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Gemini User`s Manual - J

1. 4 KEM NET DATA LOGGING AND CONTROL SOFTWARE 5 2 ADJUSTING THE CONTROLLER FOR STABLE CONTROL WITH DIFFERENT HEATERS 6 2a NV aC eS TOMNI TL 101 Laudat a een nth a tse E LL E 6 2 2 Autotuning Procedure 0 cece eee eee 7 2 3 Tuning for Heating Mantles A Special Case 9 2A FOCNSORPIACCIMCNL o3 S bostes to bud Oo ble eee ee ee 9 3 OPERATIONS GUIDE ee 10 3 1 Front Panel Description 0 0 0 0 ccc cee eee 10 22 Heater ResStICHONS iso quiae cde SS ene exte Sete ean do ce ek cg 11 3 3 Ramp to Setpoint amp Soak Feature 0 0 00 ee eee 11 3 4 Over Temperature Protection Circuit 0 0 00 eee 13 2 imer CONWOIS 229m nds acm SES aor ies pare deem dnx 14 3 6 Output Power Level 0 0 0c ee ene 17 3 7 Temperature Sensor Input 0 0 0 cece eee 19 3 8 Affect of Power Setting on Heating Profile 19 3 9 Do s and Don ts When Using Your Controller 20 3 10 Resetting the Controller for use With Heating Mantles 21 3 11 Changing the Temperature Display Resolution 21 3 12 Changing Between PID and ON OFF Operating Modes 22 3 13 Troubleshooting eere 23 4 APPLICATION NOTES 32 0520 sec eR EE deat uae E SEINEERPUS 25 4 Theory of How the Controller Works Simply 25 4 2 Controlling a Heating Mantle Temperature Direct
2. 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 UArO 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 key once and the display will alternate between hi O and the highest recorded temperature Low Temperature While holding in the key press the 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 4 or W keys until the temperature appears in the display then release both keys 21 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 ques
3. blinking number in the display Down Up Key Lowers or raises the setpoint when x button 2 is simultaneously pressed On Off Switch 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 8 even when the controller is turned off Take appropriate precautions to avoid electrical shock Channel 1 Power Level This knob is the interface to J KEM s patented power control computer which limits the maximum power delivered to the heater See Sections 3 6 and 4 1 Timer Display Indicates the status of the timer See Section 3 5 for timer operation instructions Timer Mode Selector Sets the operating mode of the timer See Section 3 5 for timer operation instructions Channel 1 Power Outlet Plug only 120 VAC devices into this outlet see Section 3 2 Channel 1 Temperature Sensor Input Use the same type of sensor probe as the sensor plug installed on the controller see Section 3 7 The correct sensor type will have the same color plug as the input 9 on the front of the controller 10 Controls for Channel Two 10 Channel 2 Temperature Display Shows the temperature of the process connected to Channel 2 as the default display Shows the setpoint temperature 1 e desired temperature when button is held in Control Key When pressed the display shows the set point temperature To decrease or increase the set point press the key
4. 300 mL 2 L or high 22 L power level The power level set for Channels 1 amp 2 are independent of one another The output power 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 See Section 4 4 for a detailed explanation of how to correctly set up a reaction using your J KEM controller 17 Heating Liquids Each power level is associated with a volume range which 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 1s set to the volume of solution not the size of the flask For example to heat 250 ml of toluene to 809 C in a 1 L round bottomed Front Panel Approx of Volume Range Full Power 1 10 mL 3 10 100 mL 10 50 500 mL 25 300 ml 2 L 50 gt 2L 100 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 t
5. 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 The Gemini controller has 2 completely independent temperature controllers in one cabinet It s important to remember that changes made to Channel 1 have no effect on Channel 2 and visa versa Each channel must be tuned and adjusted separately What is Tuning The controller s most powerful feature is its ability to regulate virtually any heater with stable temperature control To achieve stable control the controller must 1 be set to the correct power level see Section 3 6 and 2 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 describing 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 l
6. Setting 250 500 ml Power Setting 2L 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 Conditions Set point 70 C in slow heating The 300 ml 50 ml Toluene 2 L setting 5096 power is 100 ml Round bottomed flask too much power and results in sporadic control The controller adapts to a wide range of power settings In Power Setting 210 100 ml i e 10 power this example the power 1s Power Setting 50 500 ml i e 25 power varied by a factor of 5X Power Setting 2300 ml 2L i e 5096 power nevertheless reasonable control is maintained in each case 30 40 Time min 19 170 145 120 2n 3 9 95 70 45 20 Set point 155 C Graph 3 A Power gt 2L one Another factor affecting the choice of power setting is the set point temperature For set points Set point 100 C near room temperature a low Power 300 ml 2 L power level is adequate For d 50 power average temperatures 50 1009 the volumes printed on the front of the controller are a Conditions 300 ml collidine 0 good guide For high 500 ml flask d Um temperatures the next higher 500 ml heating mantle 959 power power setting might be needed to supply the heater with additional power 0 10 20 30 40 50 60 70 Time min The output power level limits the total amount of power del
7. 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 re using a heating mantle and none of the parameters have been changed or the controller hasn t been autotuned since you ve received it you re ready to go If the tuning parameters have been changed or the controller has been autotuned and you want to go back to using heating mantles J KEM recommends that the tuning parameters for heating mantles be loaded manually 1 e don t autotune to the heating mantle by following the step by step instructions given in Procedure 4 of Section 3 10 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
8. 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 have a constant that scales the equation to the process being heating These constants plus two other related terms are collectively known as the tuning constants and for the most part they are expressed in units of time since they represent delay times rate of heat transfer times and rate of error accumulation The relative value of each constant depends on the physical characteristics of the process being heated For example for the same amount of input power the rate of heat transfer is twice as high for hexane as compared to water since the coefficient of heat for hexane is 0 54 calories g C and water is 1 0 calorie gram C That means that 1000 watt seconds of input power will raise the temperature of 10 g of hexane 44 C while the same amount of power causes a 24 C rise in water In theory the tuning constants needed to heat hexane are different from those to heat water Fortunately your J KEM controller is self adaptive and is able to adapt it s 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 contro
9. 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 1 8 thermocouple that responds rapidly to changes in air temperature is better than a larger one Section 3 Operations Guide 3 1 Front Panel Description The Gemini controller has two independent temperature controllers in a single cabinet The two controllers are labeled Channel 1 and Channel 2 The controls for Channel 1 have no affect on the operation of Channel 2 and visa versa 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 Controls for Channel One Channel 1 Temperature Display Shows the temperature of the process connected to Channel 1 as the default display Shows the setpoint temperature 1 e desired temperature when the button is held in Control Key When pressed the display shows the set point temperature To decrease or increase the set point press the key 3 or y key 3 while simultaneously pressing the control key The set point appears as a
10. the fine tune autotune procedure the regular autotune procedure that precedes this should normally be performed l Set the equipment up in the exact configuration it will be used If the heater has its own thermostat or power controls turn both as high as they 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 6 If tuning Channel 1 make sure the timer switch is set so that heating is on see Section 3 5 Turn the controller and heater on then enter the desired set point temperature Press and hold in both the N and V buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons Press the AN button 5 times until CyC t appears in the display if you go past this setting press the button until you get back to it First hold in the button while holding in the button press the V button Continue to hold both buttons in until the display reads A or A where 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 48 b
11. then let go of all the keys Press and hold in both the 8 and keys until the temperature is showing again When you do this the alarm will sound Increase the set point by any amount by first holding in the key then while holding in the key press the f key Procedure 3 To Enable the Over Temperature Protection Circuit Perform this Procedure 1 Press and hold in both the 4 and keys on the front of the temperature meter for the Channel you want to change until the word tunE appears in the display then release both keys a Press the V key until LEVL is showing in the display Hold in the key while holding in the key press the key until 2 is showing in the display then let go of all the keys Press the key until SP2 A is showing in the display Hold in the key while holding in the key press the key until dU hi is showing in the display then let go of all the keys 6 Press the W key until LEVL is showing in the display Hold in the key while holding in the key press the key until 3 is showing in the display then let go of all the keys 8 Press the key until rEU d is showing in the display Hold in the key while holding in the key press the key until 1r 2r is showing in the display then let go of all the keys Press the V key until LEVL is showing in the display Hold in the key whil
12. turned heating off To avoid confusion and conflicts between the meters Hold feature and the front panel digital timer it s recommended that the Soak Time feature of Channel 1 be set to in the meters setup menu and not changed For Channel 2 Only It may be useful to use the Hold feature on Channel 2 to automatically turn power off to the heater after a specified period of time since Channel 2 does not have a front panel digital timer 3 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 4 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 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 48 and W keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the 48 key 8 times until the word SPrr appears in the display This is were you set the ramp rate in units of degrees hou
13. 12 or V key 12 while simultaneously pressing the control key The set point appears as a blinking number in the display Down Up Key Lowers or raises the setpoint when x button 11 1s simultaneously pressed Channel 2 Power Level This knob is the interface to J KEM s patented power control computer which limits the maximum power delivered to the heater See Sections 3 6 and 4 1 On Off Switch 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 16 even when the controller is turned off Take appropriate precautions to avoid electrical shock Channel 2 Temperature Sensor Input Use the same type of sensor probe as the sensor plug installed on the controller see Section 3 7 The correct sensor type will have the same color plug as the input 15 on the front of the controller Channel 2 Power Outlet Plug only 120 VAC devices into this outlet see Section 3 2 3 2 3 3 Heater Restrictions Each channel of the controller can individually deliver up to 10 amps of current at 120 VAC but the combined total current from Channels 1 amp 2 can not exceed 15 amps These current ratings are limited to resistive loads heating mantles hot plates ovens etc Use only resistive loads that are safely operated at 120 VAC and require less than 10 amps or damage to the controller and a safety hazard may result e Do not plug oil baths in
14. 6 The heater doesn t have enough Replace with a more powerful heater For assistance contact power J KEM The controller does not come 15 amp fuse on back has blown Replace the fuse on the back of the controller with a new 15 amp on fuse Internal 2 amp fuse has blown Not user serviceable Have qualified electrician replace Circuit breaker on back has tripped Allow to cool then reset circuit breaker The controller comes on but The timer controls are set Change the position of switch 18 or enter a time into the timer does not heat incorrectly See Section 3 5 The heater is broken To verify that the controller is functioning properly place the power level switch on the gt 2L setting and enter a set point of 1009 C Plug a light into the outlet of the controller then wait 1 minute If the light comes on the controller is working properly Controller blinks inPt FAIL The temperature sensor is Clean or replace broken sensor unplugged excessively corroded or broken The process temperature is hotter Correct the over temperature condition than the alarm temperature If audible alarm is sounding press the power level button for the channel who s power level LED is blinking To permanently disconnect alarm see Section 3 6 PArk Controller has been placed in Park 1 Hold in both the A and keys on the front of the J KEM mode temperature meter until tunE appears in the display 2 First hold in t
15. C t appears in the display 3 While holding in the key press the V key until the word on of appears in the display NOTE if the display shows the letter A when the key is held in press The controller can be set the key until on of is in the display then let go of all the keys back to PID control by 4 Press the W key until the word bAnd appears in the display While holding in the following Procedure 4 in key press the VV key until the value 0 1 appears in the display then let go of all Section 3 10 To completely the keys 5 Press and hold in both the 48 or W keys on the front of the controller until the temperature is displayed then release both keys reset the controller to original factory settings follow the procedure in the Appendix Section II 22 3 13 Troubleshooting Corrective Problem Action 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 6 gt 3 during initial warm up or Make sure you ve set the power unstable temperature control level for the channel actually being used Controller is not tuned for process Tune the controller as outlined in Section 2 being heated Make sure you ve set the power level for the channel actually being used The process heats too slowly Output power level is set too low Increase the output power level to the next higher setting Section 3
16. 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 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 Boulevard St Louis MO 63130 USA 314 863 5536 fax 314 863 6070 E Mail jkem911 jkem com Internet on line catalog 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 ll ever encounter If the information in this manual isn t adequate for your application contact our Engineering Department for assistance With J KEM s patented Microtune circuitry INDEX SECTION PAGE 1 QUICK OPERATING INSTRUCTIONS
17. RHONE number of minutes rotate the timer knob to the left enter minutes Hold in the timer Select Ow Set Time Step 3 To change the number of hours in the display momentarily press the timer knob 1 4 Momentarily push knob TR second and the hours digits begin to blink To dca ii M enter hours increase the number of hours rotate the timer knob Him to the right To decrease the number of hours rotate the timer knob to the left Step 4 When the desired time is displayed hold in Wu OFF aE the timer knob for 1 second to enter the time and start the timer When the timer starts the LED TETEA TE under the label ON at Zero lights This indicates iw and start timer Sie E that power to the heater will turn ON when the pom so m timer counts down to zero Hold in timer knob for At any time the timer program can be aborted by H holding in the timer knob for 1 second When this Mus d is done the display changes to t on To turn on heating push the timer knob until the display reads UR EE ilan et Time On xoc I ind Select MEET Set Time Push to Turn to Output Power Level This circuit Figure 1 s 10 amp 11 is the user s 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 1 10 mL low 10 100 mL intermediate 50 500 mL medium
18. Temperature Control For Research and Industry Gemini User s Manual ientific Inc o e 9 Instruments for Science c Scientists RRESEAREREEEERARARARSEAFSRRSARAEESSUSERERARATSESREE BRRARBARHARARESERERSAREARARRRARRRARRRAARRAARRRRERSATEE EAERSEAEESEEESERAZETARESSESRERZUAEARERHARTHESHSESAESSEERE ESESRBHASHTRSESESERESETESSEUATASSSETREATEREBEERTRAHTETEE BEUEZREHESESESESEPEESSESESSESTESEHEZETEESSETENSUAETESHTATERE BESESEHNHEEGEGEHUNXSEESEEEESESNHLTBHESHHKSEBEHUEEREHHEA THNEHHEERENNE EEEZEEREERZERREERZEZRESERZSEZXRERRZUEEZERSZEEZEESGKEEREZZCNEZEESENEEEEHGE Warranty J KEM Scientific Inc warrants this unit to be free of defects in materials and workmanship and to give satisfactory service for a period of 12 months from date of purchase If the unit should malfunction it must be returned to the factory for evaluation If the unit is found to be defective upon examination by J KEM it will be repaired or replaced at no charge However this WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of being damaged as a result of excessive current heat moisture vibration corrosive materials or misuse This WARRANTY is VOID if devices other than those specified in Section 3 2 are powered by the controller Components which wear or are damaged by misuse are not warranted This includes contact points fuses and solid state relays THERE ARE NO WARRANTIES EXCEPT AS STATED HEREIN THERE ARE NO
19. amp it begins to heat instantaneously and when it s turned off it stops heating instantaneously In contrast a hot plate takes several minutes to begin heating when electricity is applied and even longer to stop heating 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 and cools when electricity turns ON or OFF These time constants are called the tuning parameters Every type of heater has its own unique set of tuning parameters For the controller to heat with stability it must have programmed with the tuning parameters for the heater currently being used Prior to shipment tuning parameters were programmed into the controller that maximize heating performance for laboratory heating mantles since these are the most common heaters used in research Tuning is regulated by 5 of the temperature meter s user programmable functions The correct value for these 5 functions can be calculated and loaded 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 h
20. atically 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 4 or W keys on the front of the temperature meter for the channel you want to change until the word tunE appears in the display then release both keys Press the W key once and the word LEUL appears in the display While holding in the key press the f 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 key press the key until on appears in the display then release all keys Hold in both the 8 or W 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 W key until the word off appears Procedure to Read Minimum and Maximum Temperatures Press and hold in both the 4 or W keys on the front of the temperature meter for the channel you want to change until the word tunE appears in the display then release both keys Press the Y key once and the word LEUL
21. ay 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 W key until the number in the display stops changing this will be 0 or 50 or 199 9 depending on thermocouple type Let go of all the keys First hold in the key then while holding in the key press the A key until 3 appears in the display Let go of all the keys 22 Press the A key until ZEro appears in the display Next hold in the key then while holding in the key press the V or A key until the correct value see below appears in the display Let go of all the keys If the TOP meter is being reset enter the value If the BOTTOM meter is being reset enter the value Hold in the key then while holding in the key press the V key until 1 appears in the display Let go of all the keys Let go of all keys then press the A key until SEt 2 appears in the display Next hold in the key then while holding in the key press the A or V keys until the value 5 0 is entered Let of go of all keys 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 A key and Addr will appear in the display Next hold in the key then while holding in the key press the V or A key until the value 1 appears in the display Let g
22. blem 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 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
23. d 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 to be is solution but the first 74 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 specific heaters please contact j KEM 1 liter heating mantle Oil bath 10 ml heating mantle 29 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
24. e holding in the key press the or key until 5 0 is showing in the display then let go of all the keys Press and hold in both the 4 and keys until the temperature is showing again 13 3 5 Timer Controls The 100 hour timer works with Channel 1 only it has no effect on Channel 2 The timer circuit works in conjunction with the digital meter to determine when power is applied to the heater The digital meter is the actual temperature controller the timer circuit only acts as a gatekeeper to determine if the digital meter temperature controller is allowed to apply power to the heater or not By inserting the timer between the digital meter and the heater the timer can turn heater power On or Off based on a user entered time When power to the controller is turned on the timer defaults to the Power Off state as is indicated by the word Off in the display In this state no power is applied to the heater This is a safety feature that insures that power is not applied to a heater following recovery from a power failure The timer has 4 states ON al Tea OFF mi Tere ON at Zero OFF ar Fern ON at n OFF al fer and cycles between the states by pushing the silver timer knob Push to Turn to Push to Turn to Push to Turn to Push to Turn to Ea sa Select J h Set Time Select amp o Ser Time Select g Set Time momentarily ib For example push the NEA VL up timer knob once and the timer change
25. e to start to correct the problem is by loading the original factory settings as detailed in the procedure below If you still have difficulty with your controller our Engineering Department will help you resolve the problem Before beginning this procedure plug a thermocouple into the channel being reset Procedure to Reset the Controller to Original Factory Settings change until the word tunE appears in the display then release both keys Press the V key until LEVL appears in the display Next hold in the key then while holding in the key press the A key until 3 appears in the display Let go of all the keys Press the A key until rSEt appears in the display Next hold in the key then while holding in the key press the A key until the word All appears in the display Let go of all the keys Press and hold in both the W and A keys until the word inPt appears in the display then release both keys During this step the over temperature alarm will begin to sound It is turned off in Step 7 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 s 8 amp 12 Value to enter Blue type T tc i Yellow type K to Black type J er Hold in the key while holding in the key press the A key until the value from above appears in the display Let go of all
26. eating 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 to the oven stable temperature control results Plot 2 Curve 2 Plot 1 Plot 2 70 70 Curve 2 Controller loaded with tuning parameters for drying oven 60 60 Temp Temp 50 Conditions 100 ml Toluene 250 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 50 Curve 1 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 1 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 parame
27. ed 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 heating mantle to the solution to the thermocouple just doesn t occur The delay time between when power 1s 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 1s the source of most controller errors The reason for this can be seen in a simple example 25 4 2 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 pro
28. erature 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 32 II Safety Considerations and Accurate Temperature Control For safety critical and non typical organic reactions especially polymeric reactions or for use with heaters other than heating mantles the user must either 1 monitor the reaction closely to verify the tuning parameters are appropriate for the current application or 2 autotune the controller for the application For any safety critical or high value reaction call J KEM to discuss your application with an engineer prior to beginning Your J KEM controller is capable of regulating virtually any application to 0 1 C if the controller is tuned to the application being heated Since it s possible that the tuning parameters are not set correctly for your application the user must monitor a new reaction to verify the controllers operation A short primmer on tuning is presented below a more detailed explanation is presented in Sections 2 1 and 4 1 Tuning is the process that matches the control characteristics of the
29. f 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 meter 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 4 in Section 3 10 will program the controller for heating mantles For all other heaters see tuning instructions in Section 2 26 After the controller is reprogrammed place a fine gage wire thermocouple MA p 1 3 the size of kite string available from J KEM in the bottom third of Sede 10 the heating mantle and fit the flask snugly on top so that the thermocouple osa 0 100458 is in intimate contact with the heating mantle Set the output power level 50ml 22L 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 next higher power level may be necessary Procedure to Load Tuning Parameters for External T
30. hange 1 4 second DN al Zo OFF at Zern When the timer counts to 00 00 power is turned On indefenently Push t Iurn to Select d WS nel lime v To immediately exit a timed run hold in the timer knob for 1 second Function Push knob for Change 1 4 second TO c o TON at dere OFF at Zero GN at eru OPP at Term OFF at Zere PET oO E AA in ie Push knob for Hold in knob fle pia secon 1 4 second for 1 second alls MN L o Push to Turn to rogram Push to a Torn ta Function Push te Purn ti Program Push to Iurn te E 2 amp elrct P Sect Time Change Select Fr d Lime Change Select E M Set Time Change Select Set Time o y 4 then Enter Minutes Enter Hours Function Push knob for Change 1 4 second 7 ON at era OFF at Term Q n oo0um al Zero ON al fern fae UN ad fern OFF al damn A m Be Push knob for Hold in knob uidi aad E c ag second B J 1 second Program lush ta m In Function Fush te I i P Turn to sh te Turn in s ush to urn t Proaram ush to 3 lurn i demi d sel deri Select p 2 Ser Tune Change Select e Set Time a Select Set Time i 1 j h kh id Uu gt then Enter Minutes Enter Hours To immediately exit a timed run hold in the timer knob for 1 second 15 Heating for a Set Period of Time In this mode the user enters the amount of time to heat before turning heating off
31. hat indicated on the front panel should be used Power Setting Explanation 80 ml toluene 100 ml flask 100 ml heating mantle SP 80 C 80 ml collidine 100 ml flask 100 ml heating mantle SP 170 C 80 ml water 100 ml flask 100 ml heating mantle SP 80 C 125 ml toluene L flask L heating mantle SP 80 C 150 ml toluene 250 ml flask 250 ml heating mantle Sp2359 50 500 ml 25 power 300ml 2L 50 power 300ml 2L 50 power 10 100 ml 10 power 10 100 ml 1096 power Organic solvents heated to 50 110 C are set to the volume range on the front panel When choosing between 2 power settings 1 e 80 ml also falls within both the 10 100 ml range and the 50 500 ml range choose the higher setting Even though the solvent volume is less than the range of this power setting it should be used because high temperatures require additional power While the setting 50 500 ml would work since the heat capacity of water is twice that of a typical organic solvent 1 cal g 9 K a higher power setting can be used to compensate for the higher heat capacity When the heating mantle size is substantially larger 5X than the volume being heated i e the heating mantle has excess heating capacity for the volume being heated a lower power setting gives better control Even though the solvent volume isn t included in this power setting it should be used because low tem
32. he key then while holding in the 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 23 Displayed temperature is The controller has not warmed up The display temperature reads low when the controller is first incorrect turned on but will self correct as it warms up The controller can be used immediately since it will warm up during the initial stages Note Types K amp J of heating Thermocouples display negative temperatures but are not calibrated for them Wrong type of thermocouple is Thermocouples are color coded Thermocouple plug and plugged into controller thermocouple receptacle must be the same color see Section 3 7 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 Temperature display offset needed To enter a controller display offset Turn on controller Allow to warm up for 30 minutes Record displayed temperature Press both the A and V keys on the front of the temperature meter for the channel you want to change until tunE appears then let go of the keys Press the W key until LEVL appears First hold in the key then w
33. he controller monitors the shape of Temp PULM ye the heating curve during initial warm up and d DUE decreases power to the heater before the set point is reached so that the solution reaches the Td set point with minimal over shoot Notice that A 3 the heater turns off for varying periods of time 7 Power before the set point temperature Is reached F a The second feature of PID mode is that it adjusts the percent of time the heater is on so that the set Il point is maintained precisely The advantage of Of T rme 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 4 in Section 3 10 Set 1 M Point eg 1 Press and hold in both the 4 or W keys on the front of the temperature meter for the Procedure to change channel you want to change until the word tunE appears in the display then let go controller to ON OFF mode of the buttons BIS SOMNIIS MESE 2 Press until the word Cy
34. hermocouples l Press and hold in both the 4 or V keys on the front of the temperature meter for the channel you want to change until the word tunE appears in the display then release both keys Press the key once and the word bAnd will appear in the display While holding in the key press the or Y key until the value 5D 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 4 or V key until the value 2 appears in the display then release all keys Press the 4 key once and the word dEr t will appear in the display While holding in the key press the 4 or W key until the value 5 appears in the display then release all keys Press the key once and the word dAC will appear in the display While holding in the key press the N or V key until the value 5 0 appears in the display then release all keys Press the 4 key once and the word CyC t will appear in the display While holding in the key press the or V key until the value 5 0 appears in the display then release all keys Press and hold in both the or V keys until the temperature appears in the display then release both keys To return to using thermocouples in solution perform Procedure 4 in Section 3 10 4 3 Automatic Storage of Min Max Temperatures The controller will autom
35. hile holding in the key press the A key until 3 is showing in the display then let go of all keys Press the A key until ZEro is showing in the display Note the current display offset this is the number blinking in the display Calculate the new offset temperature using the equation New Current Display display offset Displayed Correct Offset blinking in display temperature temperature First hold in the key then while holding in the key press the A or V keys until the new offset temperature is showing then let go of all the keys 10 Press the A and V keys until the temperature is displayed 24 Section 4 Application Notes Supplemental application notes on the following topics are available by contacting J KEM Application Note Subject How to heat oil baths with your controller Included in Appendix 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 100ml 50 500nl InstrumentsforScience Lol 7 300mI 2L Heat Of QD gt 2L Output Power Level 120 vac Power to heater Model 210 120Vac 840 watts Temperature of process Heating mantle from the thermocouple Figure 2 The controller the heating mantle and the thermocouple form a clos
36. ithout 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 Select the Channel to Operate The Gemini has two completely independent controllers in a single cabinet Both channels provide the same type of temperature control the only difference is that Channel 1 has a 100 hour timer to turn heating On Off at a user set time and Channel 2 does not If Channel 2 is being used only steps 3 amp 4 need to be followed if Channel 1 is being used then steps 3 amp 4 must be followed but also step 5 where the timer controls are set For more information on using the timer controls see Section 3 5 3 Set the power level switch 10 100 ml 50 500 ml Hue ede we Dower Sw to th l f soluti 10m V 300 mi2L acts like a variac if the reaction 0 the volume or SOLUTION ee e is heating too slowly or you need being heated not the size of the Lon g 7 D gt 2L more power e g heating to high flask being used Adjust the power on 4 y temperatures give the heater level for the channel being used The Output Powsr Level more power by turning the power power level switch can be thought of as level up one setting If the a solid state variac Volume ranges reaction needs less power than are printed above this switch as a A power ee normal e g heating to low temperatures setting of a variac setting of guide to select the correct power level lt 60 C or the te
37. itted 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 s 8 amp 12 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 heating 3 8 Affect of Power Setting on Heating Profile The following graphs show the affect of selected power levels on heating performance in a variety of situations Each example contains 1 optimal and 1 or 2 less optimal settings demonstrating use of the output power level Graph 1 This graph shows typical Conditions Set point 75 C heating profiles for a Laboratory oven laboratory oven and an HPLC column In the example of the oven the heating curves for 2 different power levels are shown The 50 500 ml setting 1s the appropriate amount of power to heat to Conditions Set point 45 C PLC Column wrapped with heating tape 75 C and thus results in a Power Setting 50 500 ml smooth heating curve The gt 2L power setting is too much power and results in x 0 oscillation around the set Time min point Power
38. ivered to the heater In this sense it works like a variac and can be used like one If the heater isn t getting enough power turn the power level up one notch if it s getting too much power turn it down 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 coated coated thermocouple or use the ex
39. 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 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 f or W keys until the temperature appears in the display then release both keys 21 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 controller is ON when it s below the set point Tpmpersie cinis onan Mode and OFF when above The disadvantage of this eee 1 Ak Tn mode is a large over shoot of the set point 5 Set 30 on initial warm up and oscillation of temperature around the set point thereafter The reason for the overshoot is because the heater turns off only after crossing the set point and until the heater cools down the temperature continues to rise This method works well for Pone j heaters that transfer heat rapidly such as heat qunm cu o sc ep occ Wee lamps it s acceptable for heaters such as heating mantles 5 overshoot but it s terrible for heaters that transfer heat slowly vacuum ovens heating blocks etc In PID mode t
40. l 1 make sure the timer switch is set so that heating is on see Section 3 5 Turn the controller and heater on then 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 9 Press and hold in both the N and V buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons 4 Press the AN button 5 times until CyC t appears in the display if you go past this setting press the button until you get back to it 5 First hold in the button while holding in the button press the V button Continue to hold both buttons in until the display reads A or A where 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 8 While holding in the button press the 48 button to change the display to on then release both buttons 9 Press and hold both the N 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 seque
41. lding in the key press the 4 or W key until the value 50 appears in the display then let go of 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 M or V key until the value 3 0 appears in the display then let go of all the keys Press the 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 4 or Y key until the value 30 appears in the display then let go of all the keys Press and hold in both the M or W keys until the temperature appears in the display then release both keys 3 11 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 or W 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 LEVL appears in the display First hold in the key then while holding in the key press the
42. ller 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 160 C organic solvents using heating mantles since this is the most common application for J KEM controllers Since it s impossible for J KEM to predict the application the controller will be used for the researcher must be aware of the possibility that the tuning constants loaded into the controller may not be a set that results in stable temperature control It s the researcher s responsibility to monitor the temperature regulation of a reaction If you encounter a process that your J KEM controller does not heat with stability you have two resources Autotune Feature Your controller has and autotune feature that when turned on see Sections 2 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 33 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 plac
43. ly 26 4 3 Automatic Storage of Min Max Temperatures 21 4 4 How to Set Up a Reaction With Your Temperature Controller 28 APPENDIX Ge ne am a a a ee eae 32 I Using the Controller With an Oil Bath Application Note 1 22 II Safety Considerations and Accurate Temperature Control 33 III Resetting the Controller to Original Factory Settings 34 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 five steps below are the basics of using your temperature controller 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 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 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 w
44. me 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 110ml V 300 ml 2 L Heat 9 JA gt 2L Of Wes m OUTU 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 When the power control computer is set to the correct power level your Test System Set Point 1159 C 2 L of N N dimethyltormamide 3 L Round Bottomed Flask controller can regulate virtually any sala heater to 0 1 C with less than 1 C overshoot on initial warming Test System Set Point 85 C Standard Lab Oven Temperature 9C 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 3l 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 vol
45. mperature overshoots the since it s easier to guess the volume 1 10 ml 3 set point excessively turn the power being heated than the appropriate 10 100 ml 10 down one setting DO NOT set the percent power to apply to a heater 50 500 ml 25 power switch on a setting too high Heat Off turns off the heater so the 300 ml 2 L 50 initially to heat the reaction quickly and controller displays temperature only 22L 10076 then lower it to the correct setting this Section 3 6 should be read by all new degrades heating performance users 4 Enter the setpoint 1 e the desired temperature Hold in the button and simultaneously press the key to increase or the B key to decrease the setpoint The setpoint can be seen at anytime by holding in the j button the setpoint appears as a blinking number in the display 5 Set the timer lr i cr The timer controls only affect the operation of Channel 1 For Channel 1 Only The red LED display window always shows the effect that Thssanertus s the Ben tin the timer controls have on the state of Channel 1 s outlet OFF or ON depen na output power When the controller is first turned on the ee eG ee M ION timer window displays Off to indicate the timer controls ipd l Push to Turn to have disabled output power To set the timer controls so switch and whether any time select Set Time l i tin the displa that they will allow power to be applied to the outlet c pray T quickly push in
46. n heater power SPrn setPoint Ramp Run Allowable Values ON OFF Hold This parameter turns the Ramp to Setpoint feature ON or OFF During an active run if this parameter is set to Hold the setpoint ramp stops and holds at its current value This continues until the parameter is set to ON or OFF When set to OFF the values in SetPoint Ramp Rate and Soak Time are ignored SOAK soak Time Allowable Values 0 to 1440 min This specifies the amount of time to soak at the setpoint after the 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 off after the time expires 11 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 Channel 1 of this controller is equipped with a digital 100 hour timer the digital timer and the Ramp to Setpoint feature are completely independent of each other For example if the digital timer is set to turn heating OFF after 5 hours heating is turned off even if a ramp step is in progress Likewise if a Soak time turns heating off after 3 hours and the digital timer is set to turn heating off after 10 hours the digital timer has no effect since the expired Soak time already has
47. nce 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 Y button until off is displayed 7 New tuning T Pu values loaded into memory Set d L Point i Heat to set point after entering The autotune sequence PEN During autotune the controller heats Ao 0 OOP AL NN 092 V to 75 of the set point temperature set point j where it oscillates for several cycles before loading the new tuning parameters After the tuning parameters are loaded it heats to the Start Tio ta i set point temperature Tuning below During T1 4 the controll i AT asus heating delved Quarter cycle times the set point prevents any damage rates of heating and cooling that might occur from overheating Time Autotuning the Controller for Very Fine Control This procedure is not recommended for heating mantles see Section 2 3 In the majority of cases the procedure above results in stable temperature control with any heater A second version of the autotune routine is available and can be used when the heater is already at or close to the set point is being tuned at a temperature close to room temperature or for very fine control in demanding situations If stable temperature control doesn t result after performing the first autotune routine the procedure below should be performed Before performing
48. ned off See the section below titled Heating for a Set Period of Time The t on state standing for Time On allows the user to enter an amount of time to delay before applying power to the heater While time is present in the timer no power is applied to the heater even if the temperature meter calls for power to be applied but when time counts down to O heat is turned on indefinitely See the section below titled Delay Heating for a Set Period of Time 14 Over View of the Timer Functions The timer knob is a multi function knob When it s pushed in for 1 4 second it causes the timer to advance to the next function When it s pushed in for 1 second it enters programming mode In programming mode the user enters time into the timer or locks the entered time into the timer which starts the program running a running program can be aborted by holding in the timer knob for 1 second When in programming mode rotating the knob in a clockwise direction increases the amount of time entered into the timer Rotating the knob in a counter clockwise direction decrease the amount of time when rotating in a counter clockwise direction the timer rolls over from 00 to 59 minutes when entering minutes or from 00 to 99 hours when entering hours ON at fem OFF at Aer When the timer counts to 00 00 power is turned Off indefenently Push t Purn to Select 3 Sel Time P Function Push knob for C
49. ns the ramping feature ON and OFF First hold in the key then while holding in the key press the and V keys until OFF appears in the display then let go of all the keys To exit programming mode press and hold in both the and W keys until the temperature appears in the display then release both keys 12 3 4 NOTE The controller is shipped with the Over Temperature Protection Circuit DISABLED To Over Temperature Protection Circuit activate this circuit for either or both channels follow Procedure 3 below Both channels of the Gemini are equipped with over temperature protection circuits This circuit turns off heating and sounds an audible alarm if the process temperature for Channel 1 and or Channel 2 exceeds the set point by 5 degrees The high temperature limit i e the limit that must be exceeded to trigger this circuit is factory set to 5 degrees for both channels but can be changed or enabled or disabled as outlined in the procedures below The over temperature protection circuit for Channels 1 amp 2 are independent of each other A temperature limit entered into the temperature meter controlling Channel 1 has no affect on Channel 2 and visa versa To Change the Number of Degrees that the Reaction Temperature Must Procedure 1 Exceed the Set Point to Trigger the Over Temperature Alarm Perform this Procedure 1 Press and hold in both the 4 and keys on the front of the temperature meter for the Channel y
50. o of all the keys Press the A key and bAud will appear in the display Next hold in the key then while holding in the key press the V or A key until the value 9600 appears in the display Let go of all the keys Press the A key and dAtA will appear in the display Next hold in the key then while holding in the key press the V or A key until the value 18n1 appears in the display 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 If the alarm is sounding reset it by pressing the Output Power Level button for the channel being reset 35
51. ou want to change until the word tunE appears in the display then release both keys Press the key until SEt 2 is showing in the display First hold in the key while holding in the key press the or W keys until the desired temperature limit is showing in the display then let go of all the keys Press and hold in both the f and keys until the temperature is showing again Procedure 2 To Permanently Disable the Over Temperature Circuit Perform this Procedure Press and hold in both the 4 and VV keys on the front of the temperature meter for the Channel you want to change until the word tunE appears in the display then release both keys Press the W key until LEVL is showing in the display Hold in the key while holding in the key press the key until 2 is showing in the display then let go of all the keys Press the key until SP2 A is showing in the display Hold in the key while holding in the key press the W key until nonE is showing in the display then let go of all the keys 6 Press the W key until LEVL is showing in the display Hold in the key while holding in the key press the key until 3 is showing in the display then let go of all the keys 8 Press the key until rEU d is showing in the display Hold in the key while holding in the key press the key until 1r 2d is showing in the display
52. peratures are better regulated with less power 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 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 1 e 5096 power it s usually better to have too much power rather than too little If the heater heats too slow increase the power to the 22 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 8 shows the type of performance you should expect from the controller with different pieces of equipment 18 3 7 Temperature Sensor Input Both channels of the controller are f
53. permanently This is useful to heat a reaction or other lab instrument for a set period of time and then have the reaction stop heating automatically While at this setting and while entering a time into the timer no power is applied to the heater Step 1 When the timer displays toFF holding in the timer knob causes the display to change to a clock showing 00 00 The left 2 digits are hours and the right 2 digits are minutes The minutes digits are blinking which indicates that their value can be changed Step 2 To increase the number of minutes rotate the timer knob to the right To decrease the number of minutes rotate the timer knob to the left Step 3 To change the number of hours in the display momentarily press the timer knob 1 4 second and the hours digits begin to blink To increase the number of hours rotate the timer knob to the right To decrease the number of hours rotate the timer knob to the left Step 4 When the desired time is displayed hold in the timer knob for 1 second to enter the time and start the timer When the timer starts the LED under the label OFF at Zero lights This indicates that power to the heater will turn OFF when the timer counts down to zero At any time the timer program can be aborted by holding in the timer knob for 1 second When this is done the display changes to toFF To turn on heating push the timer knob twice until the display reads On 16 Push to Tu
54. r First hold in the key then while holding in the key press the AN and V keys 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 N and keys until the desired setting appears in the display then let go of all the keys Press the 48 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 AN and V keys until the desired time appears in the display then let go of all the keys If a soak time is set the controller display will alternate between showing the current reaction temperature and the word StoP when the soak time has expired to indicate that power has been turned off To exit programming mode press and hold in both the and W keys until the temperature appears in the display then release both keys Press and hold in both the 48 and W keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the key 9 times until the word SPrn appears in the display This function tur
55. ress the A key once and the word dEr t will appear in the display Next hold in the key while holding in the key press the A key until the value 50 appears in the display Let go of all the keys Press the A key once and the word dAC will appear in the display Next hold in the key then while holding in the key press the A key until the value 3 0 appears in the display Let go of all the keys Press the A key once and the word CyC t will appear in the display Next hold in the key then while holding in the key press the A key until the value 30 appears in the display Let go of all the keys Press the A key until the word SPrn appears in the display Next hold in the key then while holding in the key press the V or A key until the word OFF is displayed Let go of all the keys 34 Press the V key until the word LEVL appears in the display First hold in the key then while holding in the key press the 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 nonE 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 displ
56. rn t Select i i F OFF al Zero ON al fcr Momentarily push knob to lock in minutes CES af Aero OFF at fern lIurn to 7 het Time Turn ta Set Time Push t Select 07 Set Time N at Zero OFF at Zero lurn to Sel Time Push to Select g ON at Zero OFF at Zero Hold in the timer knob for 1 second Iurn to Set Time Push to Select eJ i Rotate knob to enter minutes Rotate knob to enter hours ONatZem OFF at Zero Hold in timer knob for 1 second to store time and start timer Set Fame 1 ON at Zero OFF at Zero Turn to Set Time Push to Select 3 3 6 Delay Heating for a Set Period of Time In this mode the user enters an amount of time to delay before turning on power to the heater This is useful to start heating a reaction or piece of equipment automatically at a specific time While at this setting and while entering a time into the timer no Pushto Turn to power is applied to the heater Aa Step 1 When the timer displays t on holding Se e the timer knob in for 1 second causes the display to change to a clock that shows 00 00 The left 2 TEE digits are hours and the right 2 digits are minutes E EUM TT EE The minutes digits are blinking which indicates that Select 7 uiid their value can be changed VL e Step 2 To increase the number of minutes rotate the timer knob to the right To decrease the EIS
57. s Push from the Off state to NOTE Pushing in on the timer knob quickly for about 1 4 second causes it to advance to the next the On state push it state Holding in the knob for 1 second changes to the mode where time is entered into the timer again and it changes to the toFF state Repeatedly pushing the knob cause the time to cycle between its three normal states of On toFF and t on If the Power Reduction Circuit Section 3 6 is set to the Heat Off position the timer window always displays oFF The four states of the timer circuit are explained below In the off state no power is applied to the heater even if the temperature meter calls for power to be applied The controller always enters the off state when power is turned on or following recovery from a power failure The controller also enters the off state when the power reduction circuit is set to the Heat Off position see Section 3 6 In the on state the timer circuit applies power to the heater when the temperature meter calls for power to be applied Whenever power is applied to the heater the small LED dot on the left of the timer window is lit Depending on the power needs of the heater this dot may blink rapidly The toFF state standing for Time Off allows the user to enter the amount of time the controller should heat until heating is automatically turned off While time is present in the timer power is applied to the heater when the time counts down to 0 heating is tur
58. solution phase reaction l 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 Placea 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 V4 1 2 is better is covered by the fluid in the reaction flask Heater power cord 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 of the digital meter 2 While holding in the Star button press the Up arrow to increase and the Down arrow to Star button Up to increase and Down to decrease arrows decrease the setpoint temperature When the desired setpoint temperature is showing 1n 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 volu
59. t 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 controller If the reason for using an oil bath is that a small volume 1s 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 temp
60. ternal thermocouple method Section 4 2 avoid exposure of the controller to corrosive gases and liquids The atmosphere of a research hood is corrosive to all electronics Place the controller outside the hood away from corrosive gases 20 3 10 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 4 Perform when using heating mantles with round bottomed flasks This procedure takes about 2 minutes to perform Press and hold in both the 4 or W keys on the front of the temperature meter for the channel you want to change until the word tunE appears in the display then release both keys Press the key once and the word bAnd will appear in the display First hold in the key then while holding in the key press the M or Vv 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 4 or Vv key until the value 10 appears in the display then let go of all the keys Press the key once and the word dEr t will appear in the display First hold in the key then while ho
61. ters 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 procedure is complete and the tuning parameters are determined the controller loads them into its memory for current and future use Heating mantles are a special case and are covered in a separate paragraph Section 2 3 Autotuning Procedure This procedure is not recommended for heating mantles see Section 2 3 Perform this procedure only on the controller channel in use 1 Setthe equipment up in the exact configuration it will be used For example to tune to a vacuum oven place the thermocouple in the room temperature oven and plug the oven into the controller If the oven or heater has its own thermostat or power control turn both as high as they ll go 25 Set the controller to the appropriate power level see Section 3 6 If tuning Channe
62. 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 5 the key press the A key until the value O C appears in the display Let go of all the keys Press the A key once and the word SP1 d appears in the display Next hold in the key then while holding in the key press the A key until the value SSd appears in the display Let go of all the keys 7 Press in both the W and A keys until the temperature appears in the display the word PArk also appears then release both keys To turn off the alarm change the set point by holding in the key then hold in the A key until a value gt 100 is entered Let go of all the keys Press the Output Power Level button for the channel being reset The alarm should turn off change until the word tunE appears in the display then release both keys Press the A key once and the word bAnd will appear in the display Next hold in the key then while holding in the key press the A key until the value 10 appears in the display Let go of all the keys Press the A key once and the word int t will appear in the display Next hold in the key then while holding in the key press the A key until the value 10 appears in the display Let go of all the keys P
63. the timer function knob once This will change the timer status to On For additional informa tion on the operation of the timer see Section 3 5 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 JE J KEM Scettific KEM Net Control Your World Pre 4 Logging of Time and Temperature Logging of Power for Exo and 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
64. tions 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 1 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 28 Thermocouples Thermocouples 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 isatype 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 Teflon coate
65. to 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 Ask about J KEM s new 400 series controllers for use with oil baths 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 Single and multi step ramps can be run using KEM Net software Examples of Program Ramps un e S 2 e Temperature Power Off Temperature un e D e z e 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 1s 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 rate of heating cooling Note this parameter specifies the desired rate of heating cooling the actual rate of heating is dependent o
66. utton to change the display to At SP then release both buttons Press and hold both the 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 displays the process temperature To abort autotune manually repeat steps 3 8 and 9 except in step 8 press the Y button until off is displayed 8 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 underpowered A more powerful heater may be needed contact J KEM for assistance Tuning for Heating Mantles A Special Case This section gives special consideration to heating mantles since they re the most commonly used heaters in research Every heating mantle size has its own optimum set of tuning parameters and if you wanted the controller could be tuned or autotuned every time
67. 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 output power level 5 amp 13 serves just this function It allows the researcher to reduce the power of the controller depending on the amount of heat needed This circuit can be thought of as determining whether the heating power is Very low 0 mL Low 10 100 mL Intermediate 50 500 mL Medium 300 mL 2 L or High gt 2 L The proper power setting becomes instinctive after you ve used your controller for awhile For additional information see Section 3 6 Controlling a 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 o

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