18. Temperature Control for Research and Industry Model 270 Manual KEM Scientific Inc Instruments for Science from Scientists g T O T SPSS SPREE SPEER SPHERES SS TERESE TEE TPP PUPP CCLRC Te Te eee PRTC COREL OP Tree iri titre irri ttre PO TURTLE TTT ee Teer Ter errr rrr rier erecta TC RR TEL Pee eee eee er Tere er er 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 10 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
19. activated in programming 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 Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the 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 P or M key until the desired ramp rate appears in the display then let go of all the keys Units are in degrees hour Press the 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 P or M 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 O First hold in the key then while holding in the key press the P or M 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
20. all keys gt Press the key once and the word dAC will appear in the display While holding in the key press the Y or key until the value 5 0 appears in the display then release all keys 1 Press the A key once and the word CyC t will appear in the display While holding in the key press the Y or key until the value 5 0 appears in the display then release all keys a aa Press and hold in both the W and 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 procedure must be started every time you want to record temperatures Procedure to Start Temperature Logging Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the Y key once and the word LEUL appears in the display While holding in the key press the key until the value 3 appears in the display then release all keys Press the key until the word ChEy appears in the display While holding in the k
21. button until you get back to it 6 First hold in the button while holding in the button press the W button Continue to hold both buttons in until the display reads A or A P where is some number 7 Release the button and press the W 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 9 While holding in the button press the button to change the display to on then release both buttons 10 Press and hold both the 4 and Y 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 displaying tunE and only displays the process temperature To abort autotune manually repeat steps 4 9 and 10 except in step 9 press the Y button until off is displayed Point Temp New tuning values loaded into memory The autotune sequence a t During autotune the controller heats to newparameters 75 of the set point temperature where it 75 of O51 0S2 N oscillates for several cycles before loading set point Start the new tuning parameters After the tuning parameters are loaded it heats
22. corded temperature The High and Lo temperatures can be examined as often as you like since updating and monitoring continues until the monitoring is stopped by turning the controller off 4 Press and hold in both the W and keys until the temperature appears in the display then release both keys 23 4 4 How to Set Up a Reaction with J KEM Scientific s Digital Temperature Controller This application note shows how to set up a typical heated reaction using J KEM Scientific s digital temperature controller For this example the Model Gemini controller is used but the application note applies equally well to all J KEM temperature controller models If you have questions about specific models of temperature controllers or any safety related question please feel free to contact J KEM Scientific This application note does not supercede any information in the Controllers actual User manual The User manual for each model is always the reference for that model The Model Gemini is a dual channel controller that allows two independent reactions to be run on the same controller one reaction on Channel and the second on Channel 2 In this example we will only use channel 1 Gemini Dual Channel Temperature Controller Thermocouple receptacle Channel 1 has a 100 hour to turn heating On Off at a user set time Channel 2 does not have a timer Thermocouple Thermocouple extension cord 24 Thermocouples Thermo
23. couples are color coded When the plastic connector on the end of the thermocouple is blue it is a type T thermocouple when it is yellow it is a type K and when it is black it is a type J The color of the thermocouple the thermocouple extension cord and the thermocouple receptacle on the face of the controller must all be the same color 1 e thermocouple type or the controller will not read the correct temperature Thermocouples are available in many different styles As long as the thermocouple has the same color connector as the connector on the controller they are 100 compatible Stainless steel no Teflon coating 12 inch length Teflon coated Bend Tatlon coaied 6 inch length Teflon coated Temperature sensitive end hypodermic needle of the thermocouple When a thermocouple is placed in solution often it is desirable to bend the thermocouple slightly so that more of the tip extends into the solution It does not hurt a thermocouple to be bent slightly The temperature sensitive portion of a thermocouple is the first 4 of the tip It s good for the first 2 to be is solution but the first 1 4 must be in solution to read the temperature correctly Heaters Your J KEM controller works with virtually any 120 volt or 230 volt heaters outside of the USA heater including any size heating mantle 120 vac oil baths hot plates ovens and many other style heaters If you have questions about the compatibility of spec
24. ction using your J KEM controller Heating Liquids Each power level is associated with a volume range that acts as a guide when heating solutions with heating mantles When solutions are heated with heating mantles set the power switch to the range that includes the volume of solution being heated Note this switch is set to the volume of solution not the size of the flask For example to heat 250 ml of toluene to 80 C in a 1L 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 by 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 100 ml flask 25 power volume range on the front panel When choosing between 2 100 ml heating mantle power settings i e 80 ml also falls within both the 10 100 ml SP 80 C range 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 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 settin
25. displays the process temperature To abort autotune manually repeat steps 4 9 and 10 except in step 9 press the button until off is displayed 2 3 2 4 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 under powered 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 unnecessary 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 are using a heating mantle and none of the parameters have been changed or the controller hasn t been autotuned since you ve rec
26. eating 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 until the range coil cooled down This problem of overshooting the set point during initial warm up is the major difficulty with process 21 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 4
27. ects of temperature control including heating cooling maintaining the temperature tuning etc The desired solution or process temperature is entered into this controller This is the meter that the desired reaction temperature is entered into This meter is equipped with ramp to setpoint and soak feature see Section 3 3 Limit Controller The over temperature meter The meter on the right labeled Limit Controller is the over temperature meter The only purpose of the Limit Controller is to turn power off if the reaction temperature reaches the temperature limit entered into this meter The Limit Controller acts as a backup controller or watchdog for the Setpoint Controller the meter that regulates reaction temperature Setting up an experiment with the Model 270 is quite simple Place the dual element thermocouple in the process to be heated and turn the controller on Enter the desired temperature into the Setpoint Controller for example 80 C then a slightly higher temperature into the Limit Controller for example 85 C Press the reset button 9 The Setpoint Controller will heat the process to 80 C where it will maintain it indefinitely The only time the Limit Controller comes into play is 1f for whatever reason the temperature of the process rises to 85 C at which point power is removed from outlets 8 Also in the event of a power failure when power is restored the Limit Controller removes power from the
28. eived 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 a 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 it 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
29. em Set Point 115 C __ to the correct power level your 2 Lof N N dimethylformamide n 3 L Round Bottomed Flask controller can regulate virtually any ical ial heater to 0 1 C with less than 1 C overshoot on initial warming Test System Set Point 85 C Standard Lab Oven Temperature C Test System Set Point 55 C 12 mL of THF 25 mL Round Bottomed Flask 25 mL Heating Mantle Time min 30 For a detailed explanation of the Power Control Computer see Section Two in the controller s User manual 27 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 designed for use with oil baths rated for any voltage and 1s 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 Instatherm oil baths The two largest baths Catalog s INS 150 and INS 160 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 cont
30. en lit See Section 3 2 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 has the same color plug as the receptacle 7 on the front of the controller To operate properly the receptacle on the left connected to the Setpoint Controller and the one on the right the Limit Controller must each have a thermocouple attached Power Outlet Plug only 120 VAC devices into this outlet See Section 3 10 Over Temperature Reset Switch Press button to reset the over temperature circuit The temperature on the limit controller 5 must be above the present reaction temperature to reset this circuit 10 Controller On Off switch For maximum accuracy of the displayed temperature turn on the controller 15 minutes prior to use 11 Power Reduction Circuit Limits the maximum power to the heater See Sections 3 5 and 4 1 12 USB serial communication port 10 3 2 Setting the Controller for Safe Operation Two completely separate controllers are contained in the J KEM Model 270 and it s important to understand what each controller does in order to take full advantage of the Model 270 s safety benefits Setpoint Setpoint Controller The meter that controls reaction temperatures Controller oC The meter on the left labeled Setpoint Controller is the main temperature controller 80 0 and is responsible for all asp
31. ey press the key until on appears in the display then release all keys Hold in both the W and 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 key until the word off appears a Procedure to Read Minimum and Maximum Temperatures Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release ed both keys Press the Y key once and the word LEUL appears in the display While holding in the key press the key until the value 3 appears in the display then release all keys Press the 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 number of degrees of variance High Temperature the highest temperature since the logging option was turned on While holding in the key press the 8 key once and the display will alternate between hi and the highest recorded temperature Low Temperature While holding in the key press the key once and the display will alternate between Lo 9 and the lowest re
32. f the digital meter 2 While holding in the Star button press the Up arrow to increase and the Down arrow to decrease Star button Up to increase and Down to decrease arrows the setpoint temperature When the desired setpoint temperature is showing in the display release the star button to load the setpoint When no buttons are pressed on the controller the controller shows the temperature sensed by the thermocouple When the Star button is pressed the setpoint appears as a blinking number 5 Set the correct Power Control Level Your J KEM controller has a built in Power Control Computer PCC that precisely regulates power to the heater For the computer to work correctly it must know the volume of solution that is being heated It s important to understand that the PCC is set to the Volume of solution being heated not the size of the heater or the size of the flask 10 100 mi 50 500 mi 1 10 mI X 300 ml 2 L Heat PN Power Level 15 ml of solution in a 100 ml flask 75 ml of solution in a 100 ml flask If the flask above is placed ina The power control computer is If the flask above is placed in a 100 ml heating mantle the always set to the Volume of 100 ml heating mantle the power control input should be solution being heated not the power control input should be set to the 10 100 ml setting size of the flask or heater set to the 50 500 ml setting m When the power control computer is set Test Syst
33. g can be used to SP 80 C compensate for the higher heat capacity 125 ml toluene When the heating mantle size is substantially larger 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 14 3 6 10 20 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 guess 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 sett
34. hile holding in the key hold in the Y 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 48 key until 3 appears in the display Let go of all the keys Press the key until ZEro appears in the display Next hold in the key then while holding in the key press the Y or key appears in the display Let go of all the keys First hold in the key then while holding in the key press the W key until 1 appears in the display Let go of all the keys Press the key until SEt 2 appears in the display Next hold in the key then while holding in the key press the or W keys until the value 5 0 is entered Let of go of all keys If your controller does not have a USB port on the back skip to step 31 Press the W key until the word LEVL appears in the display First hold in the key then while holding in the key press the W key until C appears in the display Let go of all the keys Press the 8 key and Addr will appear in the display Next hold in the key then while holding in the key press the Y or key until the value 1 appears in the display Let go of all the keys Press the 8 key and bAud will appear in the display
35. hipment 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 If the 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 effects of tuning are 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 1 70 60 Temp 50 Conditions 100 ml Toluene 50 ml Round bottomed flask 250 ml Heating mantle Power Setting 50 500 ml 40 30 20 0 10 20 30 40 50 60 Time min Plot 2 80 70 Curve 2 Controller loaded with tuning parameters for drying oven 60 Temp 50 Curve 1
36. his meter is the back up meter for Controller Button This resets the over the main temperature controller Set this meter about 5 C higher than that entered in the main controller in Step 5 If the reaction reaches this temperature for any reason heating is automatically discontinued until manually reset See Section 3 2 temperature circuit and prepares the controller for use The probe temperature must be below the temperature of the limit controller on the left for this circuit to reset P Place the thermocouple in the solution being heated Place at least the first 1 4 of the thermocouple directly in the solution 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 3 Set the power level switch to the 10 100 mi 50 500 mi TIP Because the power switch acts like volume of solution being heated iiom 300 mi2L o if the De is heating too not the size of the flask being used The N F z e yer set more power e power level switch can be thought of as or ee Ay 72 eating to hig temperatures give the a solid state variac Volume ranges are A heater more paws by turning a ea printed above this switch as a guide to Output Power Level level up one setting If the reaction needs less power than normal e g heating to low temperatures lt 60 C select the correct power level since it s
37. his parameter look similar be careful to select the exact pattern shown above Press the 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 0 C appears in the display Let go of all the keys Press the X key once and the word SP1 d appears in the display Next hold in the key then while holding in the key press the 48 key until the value SSd appears in the display Let go of all the keys Press in both the W and keys until the temperature appears in the display the word PArk also appears and release both keys Press and hold in both the W and 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 Next hold in the key then while holding in the key press the 48 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 48 key until the value 10 appears in the display Let go of all the keys Press the X key once and the word dEr t will appear in the display Next hold in the key then while holding in the key press the 48 key until the value 50 appears
38. ific heaters please contact j KEM 1 liter heating mantle Oil bath 10 ml heating mantle 25 Classes of J KEM Scientific Temperature Controllers J KEM s 200 Series Apollo and Gemini controllers are compatible with any size heating mantle from 5 ml to 50 liter and any 120 Vac oil bath do not use with oil baths rated less than 120 Vac J KEM s 150 Series economy controllers are compatible with 500 ml heating mantles and larger and 120 Vac oil baths do not use with oil baths rated less than 120 Vac J KEM s 230 Vac controllers are compatible with any 230 Vac heating mantle 100ml and larger They are not compatible with any size oil bath Shown is a typical set up for a solution phase reaction 1 Place the reaction flask in the appropriate size heating mantle then plug the power cord from the mantle directly into the power outlet of the temperature controller 2 Place a stirring bar inside of the flask in the solution Place the flask on a magnetic stirrer and stir the reaction for good heat transfer 3 Place a thermocouple in solution and make sure that at least the first 1 4 1 2 is better is covered by the fluid in the reaction flask Heater power cord 26 4 Enter the temperature that you want to heat the reaction to 1 e the Setpoint into the digital meter To enter the setpoint temperature 1 e the temperature to heat to into the controller 1 Hold in the Star button on the face o
39. 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 48 key until the value 3 0 appears in the display Let go of all the keys Press the X 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 48 key until the value 30 appears in the display Let go of all the keys Press the key until the word SPrn appears in the display Next hold in the key then while holding in the key press the Y or key until the word OFF is displayed Let go of all the keys First hold in the key then while holding in the key press the 48 key until 2 appears in the display Let go of all the keys pd pd pd pd Press the key until SP2 A appears in the display Next hold in the key then while holding in the key press the 8 key until the word Dvhi appears in the display Let go of all the keys 30 Press the key until diSP appears in the display Next hold in the key then while holding in the key press the Y or key until the value 0 10 appears in the display Let go of all the keys Press the key until Lo SC appears in the display Next hold in the key then w
40. ing 1 e 50 power it s usually better to have too much power rather than too little If the heater heats too slowly 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 6 shows the type of performance you should expect from the controller with different pieces of equipment Effect of Power Setting on Heating Profile The following graphs show the effect of selected power levels on heating performance in a variety of situations Each example contains 1 optimal and 1 or 2 less optimal settings demonstrating use of the power reduction circuit Graph 1 This graph shows typical Conditions Set point 75 C heating profiles for a laboratory Laboratory oven 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 Conditions Set point 45 C a smooth heating curve The HPLC Column wrapped with heating tape gt 2L power setting is too much Power Setting 50 500 ml power and results in oscillation around the set point Power Setting 50 500 ml Power Setting gt 2L 0 10 20 30 40 50 60 70 Time min 15 80 70 60
41. le holding in the key press the W key until the word on of appears in the display NOTE if the display shows the letter A when the keys is held in press the key until on of is in the display then let go of all The controller can be set back to the keys PID control by following the 4 Press the W key until the word bAnd appears in the display While procedure in Section 3 9 To holding in the key press the W key until the value 0 1 appears in the completely reset the controller to display then let go of all the keys original factory settings follow 5 Press and hold in both the 48 and W keys on the front of the controller until the procedure in the Appendix the temperature is displayed then release both keys Section IT 19 3 13 Troubleshooting CorrectiveAction Large over shoot of the set point Output power level is set too high Set the output power level to a lower setting see Section 3 5 being heated 3 5 power KEM The controller comes on but The heater is broken To verify that the controller is functioning properly place the does not heat 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 and wait 1 minute If the light comes on the controller is working properly The 15 amp fuse has blown Replace blown fuse See Section 3 11 The over temperature protection Set the Limit Co
42. ller is protected by two fuses The first protects outlets 8 and is a fast acting fuse designed specifically to protect solid state relays This is the larger fuse on the back panel of the controller If this fuse is replaced IT MUST BE REPLACED BY AN EXACT EQUIVALENT a Tron KAA 15 or Bussman KAX 15 One of these fuses or an exact equivalent must be used or a significant safety hazard will be created and will void the warranty The second fuse protects the Setpoint Controller and is the smaller fuse on the back panel of the controller This can be replaced with any fast acting 3 amp fuse 18 3 12 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 a ON OFF Mode controller is ON when it s below the set point and ae os OFF when above The disadvantage of this mode Set 4 Point is a large over shoot of the set point 5 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 Power method works well for heaters that transfer heat to heater erica rapidly such as heat lamps it s acceptable for
43. n 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 3 8 Changing the Temperature Display Resolution The controller is programmed to display temperature with 0 1 C resolution 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 in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the YW key once and LEVL appears in the display First hold in the key then while holding in the key press the key until 2 appears in the display then let go of all the keys Press the key repeatedly until the word diSP appears in the display First hold in the key then while holding in the key press the Y or 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 W and keys until the temperature appears in the display then release
44. nd Endotherm detection Program KEM IO Actions Section 3 10 Over amp Under temperature alarm functions KEM Net also includes a virtual comm port driver that provides a simple ASCII interface to operate and data log the controller from LabView or other software packages New Features GMP compliant data logging Exo and Enotherm monitoring KEM IO Remote Control of Laboratory Equipment based on Time and Temperature KEM IO is an optional feature that allows the controller to respond to inputs from instruments like a vacuum sensor or a hood door switch and also to control instruments like stirrers and chillers based on reaction temperature KEM IO automates programs as simple as Heat my reaction to 80 C then turn on my peristaltic pump to add reagents or as sophisticated as Turn on my stirrer then ramp my reaction from 25 C to 100 C if 45 minutes hold for 2 hours then turn off heating When the reaction cools to 50 C turn off the stirrer If at any point the reaction exotherms and heats above 110 C turn on my chiller and keep it on until I manually reset the system Contact J KEM for additional information Section 2 2 1 Adjusting The Controller For Stable Control With Different Heaters NOTE The discussion is Section 2 only applies to the Setpoint Controller meter The Limit Controller is never tuned and has no affect on the Setpoint Controller meter What is Tuning The controller s most p
45. nding on the amount of heat needed This circuit can be thought of as determining whether the heating power is Very low 7 10 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 5 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 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
46. ng the controller for unattended fractional TAREA ANS Usine 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 100n 50 500nI Instruments forScience Limo _ 300mI 2L o Output Power Level 120 vac Power to heater Model 210 120 Vac 840 watts 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 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 h
47. nput 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 into the controller are those appropriate for heating typical organic reactions i 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 encounte
48. ntroller to a temperature higher than that shown circuit is engaged on the Setpoint Controller and press the reset button see Section FZ The switch on the bottom of the Move switch back to the inactive position If accessories are Input Output board must on the attached see User s Manual for the accessory inactive position gt 3 during initial warm up or unstable temperature control Controller blinks The temperature sensor is inPt FAIL unplugged excessively corroded or Clean or replace broken sensor broken 1 Hold in both the and Y keys on the front of the J KEM PArk Controller has been placed in Park temperature meter until tunE appears in the display mode 2 First hold in the key then while holding in the key press the W key until oFF appears 3 Hold in the 4X and keys until the temperature appears in the display tunE FAIL Displayed temperature is The display temperature reads low when the controller is first incorrect The controller has not warmed up 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 negative temperatures but are not Wrong type of thermocouple is Thermocouples are color coded Thermocouple plug and calibrated for them plugged into controller thermoc
49. ouple receptacle must be the same color see Section 3 2 connections sandpaper or steel wool discard thermocouple To enter a controller display offset Turn on controller Allow unit to warm up for 30 minutes Record displayed temperature Press both the 48 and W keys on the front of the temperature meter until tunE appears then let go of the keys Press the Y key until LEVL appears First hold in the key then while holding in the key press the key until 3 is showing in the display then let go of all keys Press the 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 Temperature display offset needed New Current Display display offset Displayed Correct Offset blinking in display temperature temperature First hold in the key then while holding in the key press the M or W keys until the new offset temperature is showing then let go of all the keys 10 Press the and keys until the temperature is displayed 20 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 Changing the controller s thermocouple type the heating outlet into a cooling Usi
50. owerful 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 5 and 2 that it must 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 instantaneously 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 s
51. r 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 29 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 original factory settings If you still have difficulty with your controller our Engineering department will help you resolve the 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 The Model 270 has both a setpoint meter and an over temperature meter The table below is the procedure to reset the setpoint meter only The parameters of the
52. re 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 Only the main Setpoint Controller the meter on the far left should be autotune the Limit Controller can not be tuned 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 Il go 2 Set the controller to the appropriate power level see Section 3 5 Turn 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 Enter a temperature in the Limit Controller about 25 C higher than the set point entered into the Setpoint Controller meter 4 Press and hold in both the 8 and Y buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons 5 Press the button 5 times until CyC t appears in the display if you go past this setting press the W
53. roller 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 small 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 28 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 parameter
54. s 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 The following deiscusson only applies to the Setpoint Meter not the Limit Controller 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 being 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 i
55. se outlets In either event power remains disconnected until being manually reset The operation of the Limit Controller can be verified at any time by entering a temperature lower than ambient which should activate the over temperature protection circuit indicated by light 6 coming on The Model 270 derives its unique safety advantages from its design in which the temperature sensing ability and action of the two controllers are completely independent of the other Considering the way the controller responds to different types of failures demonstrates the safety benefits of this construction If the Limit Controller fails closed the over temperature protection circuit is activated disconnecting all power to the heater If it fails open this has no effect on the temperature regulation of the Setpoint Controller which continues to maintain the desired temperature of the process If the Setpoint Controller fails closed the most dangerous failure mode i e uncontrolled full power to the heater the Limit Controller activates the over temperature protection circuit permanently disconnecting all power to the heater If the Setpoint Controller fails open the process simply cools to room temperature Since each controller has its own thermocouple a failure with either thermocouple results in the same scenarios as above The Model 270 provides complete 100 redundant control of the heating process for maximum safety of unattended operations 11 3 3 N
56. the controller for heating mantles For all other heaters see tuning instructions in Section 2 22 After the controller is reprogrammed place a fine gage wire thermocouple oo Sa 1 3 the size of kite string available from J KEM in the bottom third of se 77 E T the heating mantle and fit the flask snugly on top so that the thermocouple is 25 ml 10 100 ml in intimate contact with the heating mantle Set the power reduction circuit 50 ml 22 L 50 500 ml to the power level shown in the table at the right Turn the controller on and enter the set point For temperatures over 120 C the f next higher power level may be necessary Procedure to Load Tuning Parameters for External Thermocouples Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the key once and the word bAnd will appear in the display While holding in the key press the W or key until the value 5 appears in the display then release all keys Press the key once and the word int t will appear in the display While holding in the key press the W or key until the value 2 appears in the display then release all keys Press the key once and the word dEr t will appear in the display While holding in the key press the Y or key until the value 5 appears in the display then release
57. to the set point temperature Tuning below the set point prevents any damage that might occur from overheating T1 T2 T4 During T1 4 the controller measures heating delays and Quarter cycle times rates of heating and cooling 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 precedes this should normally be performed Only the main Setpoint Controller the meter on the far left can be autotuned the Limit Controller will not be tuned l 10 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 ll 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
58. troller 24 AFPENDIX ooperi e ea a tees ese et oe 28 I Using the Controller With an Oil Bath Application Note 1 28 I Safety Considerations and Accurate Temperature Control 29 IHI Resetting the Controller to Original Factory Settings 30 WARNING Adhere to the restrictions of SECTION 3 10 Failure to do so may create a significant safety hazard and will void the warranty Section 1 Quick Operating Instructions The five 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 For a primer on how to set up a reaction with your temperature controller See Section 4 4 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 Enter an Over Temperature limit Press the RED Reset Limit T
59. unt 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 and if it s getting too much power turn it down 16 3 7 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 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 Teflo

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