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High Power Temperature Controllers User Manual - J

1. Controlling the Heating Mantle Temperature Directly In a normal heating setup the thermocouple is placed in the solution being heated The controller then regulates the temperature of the solution directly The thermocouple could alternately be placed between the heating mantle and the flask so that the controller regulates the temperature of the heating mantle directly which indirectly regulates the temperature of the solution Advantages to this method include 1 The temperature of any volume micro liters to liters can be controlled 2 Temperature control is independent of the properties of the material being heated e g viscosity solid liquid etc 3 Air and water sensitive reactions can be more effectively sealed from the atmosphere The temperature controller must be programmed for use with an external thermocouple before this procedure is used see following procedure The following step by step procedure programs the controller to regulate heating mantle temperature If you switch back and use the controller with the thermocouple in solution Procedure 1 in Section 3 10 will program the controller for heating mantles For all other heaters see tuning instructions in Section 2 21 After the controller is reprogrammed place a fine gage wire thermocouple 1 3 the size of kite string available from J KEM in the bottom third of the heating mantle and fit the flask snugly on top so that the thermocouple is in intimate c
2. Heat my reaction to 80 C then turn on my peristaltic pump to add reagents or as sophisticated as Turn on my Stirrer then ramp my reaction from 25 C to 100 C if 45 minutes hold for 2 hours then turn off heating When the reaction cools to 50 C turn off the stirrer If at any point the reaction exotherms and heats above 110 C turn on my chiller and keep it on until I manually reset the system Contact J KEM for additional information Section 2 Adjusting The Controller For Stable Control With Different Heaters NOTE The discussion is Section 2 only applies to the Setpoint Controller i e the meter on the far left The setpoint controller regulates heating of the reaction The Limit Controller the meter on the right only acts in the event of an over temperature condition but will have no effect on temperature regulation of the reaction Only the setpoint controller should be tuned as described below 2 1 What is Tuning The controller s most powerful feature is its ability to regulate virtually any heater with stable temperature control For stable control the controller requires two things 1 the controller must be set to the correct power level see Section 3 7 and 2 that it must be tuned to the heater being used Tuning is the process that matches the control characteristics of the controller to the heating characteristics of the heater The controller is said to be tuned to the heater when its memory Is p
3. BECO the timer knob in for 1 second causes the display to change to a clock that shows 00 00 The left an recon 2 digits are hours and the right 2 digits are ae Gan aes minutes The minutes digits are blinking which a wo a indicates that their value can be changed v Hold in the timer Step 2 To increase the number of minutes rotate TNT UNNER BIET the timer knob to the right To decrease the Rotte inka number of minutes rotate the timer knob to the enter minutes left Step 3 To change the number of hours in the display momentarily press the timer knob 1 4 Momentarily push knob EE second and the hours digits begin to blink To ee enter hours increase the number of hours rotate the timer lect y Se Time 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 mme in the timer knob for 1 second to enter the time and start the timer When the timer starts the EEEE Fara LED under the label ON at Zero lights This urn to and start timer ie Stet indicates that power to the heater will turn ON Frid Select Ga Se when the timer counts down to zero Hold in timer knob for At any time the timer program can be aborted by holding in the timer knob for I second When this is done the display changes to t on To turn on heating push the timer knob until the display RETT Tat Select 3 sat Time ON af Zero n OFF at Zeru Hold
4. button to change the display to on then release both buttons 10 Press and hold both the 4 and VW buttons for 3 seconds until the temperature appears in the display The controller is now in its autotune mode While in autotune the display alternates between tunE for autotune and the process temperature When the autotune sequence is done this may take in excess of an hour the controller stops displaying tunE and only displays the process temperature To abort autotune manually repeat steps 4 9 and 10 except in step 9 press the VW button until off is displayed New tuning Temp values loaded en into memory The autotune sequence Point During autotune the controller heats Heatto setpoint to 75 of the set point temperature after entering newparameters where it oscillates for several cycles OS1 052 N before loading the new tuning EE BE VEE 2 C Je arameters After the tunin set point p wuning US parameters are loaded it heats to the set point temperature Tuning below the set point prevents any damage ETG that might occur from overheating Start TL 42 T4 AT During T1 4 the controller measures heating delays and Quarter cycle times rates of heating and cooling Time Autotuning the Controller for Very Fine Control This procedure is not recommended for heating mantles see Section 2 3 In the majority of cases the procedure above results in stable temperature control
5. heater types Thermocouple J KEM Scientific 10 100ml 50 500m InstrumentsforScience 1 10mi 300mk 2L Heat he 120 vac Power to heater Model210 120 Vac 840 watts Temperature of process Heating mantle from the thermocouple Figure 2 The controller the heating mantle and the thermocouple form a closed loop feedback system If the process temperature is below the set point the controller turns the heating mantle on and then monitors the temperature rise of the solution If a small rise results indicating a large volume is being heated the controller sets internal parameters appropriate for heating large volumes If a large rise in temperature results the controller responds by loading a set of parameters appropriate for heating small volumes For the controller to work ideally information needs to travel instantaneously around the feedback loop That means that any power the controller applies to the heating mantle must reflect itself in an instantaneous temperature rise of the solution and the thermocouple Unfortunately this type of instantaneous heat transfer from the heating mantle to the solution to the thermocouple just doesn t occur The delay time between when power is applied to the heating mantle and when the solution rises in temperature and also the converse when power is removed from the heating mantle and the solution temperature stops rising is the source of most controller errors The reason for
6. in knob for 1 second Push t Turn to elec Set Time Select d reads On Temperature Sensor Input Each controller is fitted with a specific type of temperature sensor input and can only be used with a temperature sensor of the same type thermocouple or RTD For the correct temperature to be displayed the thermocouple type must match the receptacle type on the front of the controller Figure 1 7 All thermocouples are color coded to show their type Blue type T Yellow type K Black type J The color of the thermocouple plug must match the color of the receptacle on the front of the controller The thermocouple plug on the left is connected to the setpoint controller on the far left and that on the right to the limit controller If the thermocouple to either unit becomes broken or disconnected the controller displays an error message and stops heating Rather than using one dual element thermocouple 2 single element thermocouples can be used if desired 19 Power Reduction Circuit This circuit 11 limits the maximum output power delivered by the controller It determines whether the controller heats at a very low 1 10 mL low 10 100 mL intermediate 50 500 mL medium 300 mL 2 L or high gt 2 L power level The power reduction circuit acts as a solid state variac The table to the right shows the maximum output power from the Front Panel Approx of controller to the heater depending on
7. it will be used For example to tune a vacuum oven place the thermocouple in the room temperature oven then plug the oven into the controller If the oven has its own thermostat or power control turn both as high as they ll go 2 Set the controller to the appropriate power level see Section 3 7 Turn the controller and heater on and enter the desired set point temperature If the set point isn t at least 30 C above ambient skip this procedure and go to the next procedure Autotuning the Controller for Very Fine Control 3 Enter a temperature into the limit controller about 25 C higher than the set point entered into the setpoint controller 4 Press and hold in both the AN and Y buttons for 3 seconds on the front of the setpoint controller until the word tunE appears in the display then release both buttons 5 Press the button 5 times until CyC t appears in the display if you go past this setting press the W button until you get back to it 6 First hold in the button while holding in the button press the VW button Continue to hold both buttons in until the display reads A or A where HH is some number 7 Release the button and press the W button until tunE once again appears in the display Press and hold the button and tunE will change to off indicating that autotune is off 9 While holding in the button press the
8. of all the keys Press the key once and the word dAC will appear in the display Next hold in the key then while holding in the key press the AN key until the value 3 0 appears in the display Let go of all the keys Press the y key once and the word GyG t will appear in the display Next hold in the key then while holding in the key press the 8 key until the value 30 appears in the display Let go of all the keys Press the key until the word SPrn appears in the display Next hold in the key then while holding in the key press the Y or A key until the word OFF is displayed Let go of all the keys First hold in the key then while holding in the key press the key until 2 appears in the display Let go of all the keys Press the AN key until SP2 A appears in the display Next hold in the key then while holding in the key press the key until the word Dvhi appears in the display Let go of all the keys Press the AN key until diSP appears in the display Next hold in the key then while holding in the key press the W or key until the value 0 19 appears in the display Let go of all the keys Press the key until Lo SC appears in the display Next hold in the key then while holding in the key hold in the W key until the number in the display stops
9. power will be applied or removed from the heater when the time in the timer goes to 0 15 USB serial communications port Heater Restrictions The controller the current and voltage listed in the table below into resistive loads heating mantles hot plates ovens etc Use only resistive loads that are safely operated at the listed voltage and require less than the listed current or damage to the controller and a safety hazard may result Model Number Output Voltage Maximum Output Current HCC 130 120 VAC 30 Amps HCC 215 220 240 VAC 15 Amps HCC 230 220 240 VAC 30 Amps Do not plug low voltage oil baths into your controller Many oil baths are not 120 or 240VAC devices and become a fire hazard unless properly connected to the controller Devices other than resistive loads can be used with your controller but certain restrictions apply Device Type Incandescent lamps lt 3000 watts Set the power reduction circuit Infrared heaters to the gt 2 L position The controller must be l m Inductive loads lt 10 amps programmed for this use solenoids transformers motors lt horsepower Request application note ANS 12 Setting the Controller for Safe Operation Two completely separate controllers are contained in the J KEM Model HCC and it s important to understand what each controller does in order to take full advantage of the Model HCC s safety benefits The meter on the far left labeled S
10. shoot Notice that the heater turns off for varying periods of time rige before the set point temperature is reached The F to heater second feature of PID mode is that it adjusts the percent of time the heater is on so that the set point is maintained precisely The advantage of tim 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 the procedure in Section 3 10 1 Press and hold in both the 8 and W keys on the front of the temperature Procedure to change meter until the word tunE appears in the display then let go of the controller to ON OFF mode buttons The controller can be set 3 While holding in the key press the y key until the word on of back to PID control by appears in the display NOTE if the display shows the letter A when the following the procedure in keys is held in press the key until on of is in the display then let Section 3 10 To completely go of all the keys reset the controller to 4 Press the VW key until the word bAnd appear
11. takes about 2 minutes to perform Press and hold in both the W and AN keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the key once and the word bAnd will appear in the display First hold in the key then while holding in the key press the W or key until the value 10 appears in the display then let go of all the keys Press the key once and the word int t will appear in the display First hold in the key then while holding in the key press the W or key until the value 10 appears in the display then let go of all the keys 4 Press the key once and the word dEr t will appear in the display First hold in the key then while holding in the key press the W or key until the value 50 appears in the display then let go of all the keys 5 Press the key once and the word dAC will appear in the display D First hold in the key then while holding in the key press the Y or key until the value 3 0 appears in the display then let go of all the keys Press the A key once and the word GyG t will appear in the display First hold in the key then while holding in the key press the W or key until the value 30 appears in the display then let go of all the keys Press and hold in both the W and keys until the temperature a
12. the display if you go past this setting press the W button until you get back to it 6 First hold in the button while holding in the button press the button Continue to hold both buttons in until the display reads A or A where HH is some number Release the button and press the VW button until tunE once again appears in the display Press and hold the button and tunE will change to off to indicate that autotune is currently off 9 While holding in the button press the 48 button to change the display to At SP then release both buttons 10 Press and hold both the 4 and 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 4 9 and 10 except in step 9 press the W button until off is displayed 2 3 2 4 Autotune Errors The autotune routine can fail for several reasons If it fails the controller displays the error message tunE FAIL To remove this message turn the controller off for 10 seconds Try the procedure titled Autotuning the Controller for Very Fine Control above I
13. the position of the Volume Range Full Power power switch A new power setting was added to this circuit New setting to the left that is not labeled on the front of the cabinet The new of the 1 10 ml setting 0 setting is 1 click to the left of the 1 10 ml setting and is 1 10mL 3 power off In this position the controller doesn t heat but 10 100 mL 10 acts as a digital thermometer The correct setting for this E 50 500 mL 25 switch is the setting that supplies adequate power for the heater to heat to the set point in a reasonable period of time 300 ml 2 L 50 while at the same time not overpowering it See Section 22L 100 4 4 for a detailed explanation of how to correctly set up a reaction using your J KEM controller Heating Liquids Each power level is associated with a volume range which acts as a guide when heating solutions with heating mantles When using heating mantles set the power switch to the range that includes the volume of solution being heated Note this switch is set to the volume of solution not the size of the flask For example to heat 250 ml of toluene to 80 C in a 1 L round bottomed flask choose the third power setting 50 500 ml since this encompasses the solution volume There are situations when a power level other than that indicated by 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 1
14. with any heater A second version of the autotune routine is available and can be used when the heater is already at or close to the set point is being tuned at a temperature close to room temperature or for very fine control in demanding situations If stable temperature control doesn t result after performing the first autotune routine the procedure below should be performed Before performing the fine tune autotune procedure the regular autotune procedure that precedes this should normally be performed I Set the equipment up in the exact configuration it will be used If the heater has its own thermostat or power controls turn both as high as they Il go With this procedure it s not necessary for the equipment to start at room temperature This procedure can be performed at any time and any temperature Only tune the setpoint controller i e the meter on the left never tune the limit controller pA Set the setpoint controller to the appropriate power level see Section 3 7 Turn the controller and heater on and enter the desired set point temperature 3 Enter a temperature in the limit controller about 25 C higher than the set point entered into the setpoint controller 4 Press and hold in both the 8 and Y buttons for 3 seconds on the front of the setpoint controller until the word tunE appears in the display then release both buttons 5 Press the button 5 times until CyC t appears in
15. 00 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 1 L flask 1 L heating mantle SP 80 C 150 ml toluene 250 ml flask 250 ml heating mantle SP 35 C 50 500 ml 25 power 300 ml 2 L 50 power 300 ml 2 L 50 power 10 100 ml 10 power 10 100 ml 10 power Organic solvents heated to 50 110 C are set to the volume range on the front panel When choosing between 2 power settings i e 80 ml also falls within both the 10 100 ml range 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 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 temperatures are better regulated with less power Avoid switching between the different power levels while the controller is heating Specifically do not ini
16. 2 I Safety Considerations and Accurate Temperature Control 32 II Resetting the Controller to Original Factory Settings 33 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 I Quick Operating Instructions These six steps are the basics of using your temperature controller The User s Manual is a reference that explains the controller more fully as well as some of its more sophisticated features It s recommended that new users unfamiliar with process controllers read the entire manual carefully The controller is preprogrammed for use with heating mantles fitted to round bottomed flasks running typical organic reactions i e non polymeric reactions in solvents such as THF toluene DMF etc If the controller is used with this type of reaction the 3 steps below will help you get started For a primer on how to set up a reaction with your temperature controller See Section 4 4 To use heaters other than heating mantles See Section 2 Do not use the controller to heat oil baths See Section 3 2 For polymer synthesis atypical expensive or safety critical reactions See Appendix I Enter the Over Limit To enter a temperature into either of the digital meters hold the button Temperature Limit This meter labeled Limit Controller is the back up meter for the setpoint controller Set this meter a
17. Hours Function Push knob for Change 1 4 second Fe SED a ON af fen FT GE ON al fare UEP al Pere ON at Zero FF at Fem CVS ad Sera OFF al Jam ert second o Push knob for Hold in knob go GN second for 1 second En Push to Lorde to Function Pi ht I i Push i furn to HP n io i ish to urn io Pro ram ush to i Ui SLF eee then Enter Minutes gt Enter Hours To immediately exit a timed run hold in the timer knob for 1 second 17 Heating for a Set Period of Time In this mode the user enters the amount of time to heat before turning Oe Oa T heating off 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 EN While at this setting and while entering a time into the timer no power is Select My Set Time applied to the heater Step 1 When the timer displays toFF holding merme morie ES in the timer knob causes the display to change to 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 Select EM Set Time ER Set Time Select d can be changed br ey Step 2 To increase the number of minutes rotate the timer knob to the right To decrease the aise en number of minutes rotate the timer knob to the enter minutes left Hold in the timer knob for 1 second Step 3 To change the number of hour
18. TIES EXCEPT AS STATED HEREIN THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL J KEM SCIENTIFIC INC BE LIABLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES THE BUYER S SOLE REMEDY FOR ANY BREACH OF THIS AGREEMENT BY J KEM SCIENTIFIC INC OR ANY BREACH OF ANY WARRANTY BY J KEM SCIENTIFIC INC SHALL NOT EXCEED THE PURCHASE PRICE PAID BY THE PURCHASER TO J KEM SCIENTIFIC INC FOR THE UNIT OR UNITS OF EQUIPMENT DIRECTLY AFFECTED BY SUCH BREACH Returns requests for service and inquires should be directed to J KEM Scientific Inc 6970 Olive Blvd St Louis MO 63130 314 863 5536 FAX 314 863 6070 E Mail jkem911 jkem com Internet Catalog http www jkem com You ve purchased the most versatile controller available to the research community Were confident it can regulate ANY heating cooling situation you ll ever encounter Ifthe information in this User s Manual isn t adequate to make your application work call our engineering department for assistance With J KEM s patented Microtune circuitry INDEX SECTION PAGE 1 QUICK OPERATING INSTRUCTIONS 0 4 KEM NET DATA LOGGING AND CONTROL SOFTWARE 5 2 ADJUSTING THE CONTROLLER FOR STABLE CONTROL WITH DIFFERENT HEATERS 6 2 1 Vs WM Lane SST NSA 6 22 Avtotunmns Proce
19. Temperature Control for Research and Industry High Power Temperature Controllers User Manual for Models HCC 130 HCC 215 HCC 230 M Scientific Inc Instruments for Science from Scientists Sm g CFPC SPT S SPST PSST CS PSST SST CSC PSS EEE SEE PERC CPPCC PCC ECP TTT Pee ere eee BEE EEE EEE EEE EEE EE EEE EEE E EEE EE EEE EEr EEE nm HESEEETETEEETEETEETETEEETETEEETESEETTEKEEETEEEEETERE EEETTENTTTUETTTET TET TET TETTTETEETTTSTENETTTEETTTTTENTETTETEE TETTE EEE EE E mm ee ee ee at EE Em ET nE EE Et En EMM om MTT TT TETT TETTE TELET TELTET OLT TETTE TETTE TT TT ETTE TT TET TET TET TETTE TETTE 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 WARRAN
20. borted by holding in the timer knob for I 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 cv al fe m OFF at Zeru When the timer counts to 00 00 power is turned Off indefenently Push ta Purn to elect el Time i l gt Push knob for 1 4 second Function Change a D ON at Airi OFF al here When the timer counts to 00 00 power is turned On indefenently Push ta urn to Selvet J Set Time j Ci To immediately exit a timed run hold in the timer knob for 1 second Function Push knob for Change 1 4 second OFF af fern ON al Aeru ON at fern z OFF at ero ON m T f Orr FE Hold in knob goe second Push to Turn to a i Push to sm Made go Function Push te Purn te Ea Push to urn t j i sel I ange Select ae el iiime a Set Time ee P i Select N et Time g elect 1 Change Select 7 et Time Change Select Sel Tim 3 o 6 Cy EN at Yri cre DFF Ped ETT Push knob for 1 4 second Hold in knob gen 1 second Function Change Push knob for 1 4 second z then Enter Minutes gt Enter
21. bout 5 C higher than the temperature entered into the Setpoint Controller in Step 5 If and simultaneously press the M key to increase or the W key to decrease the setpoint The setpoint can be seen at anytime by holding in the button The setpoint appears as a blinking number in the display the reaction reaches this temperature limit for any reason heating 1s automatically stopped until being manually reset See Section 3 3 Press the Reset Button The reset button resets the over temperature circuit and prepares the controller for use The probe temperature must be below the temperature of the limit controller or the circuit will not reset 3 Place the thermocouple in the solution being heated Place at least the first 1 4 of the thermocouple directly in the solution being heated Thermocouples can be bent without harming them If you re heating a corrosive liquid use Teflon coated thermocouples If you are heating a sealed reaction see Section 4 2 A Set the power level switch to the 10 100 ml 50 500 ml TIP Because the power switch acts volume of solution being heated 110 mi 300mk2L like a variac if the reaction is heating JF too slowly or you need more power vn ore oe being used pen pp D gt 2L e g heating to high temperatures The power level switch can be thought of q sive the heater more power by turning of as a solid state variac Volume the power level up one setting If the ranges ar
22. changing this will be 0 or 50 or 199 9 depending on thermocouple type Let go of all the keys 20 First hold in the key then while holding in the key press the key until 3 appears in the display Let go of all the keys Press the key until ZEro appears in the display Next hold in the key then while holding in the key press the Y or AN key I oe No NO NO NO NO until the value ____ appears in the display Let go of all the keys Press the W key until the word LEVL appears in the display First hold in the key then while holding in the key press the W key until 1 appears in the display Let go of all the keys Press the AN key until SEt 2 appears in the display Next hold in the key then while holding in the key press the W or AN keys 2 NO AIU until the value 10 0 is entered Press and hold in both the W and keys until the temperature appears in the display then release both keys The word PArk in the display will go away when a set point is entered N ON 34
23. ctively known as the tuning constants and for the most part they are expressed in units of time since they represent delay times rate of heat transfer times and rate of error accumulation The relative value of each constant depends on the physical characteristics of the process being heated For example for the same amount of input power the rate of heat transfer is twice as high for hexane as compared to water since the coefficient of heat for hexane is 0 54 calories g C and water is 1 0 calorie gram C That means that 1000 watt seconds of input power will raise the temperature of 10 g of hexane 44 C while the same amount of power causes a 24 C rise in water In theory the tuning constants needed to heat hexane are different from those to heat water Fortunately your J KEM controller is self adaptive and is able to adapt its heating characteristics for different solvents such as hexane and water Even with the controller s self adaptive algorithms the tuning constants have to be reasonably close to a proper set or the controller will not produce stable temperature control see Section 2 1 When a controller is shipped the default set of tuning constants loaded into the controller are those appropriate for heating typical organic reactions i e small molecule chemistry in low boiling lt 160 C organic solvents using heating mantles since this is the most common application for J KEM controllers Since it s impossible f
24. ctrician If fuses are replaced THEY MUST BE REPLACED BY AN EXACT EQUIVALENTS such as a Littlefuse L15S 15 Fuses can be obtained from electrical supply houses or from J KEM 23 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 Temperature continues ON OFF Mode and OFF when above The disadvantage of this n Pa Temperature mode is a large over shoot of the set point 5 d LE ae ne 30 on initial warm up and oscillation of FO P ae E temperature around the set point thereafter The A 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 A heaters that transfer heat rapidly such as heat Brada F Time 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 the controller monitors the shape of Tarp HE the heating curve during initial warm up and k r Akira decreases power to the heater before the set point a a point is reached so that the solution reaches the co set point with minimal over
25. d reaction using J KEM Scientific s digital temperature controller For this example the Model Gemini controller is used but the application note applies equally well to all J KEM temperature controller models If you have questions about specific models of temperature controllers or any safety related question please feel free to contact J KEM Scientific This application note does not supercede any information in the Controllers actual User manual The User manual for each model is always the reference for that model The Model Gemini is a dual channel controller that allows two independent reactions to be run on the same controller one reaction on Channel and the second on Channel 2 In this example we will only use channel 1 Gemini Dual Channel Temperature Controller Thermocouple receptacle Channel 1 has a 100 hour to turn heating On Off at a user set time Channel 2 does not have a timer Thermocouple Thermocouple extension cord 29 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 diff
26. definitely The only time the limit controller comes into play is if for whatever reason the temperature of the process rises to 85 C at which point power is removed from outlets 8 Power remains disconnected until being manually reset The operation of the limit controller can be verified at any time by entering a temperature lower than ambient which should activate the over temperature protection circuit indicated by light 6 coming on The Model HCC derives its unique safety advantages from it s design in which the temperature sensing ability and action of the two controllers are completely independent of the other By considering the way the controller responds to different types of heating failures demonstrates the safety benefits of this construction If the limit controller fails closed the over temperature protection circuit is activated disconnecting all power to the heater If it fails open this has no effect on the temperature regulation of the setpoint controller which continues to maintain the desired temperature of the process If the setpoint controller fails closed The most dangerous failure mode i e uncontrolled full power to the heater The limit controller activates the over temperature protection circuit permanently disconnecting all power to the heater If the setpoint controller fails open the process simply cools to room temperature Since each controller has its own thermocouple a failure with either thermocouple resul
27. dure oa eerie n MEN Se BES E re RNS BROS i 2 3 Tuning for Heating Mantles A Special Case 0 9 2 4 Sensor Placement erben Phew dee ei a a k A A BAe 9 3 OPERATIONS GUIDE sireci iiai in eos i OEE a a OSs 10 3 1 Front Panel Descnpuon svor eS ets Sh ek Se eed 10 32 H ater Restrictions 4ms eldes 11 3 3 Setting the Controller for Safe Operation 0050 12 3 4 Ramp to Setpoint amp Soak Feature 0 0000 13 95 Tier 00108 sort n krass se AS Ge keen Send vet 15 3 6 Temperature Sensor Input 0 0 0 ccc ee eens 18 3 7 Power REGUCIION CEN sopran E G 18 3 8 Affect of Power Setting on Heating Profile 20 3 9 Do s and Don t s When Using Your Controller 21 3 10 Resetting the Controller for Use With Heating Mantles 22 3 11 Changing the Temperature Display Resolution 22 Suz PDE au J aspach arena anes a E re Nas E Be eae aa 22 3 13 Changing between PID and ON OFF Operating Modes 23 314 Troubl shooimne usttsesissa ease des Satna de tegen ges 24 4 APPLICATION NOTES ces 24 Ae ces Fac aed Se ed es oR deen Subd ker 25 4 1 Theory of How the Controller Works Simply 25 4 2 Controlling the Heating Mantle Temperature Directly 26 4 3 Automatic Storage of Min Max Temperatures 4 27 4 4 How to Set Up a Reaction With Your Temperature Controller 28 NMPENDIN 22 Ne 3
28. e key press the Y or key until the value 5 0 appears in the display then release all keys Press and hold in both the W and keys until the temperature appears in the display then release both keys To return to using thermocouples in solution perform Procedure 1 in Section 3 10 4 3 Automatic Storage of Min Max Temperatures The controller will automatically record the minimum and maximum temperatures of a process by following the procedure below These temperatures are updated continuously after the routine is started and cleared by turning the controller off This procedure must be started every time you want to record temperatures Procedure to Start Temperature Logging Press and hold in both the W and AN keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the W key once and the word LEUL appears in the display While holding in the key press the key until the value 3 appears in the display then release all keys Press the AN 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 W and keys until the temperature appears in the display and release both keys Automatic temperature logging is now on and will remain on until the controller is turned off or logging is turned off manually by
29. e printed above this switch as Output Power evel FT nomi a guide to select the correct power e g heating to low temperatures level since it s easier to guess the A power is equivalentto lt 60 C or the temperature overshoots volume being heated than the setting of setting of a variac setting of the set point excessively turn the appropriate percent power to apply Power down one setting DO NOT set to a heater Heat Off turns off the 1 10 mi 220 the power switch on a setting too high heater so the controller displays 10100m 10 initial to heat the reaction quickly temperature only All new users 50 500 ml 25 and then lower it to the correct setting Follese 300 ml 2 L 50 this degrades heating performance FJL 100 5 Enter the setpoint i c the desired reaction temperature into the setpoint controller by holding in the button and simultaneously pressing the M key to increase or the W key to decrease the setpoint The setpoint can be seen at anytime by holding in the button the setpoint appears as a blinking number in the display To turn power On to the heater briefly push in on ON stare Our ators 6 Set the timer the round timer knob and the display changes to ON When power is applied to the to show that power to the heater is ON For controller by default tv e hms complete instructions on the user of the timer see Bat a ee the timer turns power gt the section titled Timer Cont
30. erent 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 6 inch length Teflon coated Temperature sensitive end Teflon coated 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 1 2 to be is solution but the first 4 must be in solution to read the temperature correctly Heaters Your J KEM controller works with virtually any 120 volt or 230 volt heaters outside of the USA heater including any size heating mantle 120 vac oil baths hot plates ovens and many other style heaters If you have questions about the compatibility of specific heaters please contact j KEM 1 liter heating mantle 10 ml heating mantle Oil bath 30 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
31. etpoint Controller is the main process controller and Controller is responsible for all aspects of temperature control including heating cooling maintaining the temperature tuning etc The desired solution or process temperature is entered into this controller The meter on the right labeled Limit Controller has no influence on the heating Controller process which is under the complete control of the meter on the left The purpose of this unit is to monitor the temperature of the reaction or process and take control if a heating error occurs thus acting as a watchdog or backup unit to the setpoint controller In normal use a temperature is entered into this controller which is several degrees 5 C above the temperature entered into the setpoint controller If the process heats to the temperature entered into the limit controller power is physically disconnected from outlets 8 and remains disconnected until the controller is manually reset Setting up an experiment with the Model HCC is quite simple Place the dual element thermocouple in the process to be heated and turn the controller on Enter the desired temperature into the setpoint controller i e the meter on the left for example 80 C then a slightly higher temperature into the limit controller for example 85 C Press the reset button 9 The setpoint controller begins to heat the process to 80 C where it will maintain it in
32. f autotune fails again call and discuss your application with one of our engineers A common problem when tuning at high temperatures or with large volumes is for the heater to be underpowered A more powerful heater may be needed contact J KEM for assistance Tuning for Heating Mantles A Special Case This section gives special consideration to heating mantles since they re the most commonly used heaters in research Every heating mantle size has its own optimum set of tuning parameters and if you wanted the controller could be tuned or autotuned every time a different size was used However this is cumbersome and is also 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 1 of Section 3 10 Sensor Placement Placement of the sensor is basically common sense The sensor should be
33. gh efficiency heating mantles that contain large amounts of heat even after the power is turned off Your controller handles the problem of latent heat in the heating mantle in two ways 1 The controller measures the rate of temperature rise during the initial stages of heating It then uses this information to determine the temperature at which heating should be stopped to avoid exceeding the set point Using the range analogy this might mean turning the power off when the water temperature reached 60 C and allowing the latent heat of the burner to raise the water temperature from 60 to 80 C This calculation is done by the controller and is independent of the operator The next feature of the controller is directly under operator control and has a major impact on the amount of overshoot on initial warm up 2 Again referring to the range analogy you d obtain better control when heating small volumes if the range had more than two power settings Off and High J KEM s patented power reduction circuit 11 serves just this function It allows the researcher to reduce the power of the controller depending on the amount of heat needed This circuit can be thought of as determining whether the heating power is Very low 1 10 mL Low 10 100 mL Intermediate 50 500 mL Medium 300 mL 2 L or High gt 2 L The proper power setting becomes instinctive after you ve used your controller for a while For additional information see Section 3 7
34. he setpoint appears as a blinking number 5 Set the correct Power Control Level Your J KEM controller has a built in Power Control Computer PCC that precisely regulates power to the heater For the computer to work correctly it must know the volume of solution that is being heated It s important to understand that the PCC is set to the Volume of solution being heated not the size of the heater or the size of the flask 10 100 mi 50 500 mi 1 10 mIs Vet 300 ml 2 L Heat F A gt 2L Of Hip 22 CO OTD 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 1s Point 115 C _ set to the correct power level your of N N dimethylformamide 3 L Round Bottomed Flask controller can regulate virtually any 3 L Heating Mantle ike heater to 0 1 C with less than 1 C overshoot on initial warming Test System Set 2L Test System Set Point 85 C Standard Lab Oven Temperature C Test System Set Point 55 C 12 mL of THF 25 mL Round Bottomed Flask 25 mL Heating Mantle Ti
35. ill not actually heat faster than the power of the heater will allow SPrn SetPoint Ramp Run Allowable Values ON OFF Hold This parameter turns the Ramp to Setpoint feature ON or OFF During an active run if this parameter is set to Hold the setpoint ramp stops and holds at its current value This continues until the parameter is set to ON or OFF When set to OFF the values in SetPoint Ramp Rate and Soak Time are ignored SOAK Soak Time Allowable Values 0 to 1440 min This specifies the amount of time to soak at the setpoint after the setpoint temperature ramp is complete A setting of causes the controller to remain at the final setpoint indefinitely A numeric value causes the controller to stay at the setpoint for the entered time and then turn power to the heater off after the time expires 14 Important Points to Know I While the Ramp to Setpoint feature in activated the display alternates between the current reaction temperature and the word SPr to indicate that a SetPoint Ramp is active 2 Setting aramp rate will not guarantee that the reaction temperature is at the specified ramp temperature since heating is dependent on the power of the heater For example if a ramp rate of 1200 deg Hr 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 faste
36. it controller must each have a thermocouple attached Power Outlets For Models HCC 130 plug only 120 VAC devices into these outlets For Models HCC 215 and HCC 230 plug only 240 VAC devices into these outlets See Section 3 2 11 3 2 9 Over Temperature Reset Switch Press switch to reset the over temperature circuit The temperature on the limit controller 5 must be above ambient to reset this circuit 10 Controller On Off switch For maximum accuracy of the displayed temperature turn the controller on 10 minutes prior to use WARNING Due to the nature of solid state relays a small amount of output voltage is present on the outlets even when the controller is not heating Take appropriate precautions to avoid electrical shock 11 Power Reduction Circuit Limits the maximum power delivered to the heater See Sections 3 7 and 4 1 12 Timer Function Knob Multi function knob that selects timer function push knob in and enters the amount of time in the timer rotate 13 Timer Display The timer display always shows the status of the timer circuit see Section 3 5 The display can show On meaning that the circuit will allow power to be applied to the heater Off meaning that the circuit will not allow power to be applied to the heater or it will show a time when power will be applied or removed from the heater depending on the settings in the timer 14 Timer Status LED s Timer status LED s indicate whether
37. l the value from the table above appears in the display Let go of all the keys NOTE Many of the patterns for this parameter look similar be careful to select the exact pattern shown above Press the key once and unit will appear in the display Next hold in the key then while holding in the key press the key until the value C appears in the display Let go of all the keys Press the key once and the word SP1 d appears in the display Next hold in the key then while holding in the key press the A key until the value SSd appears in the display Let go of all the keys 7 Press and hold in both the W and AN keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the key once and the word bAnd will appear in the display Next hold in the key then while holding in the key press the 8 key until the value 10 appears in the display Let go of all the keys Press the 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 M key until the value 10 appears in the display Let go of all the keys Press the key once and the word dEr t will appear in the display Next hold in the key then while holding in the key press the X key until the value 50 appears in the display Let go
38. ler is tuned to one type of heater heating mantles for example any size heating mantle can be used without the need to retune When changing from heating mantles to a different type of heater an oven for example the controller should be tuned with values describing the oven s heating characteristics The effect of tuning is seen below When the controller is tuned for heating mantles using it with any size heating mantle yields stable temperature control Plot 1 but poor control results when the same tuning parameters are used with an oven Plot 2 Curve 1 However after tuning the controller to the oven stable temperature control results Plot 2 Curve 2 Plot 2 Plot 1 80 70 70 Curve 2 Controller loaded with tuning parameters for drying oven 60 60 Temp Temp o 50 Conditions 100 ml Toluene Curve 1 Controller loaded with 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 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 13 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 t
39. ler 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 Teflon coated thermocouple or use the external thermocouple method Section 4 2 avoid exposure of the controller to corrosive gases and liquids The atmosphere of a research hood is corrosive to all electronics Place the controller outside the hood away from corrosive gases 22 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 1 Perform when using heating mantles with round bottom flasks This procedure
40. me min 30 For a detailed explanation of the Power Control Computer see Section Two in the controller s User manual 32 Appendix I Safety Considerations and Accurate Temperature Control For safety critical and non typical organic reactions especially polymeric reactions or for use with heaters other than heating mantles the user must either 1 monitor the reaction closely to verify the tuning parameters are appropriate for the current application or 2 autotune the controller for the application For any safety critical or high value reaction call J KEM to discuss your application with an engineer prior to beginning Your J KEM controller is capable of regulating virtually any application to 0 1 C if the controller is tuned to the application being heated Since it s possible that the tuning parameters are not set correctly for your application the user must monitor a new reaction to verify the controllers operation A short primmer on tuning is presented below a more detailed explanation is presented in Sections 2 1 and 4 1 Tuning is the process that matches the control characteristics of the controller to the heating characteristics of the process being controlled The controller uses a PID Proportional Integral Derivative algorithm to regulate heating Each of the terms in the PID equation has a constant that scales the equation to the process being heating These constants plus two other related terms are colle
41. nE appears then let go of the keys Press the W key until LEVL appears First hold in the key then while holding in the key press the key until 3 is showing in the display then let go of all keys Press the key until ZEro is showing in the display Note the current display offset this is the number blinking in the display Calculate the new offset temperature using the equation Temperature display offset needed New Current Display display offset Displayed Correct Offset blinking in display temperature temperature First hold in the key then while holding in the key press the M or W keys until the new offset temperature is showing then let go of all the keys Press the AN and VW keys until the temperature is displayed 25 Section 4 Application Notes Supplemental application notes on the following topics are available by contacting J KEM Application Note Subject How to heat oil baths with your controller Included in Appendix Changing the controller s thermocouple type Changing the heating outlet into a cooling outlet Using the controller for unattended fractional distillations Using the controller with inductive motors valves loads 4 1 Theory of How the Controller Works Simply For the purpose of explaining how the controller works the example of a solution heated with a heating mantle is used The principles are the same for all
42. o the heater This is a safety feature that insures that power is not applied to a heater following recovery from a power failure Hamp f Setpoint Model 210 Timer Os al Zero OFF at fern ee ne EEE EEE The timer has 4 states ON st Zera FE st Zee EEE The timer cycles Push Push between the 4 states by 5 pushing in on the silver Push to Turn to Push to Turn to Push to n Purn to Pushto Turn to Select P Set Time Select To Set Time Select Set Time Select Set Tim knob i momentarily we ay WP ay For example push the timer knob once and Push the timer changes from NOTE Pushing in on the timer knob quickly for about 1 4 second causes it to advance to the next the Off state to state Holding in the knob for 1 second changes to the mode where time is entered into the timer the On state push it again and it changes to the toFF state Repeatedly pushing the knob cause the time to cycle between its three normal states of On toFF and t on If the Power Reduction Circuit Section 3 6 is set to the Heat Off position the timer window always displays oFF The four states of the timer circuit are explained below 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 se
43. o the heater now to control the shape of the heating curve minutes in advance The importance of the tuning parameters is that they are constants in the equation the temperature meter uses to perform its predictive calculations If the temperature meter is programmed with tuning parameters that incorrectly describe the heater being used poor temperature control will result But when the correct values are loaded temperature regulation of 0 1 is typically achieved Manual Tuning Manual tuning is when the values of the 5 tuning parameters are determined manually then entered into the temperature meter via the push buttons on the front of the controller Experienced users might prefer to manually tune the controller since this allows customization of the heating process Autotune Autotune is a feature built into the temperature meter that automatically calculates the tuning parameters i e delay times heating efficiency etc for any type of heater After the autotune 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 Only the setpoint controller the meter on the far left should be autotuned never tune the Limit Controller I Set the equipment up in the exact configuration
44. oil baths do not use with oil baths rated less than 120 Vac J KEM s 230 Vac controllers are compatible with any 230 Vac heating mantle 100ml and larger They are not compatible with any size oil bath Shown is a typical set up for a solution phase reaction 1 Place the reaction flask in the appropriate size heating mantle then plug the power cord from the mantle directly into the power outlet of the temperature controller 2 Place a stirring bar inside of the flask in the solution Place the flask on a magnetic stirrer and stir the reaction for good heat transfer 3 Place a thermocouple in solution and make sure that at least the first 4 1 2 is better is covered by the fluid in the reaction flask Heater power cord 31 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 in the display release the star button to load the setpoint When no buttons are pressed on the controller the controller shows the temperature sensed by the thermocouple When the Star button is pressed t
45. one 120 vac 30 amps 8 oo 5 amps receplade Model HCC ames 2 3 4 3 7 Figure 1 J KEM highly recommends that all users read Section 4 4 How to Set Up a Reaction with J KEM Scientific s Digital Temperature Controller prior to using the controller for the first time l Temperature Display Shows temperature of the process as the default display Shows set point temperature i e desired temperature when button is pressed Control Key When pressed the display shows the set point temperature To decrease or increase the set point press the A key 3 or W key 4 while simultaneously depressing the control key The set point appears as a blinking number in the display Lowers set point when button 2 is simultaneously pressed Raises set point when x button 2 is simultaneously pressed Limit Controller This controller sets the temperature that causes the over temperature circuit to activate disconnecting power from outlets 8 see Section 3 3 Indicates an over temperature condition and heating has stopped when lit See Section 3 3 Temperature Sensor Input Use the same type of sensor probe as the sensor plug installed on the controller see Section 3 6 The correct sensor type has the same color plug as the receptacle 7 on the front of the controller To operate properly the receptacle on the left connected to the process controller on the left and the one on the right connected to the lim
46. ontact with the heating mantle Set the power reduction circuit to the power level shown in the table at the right Turn the controller on and enter the set point Procedure to Load Tuning Parameters for External Thermocouples Heating Mantle Size 5 amp 10 ml 25 ml 50 ml 22 L Power Level 1 10 ml 10 100 ml 50 500 ml For temperatures over 120 C the next higher power level may be necessary Press and hold in both the W and AN keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the AN key once and the word bAnd will appear in the display While holding in the key press the Y or key until the value 5 appears in the display then release all keys Press the key once and the word int t will appear in the display While holding in the key press the W or key until the value 2 appears in the display then release all keys Press the AN key once and the word dEr t will appear in the display While holding in the key press the W or key until the value 5 appears in the display then release all keys Press the AN key once and the word dAC will appear in the display While holding in the key press the Y or key until the value 5 0 appears in the display then release all keys Press the y key once and the word CyC t will appear in the display While holding in th
47. or J KEM to predict the application the controller will be used for the researcher must be aware of the possibility that the tuning constants loaded into the controller may not be a set that results in stable temperature control It s the researcher s responsibility to monitor the temperature regulation of a reaction If you encounter a process that your J KEM controller does not heat with stability you have two resources Autotune Feature Your controller has and autotune feature that when turned on see Sections 2 1 amp 2 2 automatically determines the proper tuning constants for your application and then loads them into memory for future use J KEM Technical Assistance If you have an application you wish to discuss call us we re always anxious to help our users For an additional description of the PID algorithm and the concept of tuning see Sections 2 and 4 1 33 II Resetting the Controller to Original Factory Settings J KEM manufactures the most technically advanced temperature controller available and should give you consistently flawless control If you have difficulty with your controller a good place to start to correct the problem is by loading the original factory settings into the setpoint controller 1 e the meter on the left If you still have difficulty with your controller our Engineering department will help you resolve the problem The factory settings of a J KEM controller are 0 1 C resolution PID con
48. 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 increase in temperature isn t sensed by the controller within a reasonable period of time Several examples follow that show the type of consideration that should be given to sensor placement Use With Place the sensor in the solution Stir vigorously so that heat is homogeneously mixed Solutions throughout the solution Tape a thin wire thermocouple directly to the HPLC column Place several layers of HPLC column heated paper over the thermocouple to insulate it from the heating tape the thermocouple with a heating tape should sense the column temperature not the heater temperature Wrap the HPLC column completely with heating tape The thermocouple needs to be shielded from transient hot and cold air currents Don t Oven place the thermocouple near the heating coil or an air vent A small thermocouple 1 16 or 1 8 thermocouple that responds rapidly to changes in air temperature 1s better than a larger one 10 Section 3 Operations Guide 3 1 Front Panel Description 14 13 14 10 9 6 12 15 USB port on back 10 1001 50 500 mi DE 1 10 mi gh 300 ml 2 L Hea N f gt eX 16 on W Output J KEN Scientific d a Fower Level Push te s Select a I L 9 P9 8 Setppini can c
49. ppears 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 also display 1 C resolution by following the procedure below the display can also be changed to read in F call for information There are two reasons to change the display resolution 1 To enter a setpoint faster the display scrolls 10X faster in 1 mode than in 0 1 mode 2 To display temperatures above 999 9 Press and hold in both the W and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the W key once and LEVL appears in the display First hold in the key then while holding in the key press the key until 2 appears in the display then let go of all the keys Press the key repeatedly until the word diSP appears in the display First hold in the key then while holding in the key press the W or key until the value 1 not 0 1 appears in the display then let go of all the keys Press and hold in both the W and keys until the temperature appears in the display then release both keys 3 12 Fusing The controller is protected by a bank of fuses designed for solid state equipment that are inside the controller None of the fuses are user serviceable and should be replaced by a qualified ele
50. r Clean or replace broken sensor broken SAL The process temperature is hotter Correct the over temperature condition than the alarm temperature 1 Hold in both the AN and keys on the front of the J KEM PArk Controller has been placed in Park temperature meter until tunE appears in the display mode 2 First hold in the key then while holding in the Coe key press the W key until oFF appears 3 Hold in the AN and W keys until the temperature appears in the display tunE FAIL Autotune routine failed Turn off controller for 10 seconds See Section 2 2 Displayed temperature is The display temperature reads low when the controller is first incorrect The controller has not warmed up turned on but will self correct as it warms up The controller can be used immediately since it will warm up during the initial stages Note Types K amp J of heating Thermocouples display negative temperatures but are not Wrong type of thermocouple is Thermocouples are color coded Thermocouple plug and calibrated for them plugged into controller thermocouple receptacle must be the same color see Section 3 6 connections sandpaper or steel wool discard thermocouple To enter a controller display offset Turn on controller Allow unit to warm up for 30 minutes Record displayed temperature Press both the 4X and W keys on the front of the temperature meter until tu
51. r than natural cooling by ambient air 3 Once the Ramp to Setpoint feature is activated in programming mode it remains on until it s deactivated in programming mode The Ramp to Setpoint feature remains activated even if power is turned off to the controller Activating amp Programming the Ramp to Setpoint Feature l Press and hold in both the VW and keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the key 8 times until the word SPrr appears in the display This is where you set the ramp rate in units of degrees hour First hold in the key then while holding in the key press the Vorma key until the desired ramp rate appears in the display then let go of all the keys Units are in degrees hour Press the key once and the word SPrn will appear in the display This function turns the ramping feature ON OFF or to Hold First hold in the key then while holding in the key press the P or M key until the desired setting appears in the display then let go of all the keys Press the A key once and the word SoaK will appear in the display This is where the soak time is set in units of Minutes A soak time of means to soak forever this setting is one below 0 First hold in the key then while holding in the key press the P or M key until the desired time appears in the display then let go of all
52. repeating this procedure except in Step 3 pressing the key until the word off appears Procedure to Read Minimum and Maximum Temperatures Press the Y key once and the word LEUL appears in the display While holding in the key press the AN key until the value 3 appears in the display then release all keys Press the key until the word rEAd appears in the display The rEAd screen displays 3 parameters Variance the difference between the highest and lowest logged temperatures Hold in the key and the display will alternate between UAr and number of degrees of variance High Temperature the highest temperature since the logging option was turned on While holding in the key press the 8 key once and the display will alternate between hi and the highest recorded temperature Low Temperature While holding in the key press the y key once and the display will alternate between Lo 9 and the lowest recorded temperature The High and Lo temperatures can be examined as often as you like since updating and monitoring continues until the monitor is stopped by turning the controller off Press and hold in both the W and keys until the temperature appears in the display then release both keys 28 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 heate
53. rogrammed with values telling it how fast the heater warms up cools off and how efficiently it transfers heat For example consider the difference between a heat lamp and a hot plate When electricity is applied to a heat lamp it begins to heat instantaneously and when it s tuned off it stops heating instantaneously In contrast a hot plate may take several minutes to begin heating after electricity is applied and even longer to stop heating after electricity is turned off Your controller can regulate both a heat lamp and a hot plate to 0 1 C But to do this it must be programmed with the time constants describing how fast the heater heats when electricity is turned on and how fast it begins to cool when it s turned off These time constants are called the tuning parameters Every type of heater has its own unique set of tuning parameters For the controller to heat with stability it must have programmed with the tuning parameters for the heater currently being used Prior to shipment tuning parameters were programmed into the controller that maximize heating performance for laboratory heating mantles since these are the most common heaters used in research Tuning is regulated by 5 of the temperature meter s user programmable functions The correct value for these 5 functions can be calculated and loaded by the user manually or the controller can do it automatically with its autotune feature When Should the Controller be Tuned If the control
54. rols fa SA OFF to the heater as a SLV If the display does not change when the timer knob Gy safety precaution is pressed make sure that the Power Level Switch is 4 not set to the Heat Off position KEM Net Data Logging and Control Software The USB port on the back panel of the controller is an interface to J KEM s KEM Net Software KEM Net is free and can be downloaded from J KEM s web site at www jkem com KEM Net provides remote control of up to 8 controllers graphical presentations of each digital meter and time amp temperature plots Highlights of KEM Net include GLP and GMP compliant data logging Runs a 12 step temperature ramp Eh J KEM Scettific KEM Net Logging of Time and Temperature Logging of Power for Exo 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 1s 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
55. rtheless reasonable control is maintained in each case 170 145 120 Temp 3 9 95 70 45 20 Set point 155 C Graph 3 Power gt 2L dd BOWEN 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 ra 50 power average temperatures 50 100 the volume is printed on the front of the controller is a good guide Conditions 300ml collidine ee For high temperatures the next 500 ml flask setpoint 45 C higher power setting might be 500 ml heating mantle DE poe R 300 ml needed to supply the heater with oF additional power 0 10 20 30 40 50 60 70 Time min The power reduction circuit limits the total amount of power delivered to the heater In this sense it works like a variac and can be used like one If the heater isn t getting enough power turn the power level up one notch and 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 control
56. s I optimal and 1 or 2 less optimal settings demonstrating use of the power reduction circuit 80 10 z 7 Conditions Set point 75 C Laboratory oven 60 Power Setting 50 500 ml Power Setting gt 2L 50 40 Conditions Set point 45 C HPLC Column wrapped with heating tape 30 Power Setting 50 500 ml 20 0 10 20 30 40 50 60 Time min 80 70 60 Conditions Set point 70 C 50 50 ml Toluene 100 ml Round bottomed flask 40 Power Setting 10 100 ml i e 10 power 30 Power Setting 50 500 ml i e 25 power ses Power Setting 300 ml 2 L i e 50 power 20 0 10 20 30 40 50 60 70 Time min 21 10 Graph 1 This graph shows typical heating profiles for a laboratory oven and an HPLC column In the example of the oven the heating curves for 2 different power levels are shown The 50 500 ml setting is the appropriate amount of power to heat to 75 C and thus results in a smooth heating curve The gt 2L power setting is too much power and results in oscillation around the set point Graph 2 This graph shows the affect of different power settings when heating liquids with heating mantles The 10 100 ml setting 10 power is underpowered and results in slow heating The 300 ml 2 L setting 50 power is too much power and results in sporadic control The controller adapts to a wide range of power settings In this example the power is varied by a factor of 5X neve
57. s in the display While original factory settings holding in the key press the VW key until the value 0 1 appears in the follow the procedure in the display then let go of all the keys Appendix Section II 5 Press and hold in both the and W keys on the front of the controller until the temperature is displayed then release both keys 24 3 14 Troubleshooting Corrective 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 7 gt 3 during initial warm up or unstable temperature control being heated 3 7 power KEM To verify that the controller is functioning properly place the The controller comes on but The heater is broken power level switch on the gt 2L setting and enter a set point of 100 does not heat C Plug a light into the outlet of the controller and wait I minute If the light comes on the controller is working properly The over temperature protection Set the limit controller to a temperature higher than that shown on the setpoint controller then press the reset button see Section 3 3 The switch on the bottom of the Move switch back to the inactive position If accessories are Input Output board must on the attached see User s Manual for the accessory inactive position Controller blinks The temperature sensor is inPt FAIL unplugged excessively corroded o
58. s in the mm display momentarily press the timer knob 1 4 Momentarily push knob Se second and the hours digits begin to blink To eee enter hours increase the number of hours rotate the timer KO Sim 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 as Tne LED under the label OFF at Zero lights This furnte and start timer indicates that power to the heater will turn OFF IA when the timer counts down to zero ON at Zero OFF at dere Hold in timer knob for Turn to Set Time At any time the timer program can be aborted by holding in the timer knob for 1 second When this Go md ESTE is done the display changes to toFF To turn on heating push the timer knob twice until the display reads On Push to Turn to Pashto Turnte Select lt S hk set Time Select Set Time we uy 18 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 Push to Tura to power is applied to the heater Select Sel Time D Step 1 When the timer displays t on holding syns
59. t 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 turned 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 0 heat is turned on indefinitely See the section below titled Delay Heating for a Set Period of Time 16 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 a
60. 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 W and keys until the temperature appears in the display then release both keys Press the key 9 times until the word SPrn appears in the display This function turns the ramping feature ON and OFF First hold in the key then while holding in the key press the V or key until OFF appears in the display then let go of all the keys To exit programming mode press and hold in both the W and keys until the temperature appears in the display then release both keys 15 3 5 Timer Controls This section applies to the Model 210 Timer only 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 t
61. this can be seen in a simple example 26 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 problem comes as the water temperature approaches 80 C If you turned the range off just as the water reached 80 C the temperature would continue to rise even though all power had been disconnected until the range coil cooled down This problem of overshooting the set point during initial warm up is the major difficulty with process 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 hi
62. tially set the controller on a high power level to rapidly heat the solution and decrease the power level to the correct setting as the solution approaches the set point Changing power levels doesn t damage the controller but it will reduce its heating performance Heating Equipment Two factors need to be considered when heating equipment ovens hot plates furnaces HPLC columns etc 1 placement of the temperature sensor Section 2 4 and 2 the appropriate power setting The best guide to the correct power setting for various pieces of equipment is the researcher s experience If your best guess is that the equipment needs 1 3 full power to heat to the set point set the power switch on the 300 ml 2 L setting 1 e 50 power it s usually better to have too much power rather than too little If the heater heats too slowly increase the power to the gt 2 L setting if it heats too fast or has excessive overshoot decrease the power to the 50 500 ml setting If the amount of power seems to be adequate but the heater doesn t heat with stability the controller probably needs to be tuned see Section 2 Section 3 8 shows the type of performance you should expect from the controller with different pieces of equipment 20 3 8 Temp C Effect of Power Setting on Heating Profile The following graphs show the effect of selected power levels on heating performance in a variety of situations Each example contain
63. trol with tuning parameters for a heating mantle thermocouple type to match the thermocouple originally installed on the controller high temperature alarm turned on and a thermocouple offset entered at the time of original calibration This reset procedure should only be applied to the setpoint controller i e the meter on the left None of the parameters of the limit controller should be changed Press and hold in both the W and AN keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the W key until LEVL appears in the display Next hold in the key then while holding in the key press the key until 3 appears in the display Let go of all the keys Press the AN key until TSEt appears in the display Next hold in the key then while holding in the key press the key until the word All appears in the display Let go of all the keys Press and hold in both the W and keys until the word inPt appears in the display then release both keys The value that needs to be entered depends of the type of thermocouple receptacle your controller was shipped with Determine the thermocouple type below Color of thermocouple receptacle Fig 1 7 Value to enter Blue type T te Ic Yellow type K tc Black type J tc i First hold in the key then while holding in the key press the key unti
64. ts in the same scenarios as above The Model HCC provides complete 100 redundant control of the heating process for maximum safety of unattended operations 13 3 4 N Li ge Ramp to Setpoint amp Soak Feature A new feature of J KEM s controllers called Ramp To Setpoint allows the controller to heat at a specific heating rate e g heat to 120 C at a rate of 5 C Hour a second feature called Soak allows the controller to be programmed to stay at that temperature for a user specified period of time before turning off NOTE This feature should be used on the Setpoint Controller only not on the Limit Controller Examples of Program Ramps Temperature Power Off Temperature UN a ge 2 Time Time The controller is shipped with the Ramp to Setpoint feature OFF the user must specifically turn Ramp to Setpoint ON When Ramp to Setpoint is OFF the controller heats to the entered setpoint at the fastest rate possible When Ramp to Setpoint is ON the controller heats at the user entered ramp rate The Ramp to Setpoint feature and its associated parameters are turned on and set in the controller s programming mode The parameters of importance are SPrr SetPoint Ramp Rate Allowable Values 0 to 9990 deg Hr This specifies the desired rate of heating cooling Note this parameter specifies the desired rate of heating cooling but in cases of extremely high ramp rates the reaction w

High Power Temperature Controllers User Manual - J

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