ThermoClamp™-1 Temperature Controller User Manual
Contents
1. The CU contains the PID Proportional Integral Derivative temperature controller Fuji PXR3 which controls the temperature of the liquids in the Pencil Red Set Value SV indicator LED Main display of PV current temp SV set value or other parameter Blinking rightmost decimal point indicates autotuning Green Control 1 C1 LED heating in progress DOWN key Select SEL key UP key Figure 7 Faceplate of the Fuji temperature controller NOTE See also page 5 of the PXR3 manual To change the setpoint 1 Press the SEL key and hold it until the SV light red turns on Now the controller displays the setpoint value 2 With UP and DOWN keys adjust the temperature to the desired value 3 Press and hold the SEL key again until the SV light turns off Now the controller displays the measured temperature NOTE See also the separate manual for the Fuji controller for more details of the controller operation Autotuning the temperature controller Since the Fuji temperature controller was designed as a generic temperature controller it needs to be autotuned for the ThermoClamp system During autotuning the controller determines the PID coefficients and stores them in its nonvolatile memory Autotuning of the controller must be done every time physical parameters such as plumbing or flow rate are changed significantly To autotune the controller 1 Open the bath solution flow to your desired flow rate if you pl2. ThermoClamp 1 Temperature Controller User Manual Bath Pencil Heater Temperature Pencil TC TC Power Output Overheat 100 mv C AutoMate Scientific Inc ThermoClamp 1 PAN AutoMate Scientific 2005 AutoMate Scientific Inc AutoMate Scientific ThermoClamp 1 Temperature Controller User Manual Table of Contents RESEARCH USE ONLY PACKING LIST FEATURES AND SPECIFICATIONS ACRONYMS ABBREVIATIONS AND DEFINITIONS COMPONENTS Controller unit Perfusion Pencil Perfusion Pencil Placement CHEMICAL INFORMATION GETTING STARTED Bath Perfusion Water Jacket Feature INSTRUCTIONS FOR USE Making sure the device works properly Adjusting the setpoint Autotuning the temperature controller Other temperature controller parameters and features os N an OF uN kw ND NN N Switching fluids pd Operating without the bath sensor p Maintenance p Cutting the Pencil tips TROUBLESHOOTING Overtemp Thermocouple LED p p ah O Sensors REPLACEMENT PARTS SAFETY INSTRUCTIONS WARRANTY CONTACT INFORMATION h h a mah Aa OO N N Research Use Only The ThermoClamp is designed for solution switching use in research applications ONLY AutoMate Scientific Inc cannot be responsible for injury or death resulting from medical or pharmacological use Packing list Power cable This ThermoClamp 1 user manual Fuji PXR3 controller user manual Features and specific
3. ages or if this warranty is found to fail 1ts essential purpose AutoMate Scientific Inc s liability is limited to the reimbursement of the cost of the product All other warranties including but not limited to warranties for fitness or merchant ability for a particular purpose are expressly excluded No verbal changes to this policy will be authorized AutoMate Scientific Inc manufacturers and sells goods in accordance with U S federal state and local laws but assumes no responsibility or liability for laws regulations duties or taxes imposed by any foreign country All terms and conditions hereof shall be governed by the laws of the State of California 13 PAN AutoMate Scientific Contact information AutoMate Scientific Inc 336 Baden Street San Francisco California 94131 USA info autom8 com http www autom8 com Phone 415 239 6080 Free 800 998 MATE 6283 Fax 415 239 6801
4. ain electrophysiology Perfusion Pencil The Heated Perfusion Pencil Pencil manifold is shown in Figures 3 4 and 5 The actual heating of the drug solutions happens in the Pencil The optional bath solution is also heated as it flows through the Pencil Power cables to outflow Na Thermal insulation Drug flow orifice Tighten removable tip for minimum dead volume Multiple solution heater inflow tubes L a P gt 1 gt e A 4 i Ba AA Erg a a p A Figure 3 Side view of the Perfusion Pencil T Multiple solution heater inflow tubes Pencil mounting rod Chamber bath inflow Figure 4 Detailed view of the rear part of the Perfusion Pencil Power cable to the CU From or bath From drug Polyimide drug f a reservoirs heating tubes Perfusion tip luid source P To the DEA lt bai To bath or water jacket Electric heating Heated metal Thermocouple element Pencil body inside Pencil Figure 5 Heated Perfusion Pencil schematic Perfusion Pencil Placement Your Heated Perfusion Pencil must be placed as close as possible to the perfusion chamber If it is too far away the liquid in your tubes will lose all of its heat before it reaches the chamber The maximum distance between the Pencil and chamber depends on a number of variables including tubing mate
5. alculations 4 Ramp The Ramp Soak program automatically changes the setpoint value over time according to a preset pattern See page 14 of the Fuji manual for a description of the variables necessary to start and stop Ramp Soak mode and how to change them Then see pages 45 48 for a description of how to set the four segments of ramp and soak See the Fuji manual for additional system parameters Switching fluids While fluid remains stagnant within the Heated Pencil its temperature will climb higher than the setpoint When you switch liquids there will be a small temperature overshoot like the one shown in Figure 8 below When all solution flow is stopped the ThermoClamp tries to maintain the desired bath temperature by increasing heat to the Pencil Without liquid flow none of this added heat reaches the chamber so the Pencil continues heating until the overtemp alarm sounds Consider turning off the temperature controller when liquids are not flowing 36 8 Le a A 36 4 Insulation Bath 5cc min 36 2 Overshoot X Insulation no bath 35 8 e Setpoint 37C x 35 6 Drug 5cc min 7 3 2003 20 10 O 10 20 30 40 50 Figure 8 Temperature vs Time curves for fluid switching Operating without the bath sensor The bath thermocouple allows the ThermoClamp controller to monitor bath temperature and heat your solutions in order to maintain the overall b
6. an get very hot turn off the controller and wait for a few minutes Running liquids buffer and or inexpensive drug through the Pencil will cool it more quickly Do NOT apply liquid to the outside of the Pencil or submerge it in liquid This may permanently damage the Pencil 5 If the LED does not go off even after the Pencil has cooled you may have a broken thermocouple inside your Pencil You can measure the resistance at the PENCIL TC plug If it is infinite then the wire or thermocouple has broken Please contact AutoMate Scientific about a repair or replacement NOTE The overtemp circuit has been factory set at a safe temperature for the Pencil Despite the warning sound nothing in the ThermoClamp system is harmed at the alarm temperature even long term Sensors Several problems can arise with your ThermoClamp sensors One of the simplest problems is having the bath sensor fall out of the bath The bath sensor must be in good thermal contact with the bath solution The insulation on the bath sensor can also degrade until the bath solution makes electrical contact with the thermocouple If the control unit displays UUUU the bath sensor may be shorting to the bath solution Try removing the sensor from the bath to see if the UUUU disappears Make sure you are not grounding the thermocouple with your fingers If you suspect broken insulation on the thermocouple dip it in epoxy and allow it to dry The thermocouples o
7. an on using it Open one of the drug tubes with your normal drug delivery flow rate Turn on the CU Wait until the temperature in the Pencil reaches the vicinity of the setpoint If you plan on using the controller at a variety of temperatures or a ramp consider using the middle temperature as your setpoint Depress the SEL key on the controller until you see STby on the screen 3 6 sec Press the DOWN key until you see AT which looks like A7 on the screen Press the SEL key to change the value It should read 0 Press the UP key until you see 1 and press SEL to enter this value 10 Hold the SEL button until the SV light turns on 11 Press the SEL button again Now the controller displays the measured temperature ae ta oo AN Autotuning can take up to several hours usually under 30 minutes During autotuning the controller deliberately overheats the Pencil and flowing liquid several times and then allows them to cool below the setpoint When the decimal point stops blinking autotuning 1s finished The autotuning process does not always work The decimal point may flash indefinitely Two possible reasons are variance in the system and an open loop Variance in the system means something other than the ThermoClamp 1s affecting the system parameters while autotuning is happening Three possibilities are another temperature controller is also being used simultaneously on the perfusion chamber or stage an
8. ath temperature If you are using another controller to maintain your bath temperature with stage chamber or objective heaters etc then you do not want the ThermoClamp to use the bath temperature for deciding whether to heat your solutions If your other temperature controller is doing a good job then the ThermoClamp will always think that its liquids are at the correct temperature and will not apply any heat Instead it will be dispensing cold reagent into a warmed chamber If you use another controller to maintain your chamber bath temperature or you do not wish to use the ThermoClamp bath thermocouple simply connect the Pencil s thermocouple into the BATH TC socket This way the ThermoClamp will observe and maintain the temperature of the Pencil irrespective of the bath NOTE the ThermoClamp will not operate an alarm will sound if you try to use it without anything plugged into the PENCIL TC socket You must plug the unused bath thermocouple into the PENCIL TC socket Leave the bath thermocouple at room temperature In this configuration the temperature measured and displayed by the ThermoClamp will be the internal temperature of the Perfusion Pencil not the temperature of your chamber bath If you wish to maintain a particular bath temperature with flow from the Heated Pencil but without using the bath sensor you will need to measure the difference between the bath temperature and stable Pencil temperature Since the liquid will cool
9. ations e Auto tuning PID Proportional Integral Derivative temperature control accurate to lt 1 C e 4 to 8 channels for solution heating with flow rates up to 5cc min 37 C e Temperature controlled bath perfusion inline heater with a flow rate up to 5cc min e Small manifold volume for rapid switching e Temperature can be maintained for the entire bath or just for solutions being delivered e Perfusion Pencil tips are interchangeable replaceable with standard AutoMate tips e Ramp and soak feature for automatically changing the set temperature over time e Low noise design for electrophysiology e Over temperature protection Acronyms abbreviations and definitions PdP Decimal place parameter Grounding earth point PVOF Process Variable Offset parameter PID Proportional Integral Derivative Thermocouple temperature sensor Components Controller unit The Controller Unit CU is shown in Figures 1 and 2 The integrated temperature controller and power supply for the heater are the main components of the controller unit Fuji temperature controller Pencil connector ThermoClamp 1 PAN AutoMate Scientific Power switch Figure 1 Controller unit front view TC thermocouple temperature sensor Power entry module Isopotential Ground e BE grounding point Figure 2 Controller Unit rear view NOTE The ThermoClamp 1 and its heated Perfusion Pencil should both be grounded for high g
10. by several degrees before reaching the bath you must set the Pencil temperature setpoint higher by the observed offset Maintenance You can expect several years of useful lifetime for your tip 1f you wash it daily Use a syringe or vacuum to pull water then alcohol three times through the tip If the Perfusion Pencil tip is filled with pure salt solution leaving it in the syringe overnight will not usually cause the tip to block However if it is used for high viscosity fluids flushing after each use is recommended Cutting the Pencil tips The removable tips are shipped with 1 5 3 8 cm length polyimide needles They are intended to be cut to a desired length by rolling a razor blade on them against a hard surface However this may leave a small crack or barb on the tip To get a flat cut score the coating of the needle with a ceramic cleaving stone or a diamond cutter and pull directly apart making sure not to pull at an angle You may notice a larger outer tube enclosing the lower part of our smaller 100um needles This is simply for added rigidity and can be cut if needed Troubleshooting Overtemp Thermocouple LED The ThermoClamp is equipped with a warning light These will warn you of an overtemp or broken thermocouple situation If the LED lights during use it means that either the Pencil has reached its maximum temperature or its thermocouple has broken This is not necessarily a problem The LED may illuminate while heati
11. claved However repeated autoclaving may weaken the adhesive bond between the luer lock fitting and the needle Getting started 1 Connect the 7 pin Pencil connector to the CU 2 Connect the Pencil thermocouple plug to the PENCIL TC socket 3 Connect the bath thermocouple plug to the BATH TC socket 4 Connect the bath perfusion inflow tube to its fluid source Notice the fragile capillaries 5 Connect the bath perfusion outflow tube to the chamber Notice the fragile capillaries 6 Connect the drug tubes to their valves and reservoirs Notice the fragile capillaries Warning Leaving any solution tubes at the rear of the Perfusion Pencil unconnected may result in bubbles or liquid backflow 7 Fill and plug any unused drug tubes on the rear of the Perfusion Pencil to prevent backflow 8 Connect the power cable to the CU via power entry module 9 Ground the CU using the grounding post on the rear face and the Pencil Bath Perfusion Water Jacket Feature The Heated Perfusion Pencil includes an extra tube for heating a flowing bath solution This heated high flow line will maintain the bath temperature while quickly washing out drugs applied through the tip The Pencil can maintain at least 37 C with flow rates of Scc min This extra line can also be used with a water jacket on certain perfusion chambers A water jacket is usually a separate chamber or bath outside a perfusion chamber for circulating a heating or cooling li
12. exothermic reaction is occurring in the chamber unlikely or the bath liquid level is changing enough during autotuning to affect the thermal inertia Open loop means the ThermoClamp s feedback sensor is not working The primary cause would be if the bath thermocouple has fallen out of the bath or was unplugged Make sure any other temperature controllers are turned off that the bath liquid level is stable and the sensor remains in the bath If the Fuji still will not autotune please see Troubleshooting section 13 on page 71 of the Fuji manual for further information and consider manually tuning the controller The PID parameters calculated by autotuning will be retained even if the power is lost However if the power 1s turned off during the autotuning process you must restart it To abort the autotune procedure set AT to 0 Autotuning has to be repeated if there is a significant change in setpoint flow rate perfusion chamber or stage NOTE Also see page 16 of the separate manual for the Fuji PXR3 for more details on controller autotuning For manual tuning consider the Fuji default valves of P 5 0 I 240 sec and D 60 0 sec Contact AutoMate Scientific if you would like further instructions in how to manually tune the controller If you plan on changing flow rates or setpoint temperature frequently you may want to consider either the Fuzzy logic or Self tuning control setting see page 27 of Fuji manual IMPORTANT If you are
13. hannel Heated Pencil wetsuit ThermoClamp 1 Control Unit 03 sensor Bath thermocouple sensor Safety Instructions The following instructions pertain to the risk of fire electric shock or bodily injury Please read all of these instructions carefully 1 Follow all the instructions and warnings marked on this product and included in this manual 2 Do not use this product on an unstable cart stand or table This product may fall causing serious damage to the product 3 Slots and openings in the cabinet and the back are provided for ventilation To ensure the reliable operation of your product and to protect it from overheating these openings must not be blocked or covered Do not use this product on a bed sofa rug or other similar surfaces This product should never be placed near or over a radiator or heat register This product should not be placed in a built in installation unless proper ventilation is provided 4 Never push objects of any kind into the product through the cabinet openings as they may touch dangerous voltage points or short out parts that could result in fire or electric shock Never spill liquids of any kind in the product 5 This product should only be connected to the AC power source indicated on your product system s information label If you are not sure of the type of AC power available consult your dealer or local power company Only connect this product to a power outlet that matches the power
14. ng a cold perfusion chamber The overtemp circuit will reset itself once the temperature drops You do not need to do anything except remedy the cause of the high temperature and allow the Pencil to cool following the instructions below 10 Here 1s an example of an overtemp situation If you leave the bath thermocouple sitting on a cold table while the ThermoClamp is running the controller will think that the bath temperature is significantly below your setpoint It will apply heat to the Pencil but will not observe an increase in the bath It will continuing heating the Pencil indefinitely The overtemp sensor automatically turns off heat to the Pencil and lights the indicator LED once the Pencil reaches a pre set maximum The LED will also alert you if the Pencil thermocouple is broken or not plugged in If you wish to operate the ThermoClamp without a bath sensor and you plug the Pencil thermocouple into the BATH TC socket then you must plug the bath thermocouple into PENCIL TC See the preceding section called Operating without the bath sensor Troubleshooting If the LED lights check the following 1 Is a thermocouple plugged into the PENCIL TC socket on the controller 2 Is the bath sensor in the bath or desired location 3 Has liquid flow been off for a long time Consider turning off the temperature controller when liquids are not flowing 4 If the Pencil feels hot WARNING the metal surface of the Pencil c
15. not using the bath perfusion line autotune the controller without it flowing Other temperature controller parameters and features To view or change the following parameters press and HOLD the SEL key for about 3 seconds until you see P on the display Press UP DOWN to advance through the different parameters When the desired parameter is displayed press SEL to modify it then UP DOWN to make a change Press SEL for 3 seconds to return to the set temperature and SEL again for operational mode 1 Calibration The PVOF or Process Variable Offset variable allows you to shift the temperature controller s measured temperature to match an actual temperature measured with a calibrated thermometer The value entered is a percentage of full scale from 10 Full scale is determined by the maximum and minimum parameters described in number 3 below 2 Decimal place The P dP parameter sets the number of decimal places displayed on your temperature controller The display can indicate integers tenths or hundredths of a degree The decimal point position does not increase the accuracy of the controller it only increases the resolution 3 Maximum and minimum temperature parameter The P SL parameter sets the lowest setpoint value while the P SU sets the highest desired temperature This is simply a convenience for entering your desired setpoint later but it also determines full scale for some internal controller c
16. quid The perfusion chamber must be equipped with a water jacket It is not usually something that can be added later Simply provide a high flow of water from a large reservoir through the Pencil into the chamber s water jacket and out to a drain or recirculating pump for ideal heating Reservoirs with the drug A solutions j 2 Bath and Pencil TCs are connected to their corresponding sockets 5 7 ER R Re Perahu rer gt Ty 1 Chamber heating fluid source Figure 6 Set up example of ThermoClamp temperature controller and accessories Instructions for use Making sure the device works properly 1 Connect both the bath and Pencil thermocouples 2 Turn on the on the CU power switch The temperature controller should display the ambient temperature If an alarm sounds check the Pencil thermocouple plug If the temperature controller displays UUUU check if the bath thermocouple is connected properly 3 Adjust the setpoint above the ambient temperature Refer to the section on adjusting the setpoint The controller will start heating the Pencil If the controller has not been autotuned the temperature will probably overshoot Refer to the section on autotuning the temperature controller 4 To verify that the Pencil does not leak internally open the bath perfusion flow and all of the delivery valves Look for leaks at each end of the Pencil Adjusting the setpoint
17. r their wires or plugs can break This is easy to observe with a multimeter ohmmeter as an infinite resistance measurement Check inside the sensor s blue plug for a loose screw The sensors are simply two different thermocouple wires soldered together It may be possible to solder them back together if you can find the break Remove any oxidation build up on the plugs It may be possible for the Pencil TC to short to the inside of the Pencil This can be observed as a zero resistance between the Pencil TC plug either lead and the metal Pencil body If you suspect a shorted Pencil TC carefully remove the Pencil s wetsuit Remove two screws holding the top of the Pencil You can see the Pencil TC at the end of its two wires Dip the ends of the bare wires into some epoxy for insulation and allow to dry Reassemble and test the Pencil The ThermoClamp 1 uses standard T type thermocouples for bath and Pencil 11 Finally we wanted to mention that most digital voltmeter thermometers with thermocouples are only accurate to 2 C Unless you perform a multi point calibration on your digital thermometer it should probably not be trusted to calibrate your ThermoClamp Ice water is always a good 0 C test Replacement parts Part No Description 04 360 360um Removable Tip 04 250 250um Removable Tip 04 100 100um Removable Tip 03 08 xxx Heated Perfusion Pencil 8 channel with xxx size tip 03 08 Replacement Heated Perfusion Pencil 8 c
18. rcle en place et remettre le cordon d alimentation Warranty AutoMate Scientific Inc warrants its products against defects of workmanship and or material for ONE YEAR from the date of sale Any product that fails to perform as specified may be returned freight pre paid to the factory with a written explanation of the problem for examination and repair or replacement If it 1s defective AutoMate Scientific will repair or replace at our option the product without charge and return it to you If the examination indicates that non compatible fluid destructive environment accidental damage modification or abusive practices have occurred all labor materials and freight costs shall be at the expense of the customer Due to the nature of clinical laboratory applications AutoMate Scientific Inc will NOT accept the return of any products which have been used with HAZARDOUS MATERIALS or in a harmful environment This warranty is in lieu of all other warranties whether oral or written express or implied In no event shall AutoMate Scientific Inc or its licensor licensees be liable for contingent special direct indirect or consequential damages for the breach of any express or implied warranty or resulting from the use failure or malfunction of any product including damage to property and to the fullest extent permitted by law damages for personal injury even if AutoMate Scientific Inc has been advised of the possibility of such dam
19. requirements of this product 6 Do not allow anything to rest on the power cord Do not locate this product where people will walk on the cord 7 If you have to use an extension cord with this product make sure that the total amperage rating of all equipment plugged into it does not exceed the amperage rating of the extension cord Also make sure that the total of all products plugged into the main AC power outlet does not exceed 15 Amps 12 8 Unplug your product from the main electrical power before cleaning Do not use liquid cleaner or aerosol cleaners Use a damp cloth for cleaning 9 Do not use this product near water 10 Unplug this product from the main power outlet and call for service under any of the following conditions If the power cord or plug is damaged or frayed If liquid has been spilled into the product If the product has been exposed to rain or water If the product has been dropped or the cabinet has been damaged If the product exhibits a distinct change in performance indicating a need for service Pa C C ee STOP If you ever have to remove the main system unit cover observe the following precautions A The power supply cord must be unplugged before the main system unit cover is removed Separe le cordon d alimantation et puis enleve le couvercle B Once removed the cover must be replaced and screwed in position before the power supply is plugged back in Apres le couve
20. rial thermal conduction fluid dripping versus flowing into the perfusion chamber via submerged tube and ambient temperature and drafts You may be able to mount your Pencil farther from the chamber if you try double tubing between the two use a piece of large Tygon tubing as thermal insulation outside a small piece of Teflon tubing Make sure your solution flows into your chamber rather than dripping The extra exposure to cool room air will greatly decrease the delivered liquid temperature Finally avoid placing your chamber in a location where it is regularly blown by air drafts Many researchers purchase or build enclosures around their chambers or entire microscopes to help control the temperature and avoid air drafts Chemical Information The tubing inside the manifold body is polyimide nylon Additional connection tubing 1s silicone The removable tips include a medical grade polypropylene Luer lock fitting with a fused silica quartz needle coated with polyimide These materials are resistant to most acids bases and organic solvents To avoid dust contamination we recommend pre rinsing the Perfusion Pencil and tip with distilled water Also it is good practice to discard the first few microliters of solution before using the device The Heated Perfusion Pencil and removable tips are shipped non sterile The Pencil can be chemically sterilized with cleaning solutions in each line The removable tips can be chemically sterilized or auto
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