Model 410 User`s Manual
Contents
1. appears in the display if you go past this setting press the DOWN button until you get back to it 5 First hold in the button while holding in the button press the DOWN button Continue to hold both buttons in until the display reads A or A where is some number 6 Release the button and press the UP 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 UP button to change the display to on then release both buttons 9 Press and hold both the UP and DOWN 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 3 8 and 9 except in step 8 press the DOWN button until off is displayed New tuning Jem P values loaded into memory Point Heat to set point aferenterng The autotune sequence newparameters During autotune the controller heats 75 of 0s OS2 N to 75 of the set point temperature set point where it oscillates for2. CyC t appears in the display d 3 While holding in the key press the W key until the word on of appears moce in the display NOTE if the display shows the letter A when the keys is held in press the A key until on of is in the display then let go of all the The controller can be set keys back to PID control by 4 Press the W key until the word bAnd appears in the display While following Procedure 1 in holding in the key press the W key until the value 0 1 appears in the Section 3 7 To completely display then let go of all the keys reset the controller to 5 Press and hold in both the A and V keys on the front of the controller until original factory settings the temperature is displayed then release both keys follow the procedure in the Appendix Section II 17 Troubleshooting Corrective Problem 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 5 point Controller is not tuned for process Tune the controller as outlined in Section 2 being heated The process heats too slowly Output power level is set too low Increase the output power level to the next higher setting Section 3 5 The heater doesn t have enough Replace with a more powerful heater For assistance contact J power KEM The controller does not come Internal 2 amp fuse has blown Not user serviceable Have qualified elec
3. 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 V or A keys until the value 5 0 is entered Press the A key until Bnd 2 appears in the display Next hold in the key then while holding in the key press the W key until the value 0 1 is entered Press and hold in both the W and A 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 26
4. 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 25 II 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 or oil bath 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 Press and hold in both the W 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 until LEVL appears in the display Next hold in th
5. 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 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 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 then 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 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 low
6. all the keys Press in both the W and A keys until the temperature appears in the display the word PArk also appears then release both keys 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 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 15 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 5 0 appears in the display Let go of all the keys Press the A 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 A key until the value 15 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 4 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 14 appears in the display Let go of all the keys Press the A key until the wo
7. equation New Current Display display offset Displayed Correct Offset blinking in display temperature temperature First hold in the 32 key then while holding in the x2 key press the A or V keys until the new offset temperature is showing then let go of all the keys Press the A and W keys until the temperature is displayed 3 10 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 Don t remove either the thermocouple or heater from the solution without setting the power level to the Heat Off position As the thermocouple cools the controller turns the heater on Since this heat is never fed back to the thermocouple it heats continuously Don t 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 Do 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 Do place the thermocouple directly in the solution Place at least the first 1 4 of the thermoc
8. several cycles us before loading the new tuning parameters After the tuning p l Woe alle parameters are loaded it heats to the Start T4 T2 T3 T4 set point temperature Tuning During T1 4 the controller below the set point prevents any measures heating delays and Quarter cycle times rates of heating and cooling damage that might occur from gt Time overheating Autotuning the Controller for Very Fine Control 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 1 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 see Section 3 5 Turn the controller and heater on then enter th
9. 50 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 Avoid switching between power levels while the controller is heating Specifically do not initially set the controller on a high power level to rapidly heat the solution then 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 Oil Baths Set the power level switch to the voltage position that equals the voltage rating of the bath You should set the power level switch one voltage setting lower than the rating of the bath if heating to temperatures below 60 C For example to heat a bath rated at 40 volts to 45 C set the power level switch one setting below the 40 volt setting 1 e set to the 20 volt setting 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 setting i e 50 power it s usually better to have too much power rather th
10. D 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 Boulevard St Louis MO 63130 USA 314 863 5536 FAX 314 863 6070 Web site http www jkem com E Mail jkem911 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 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 2 ADJUSTING THE CONTROLLER FOR STABLE CONTROL WITH DIFFERENT HEATERS 5 21 WE TS CA os Got ee meer ids aie ard we ao Karlee a E we ea ee 5 2 2 Autotuning Procedure 2 2 5 we acien A ecwis cme a ech aa e arenes 6 2 3 Tuning for Heating Mantles and Oil Baths Special Cases 8 ZA JSCMSORPIGCEMICNE S ssgc yi as a2 eG Giles han einen begat ee ecg wn 8 3 OPERATIONS
11. GUIDE 32 9 ccs jane walea do ae paw a bad aad bain 9 3 1 Front Panel Description 2 vue en teed eee the Cos vee s 9 3 2 HMeater REStMICHONS 4 easuevan es SCARE RRR ADWARE ee 10 3 3 Ramp to Setpoint amp Soak Feature 0 000 10 3 4 Temperature Sensor Input vss vstuwsuseceees care seweeees 12 3 5 Power Reduction Circuit sol ou Se oniee a sets Hike ev nes 12 3 6 Effect of Power Setting on Heating Profile 14 3 7 Resetting the Controller for Use With Heating Mantles amp Baths 15 3 8 Changing between PID and ON OFF Operating Modes _ 16 3 9 Troubleshooting siss ke cea aeie ea were aaa eee wee ee 17 3 10 Do s and Don ts When Using Your Controller 18 4 APPLICATION NOTES wiscddeiosdsjdtaovred seas pebatdeodvans 19 4 1 Theory of How the Controller Works Simply 19 4 2 Controlling the Heating Mantle Temperature Directly 21 4 3 Automatic Storage of Min Max Temperatures 22 TABLED sigurreiiion oian a E E E ee E 23 APPENDIX i aiea a E Ponte A OEE E TE ee eon Bale lett 3 24 I Safety Considerations and Accurate Temperature Control 24 II Resetting the Controller to Original Factory Settings 25 WARNING 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 three steps below are the ba
12. Off switch For maximum display accuracy turn on the 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 Power Reduction Circuit Controls the computer that limits the maximum power delivered to the heater See Sections 3 5 and 4 1 Optional Serial Port For controllers equipped for serial communications this port connects to a PC for remote control and data acquisition Controllers equipped for RS232 communications have a 9 pin connector RS485 multi drop controllers have a RJ 11 phone connector See supplemental Serial Communications Manual 10 3 2 3 3 n o 3 ep 3 Heater Restrictions The controller delivers 15 amps of current at 120 VAC into resistive loads heating mantles oil baths 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 When used with an oil bath do not set the power reduction circuit to a voltage setting higher that the rating for the bath being used Devices other than resistive loads can be used with your controller but certain restrictions apply Device Type Incandescent lamps lt 1000 watts Infrared heaters Inductive loads lt 6 amps 720 watts The con
13. Temperature Control for Research and Industry Model 410 User s Manual Instruments for Science from Scientists KEM Scientific mc 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 Ifthe 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 THE PURCHASE PRICE PAI
14. an 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 Ifthe 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 14 3 6 Effect of Power Setting on Heating Profile of selected power levels on heating performance in a variety of situations Each example contains optimal and 1 or 2 less optimal settings demonstrating use of the power reduction circuit 70 Conditions Set point 75 C Laboratory oven Power Setting 50 500 ml ae Power Setting gt 2L o 50 40 Conditions Set point 45 C HPLC Column wrapped with heating tape 30 Power Setting 50 500 ml 20 0 10 20 30 40 50 Time min 80 70 60 Temp oC Conditions Set point 70 C 50 50 ml Toluene 100 ml Round bottomed flask 40 Power Setting 10 100 mI i e 10 power 30 Power Setting 50 500 m i e 25 power oases Power Setting 300 ml 2L i e 50 power 20 0 10 20 30 40 50 Time min 15 The following graphs show the effect 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 dif
15. antles 5 overshoot but it s terrible for heaters that transfer heat slowly vacuum ovens heating blocks etc In PID mode the controller monitors the Temp PID Mod shape of the heating curve during initial A soutien warm up and decreases power to the heater IN eee before the set point is reached so that the solution reaches the set point with minimal E over shoot Notice that the heater turns off to heater for varying periods of time before the set l l point temperature is reached The second feature of PID mode is that it adjusts the Time 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 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 Procedure 1 in Section 3 7 ON OFF Mode of gt 1 Press and hold in both the A and V keys on the front of the temperature Procedure to change meter until the word tunE appears in the display then let go of the buttons controller to ON OFF 2 Press A until the word
16. arameters 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 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 input power the rate of heat transfer is twice as high for hexane as compared t
17. ce you ve received it you re ready to go Ifthe tuning parameters have been changed or the controller has been autotuned and you want to go back to the factory settings J KEM recommends that the tuning parameters be loaded manually i e don t autotune by following the step by step instructions given in Procedure 1 of Section 3 7 If the default parameter set does not result in satisfactory performance the controller can be autotuned with no detrimental effect 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 throughout the solution Tape a thin wire thermocouple directly to the HPLC column Place several layers of paper over the thermocouple to insulate it from the heating tape the thermocouple 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 h
18. d can be used like one If the heater isn t getting enough power turn the power level up one notch if it s getting too much power turn it down 3 7 Resetting the Controller for Use With Heating Mantles and Oil Baths If you want to use your controller with heating mantles or oil baths after it s been tuned for a different style heater rather than autotuning the controller J KEM recommends that the controller be manually tuned by following the procedure below Procedure 1 Perform when using heating mantles or oil baths 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 15 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 key then while holding in the key press the V or A key until the value 5 appears in the display then let go of all the keys 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 15 appears in the display then let go of all the keys Press
19. e 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 W 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 tein Yellow type K toi Black type J to 1 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 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
20. e desired set point temperature Press and hold in both the A and F 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 W button Continue to hold both buttons in until the display reads A or A where is some number Release the button and press the VW 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 then release both buttons Press and hold both the A and VW 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 2 3 2 4 Autotune Errors The autotune
21. e 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 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 poi
22. eating 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 Solutions HPLC column heated with a heating tape Section 3 Operations Guide 3 1 Front Panel Description 7 9 Serial Communications Port Back J KEM Scientific 40 100 ml 20v 50 500 ml 40v Instruments for Science from Scientists 1 10 ml 10 7300 ml 2 L 60v ON Heat Off gt 2L 110v 8 Output Power Level OFF 6 120 Vac 1800 watts Figure 1 Temperature Display Shows temperature of the process as the default display Shows set point temperature i e desired temperature when button is pressed Control Key When pressed the display shows the set point temperature To decrease or increase the set point press the Wkey 3 or Akey 4 while simultaneously depressing the control key The set point appears as a blinking number in the display Lowers set point when button 2 is simultaneously pressed Raises set point when button 2 is simultaneously pressed 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 thermocouple input 5 on the front of the controller Power Outlet Plug only 120 VAC devices into this outlet see Section 3 2 Controller On
23. est 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 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 Press and hold in both the W and A keys until the temperature appears in the display then release both keys 23 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 int t dEr t dAC CyC t Heating Mantles Oil Baths 15 5 0 15 4 0 14 Factory Default Oo owm Vaemmosen C E a a 24 Appendix I 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 p
24. f 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 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 W 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 7 22 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
25. ferent 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 Graph 3 Set point 155 C Koia Pa 100 7 ks j Another factor affecting the d choice of power setting is the 145 set point temperature For set points near room temperature m Ha p Bower 300 mi L low power ee is aoe agi iv 50 power or average temperatures 95 50 100 the volumes printed on the front of the 70 Conditions 300 mi colidine Set point 16 controller are a good guide For high temperatures the PUN heaung hante 28 power iid next higher power setting 45 might be needed to supply the heater with additional power 20 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 an
26. gulates 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 7 will program the controller for heating mantles For all other heaters see tuning instructions in Section 2 After the controller is reprogrammed place a fine gage wire eee SN thermocouple 7 1 3 the size of kite string available from J KEM in 5 amp 10 ml 1 10 ml the bottom third of the heating mantle and fit the flask snugly on top a a so that the thermocouple is in intimate contact with the heating mantle Set the power reduction circuit to the power level shown in For temperatures over 120 C the table at the right Turn the controller on and enter the set point the neat 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 o
27. ia 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 and oil baths are special cases and are covered in a separate paragraph Section 2 3 Autotuning Procedure l 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 Ifthe 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 5 Turn the controller and heater on then enter the desired set point temperature Ifthe 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 UP and DOWN 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 UP button 5 times until CyC t
28. ing Power Reduction Circuit This circuit 8 is the interface to J KEM s patented power control computer which limits the maximum output power delivered by the controller It determines whether the controller heats at a very low 10V 1 10 mL low 20V 10 100 mL intermediate 40V 50 500 mL medium 60V 300 mL 2 L or high 110V 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 turns 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 while at the same time not overpowering it Heating Liquids Each power level is associated Front Panel Approx of with a volume range which acts as a guide when heating Volume Range Full Power solutions with heating mantles When solutions are 1 10 mL 3 heated with heating mantles set the power switch to the 10 100 mL 10 range that includes the volume of solution being heated 50 500 mL 25 Note this switch is set to the volume of solution not 300 ml 2 L 50 the size of the flask For example to heat 250 ml of gt 2L 100 toluene to 80 C in a 1 L round bottomed flask choo
29. mains activated even if power is turned off to the controller Activating amp Programming the Ramp to Setpoint Feature 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 A key 8 times until the word SPrr appears in the display This is were 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 Ifa soak time is set the controller display will alternate between showing the current reaction temperature and the word StoP when the soak time has expired to indicate that powe
30. nt 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 8 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 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 awhile For additional information see Section 3 5 21 4 2 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 re
31. o 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 encounter a process that your J KEM controller does not heat with stability you have two
32. ouple directly into the solution If a corrosive mixture is heated use a coated coated thermocouple or use the external thermocouple method Section 4 2 Do 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 19 Section 4 Application Notes Supplemental application notes on the following topics are available by contacting J KEM Application Note Subject Changing the controllers thermocouple type Changing the heating outlet into a cooling outlet Using the controller for unattended fractional distillations 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 10 50 500n InstrumentsforScience 410ml we 300mi2L ON Heat __ S Output Power Level PC Power 8 0 0 m my mN Power to heater Model210 120 Vac 840 watts Heating mantle Temperature of process 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 se
33. r has been turned off BE To exit programming mode press and hold in both the W and A keys until the temperature appears in the display then release both keys Deactivating the Ramp to Setpoint Feature 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 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 W and A keys until the temperature appears in the display then release both keys 12 3 4 3 5 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 5 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 controller stops heat
34. rd SPrn appears in the display Next hold in the key then while holding in the key press the W or A 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 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 BAnd appears in the display Let go of all the keys Press the A key until SP2 b appears in the display Next hold in the key then while holding in the key press the V or A key until the word Hold 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 V or A key until the value 0 10 appears in the display Let go of all 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 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 value appears in the display
35. ribing 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 and oil baths 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 effect 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
36. 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 and oil baths Two Special Cases This section gives special consideration to heating mantles and oil baths since they re the most commonly used heaters in research When used with a heating mantle the probe should be in the solution inside the flask when used with oil baths the probe should be in the oil in the bath Every heating mantle and oil bath size has its own optimum set of tuning parameters and if desired the controller could be tuned or autotuned every time a different size is used However this is cumbersome and is also unnecessary Factory tests show that there s one set of tuning parameters that deliver good performance for all heating mantle and oil bath sizes These tuning parameters were loaded into the controller at the factory prior to shipping If you re using a heating mantle or oil bath and none of the parameters have been changed or the controller hasn t been autotuned sin
37. se 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 100 ml flask 25 power 100 ml heating mantle Organic solvents heated to 50 110 C are set to the volume range on the front panel When choosing between 2 power settings i e 80 ml also falls within both the 10 100 ml range SP 809 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 13 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 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 800 C power setting gives better control 150 ml toluene Even though the solvent volume isn t included in this power 2
38. 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 butare lugged into controller thermocouple receptacle must be the same color see Section 3 4 not calibrated for them p ugg i p P ia Corroded thermocouple Clean plug on thermocouple and receptacle on controller with connections sandpaper or steel wool Corroded thermocouple If the temperature measuring end of the thermocouple is corroded discard thermocouple 18 Displayed temperature is 5 cuit Temperature display offset needed To enter a controller display offset Turn on controller Allow to warm up for 30 minutes Note Types K amp J Record displayed temperature Thermocouples display Press both the A and V keys on the front of the temperature negative temperatures but are meter until tunE appears then let go of the keys not calibrated for them Press the V key until LEVL appears First hold in the 32 key then while holding in the 32 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
39. sics 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 Users unfamiliar with J KEM s temperature controllers should particularly read the safety notices in Appendix I To use heaters other than heating mantles and oil baths For polymer synthesis atypical expensive or safety critical reactions See Section 2 See Appendix I 1 Place the thermocouple in the solution being heated Place at least the first 1 4 of the thermocouple directly in the solution being heated If the controller is used with an oil bath the probe should be placed in the oil if with a flask in a heating mantle then place the probe in the solution inside the flask When the probe is in the oil of an oil bath the oil should be stirred for uniform heat distribution since the oil heats very rapidly Placing the oil bath on top of a running magnetic stirrer with a stirring bar inside the oil works well Thermocouples can be bent without harming them If you re heating a corrosive liquid use a Teflon coated thermocouple If you are heating a sealed reaction see Section 4 2 2 Set the power level switch to the 10 10O OV oro Tn ANY 3 1 40 mi 10v _ 300 mk2 L 60v correct power setting E SLD Oil Baths Set the power level switch
40. t 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 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 20 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 th
41. the button and simultaneously press the UP key to increase or the DOWN 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 Section 2 Adjusting The Controller For Stable Control With Different Heaters 2 1 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 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 desc
42. 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 4 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 14 appears in the display then let go of all the keys Press and hold in both the W and A keys until the temperature appears in the display then release both keys 16 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 power is supplied to the heater In ON OFF mode the simplest heating mode the controller is ON when it s below Ban renee the set point and OFF when above The py paa A an disadvantage of this mode is a large over Set ce ee 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 ie heater cools down the temperature continues to heater ime to rise This method works well for heaters that transfer heat rapidly such as heat lamps it s acceptable for heaters such as heating m
43. to the voltage setting equal to the voltage rating of the 3 Supit oil bath being used i e if a 40 volt bath is being are used set the power level switch to the 40V setting A power is equivalent to Heating Mantles Set the power level switch to ema a variac setting of the volume of solution being heated not the size 1 10 ml 3 of the flask The power level switch can be 10 100 ml 10 thought of as a solid state variac Volume ranges 50 500 ml 25 are printed above this switch as a guide to select 300 ml 2 L 50 the correct power level since it s gt 2L 100 TIP Because the power switch acts like a variac if the reaction is heating too slowly or you need more power e g heating to high temperatures give the heater more power by turning the power level up one setting If the reaction needs less power than normal e g heating to low temperatures lt 60 C or the temperature overshoots the set point lexcessively turn the power down one setting DO NOT set the power switch on a setting too high initially to heat the reaction quickly and then lower it to the correct setting this degrades heating performance easier to guess the volume being heated than the appropriate percent power to apply to a heater Heat Off turns off the heater so the controller displays temperature only Section 3 5 should be read by all new users 3 Enter the setpoint i c the desired temperature Hold in
44. to the oven stable temperature control results Plot 2 Curve 2 Plot 2 Plot 1 ss 704 60 Curve 2 Controller loaded with d tuning parameters for Temp drying oven Temp C C re Conditions 100 ml Toluene 50 Curve 1 Controller loaded with 250 ml Round bottomed flask tuning parameters for 250 ml Heating mantle heating mantles Power Setting 50 500 ml 1 40 407 304 204 OEE At ee at ee 0 10 20 30 40 50 60 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 i e ON when below the set point OFF when above though it can be made to work this way see Section 3 8 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 Ifthe 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 v
45. trician replace on Circuit breaker on back has tripped Allow to cool then reset circuit breaker 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 then wait 1 minute Ifthe light comes on the controller is working properly 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 AL The process temperature is hotter Correct the over temperature condition than the alarm temperature BOE This indicates that a setpoint ramp See Section 3 3 rate program in effect PArk Controller has been placed in e 1 Hold in both the A and W keys on the front of the J KEM Park mode temperature meter until tunE appears in the display 2 First hold in the 3 key then while holding in the 3 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 Autotune routine failed Turn off controller for 10 seconds See Section 2 2 Displayed temperature is The controller has not warmed up The display temperature reads low when the controller is first incorrect turned on but will
46. troller must be solenoids programmed for this use transformers Request application note motors ANS 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 Examples of Program Ramps Ramp Temperature Power Off g Soak Nn rar asi Q 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 11 SPrn SetPoint Ramp Run Allowable Values ON OFF Hold This parameter turns the Ramp to Setpoint feature ON or OFF During an acti
47. ve 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 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 1 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 deactivated in programming mode The Ramp to Setpoint feature re
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