Ace Glass temperature controllers Operation Manual

BULLETIN 0612

Catalog Number	Page
□ 12102-12.............	4
□ 12103-05.............	5
□ 12105-14.............	6
□ 12106-10.............	7
□ 12107-20.............	8
□ 12107-46.............	9
□ 12108-13.............	10
□ 12110-06.............	11
□ 12111-15..............	8
□ 12111-47.............	9
□ 12113-17.............	8
□ 12113-50.............	9
□ 12125-14..............	12
□ 12126-24.............	13
□ 12127-30.............	14

IMPORTANT!

Heater voltage rating must be equal to or greater than the Temperature Controller output outlet used.

The sensor circuit on all ACE Temperature Controllers has been isolated from the power input lines in order to protect the operator from electrical shock due to earth ground return when handling the sensor assembly. This also protects the sensitive amplifier circuit from burnout due to the same possible short circuit to ground.

Unfortunately, shock hazard still exists while handling the output leads when connecting the heater circuits.  It is advisable, therefore, that the power cord be discon-  nected from the 120v source, or at the very least, the MAIN POWER SELECTOR SWITCH be in the “OFF” position during setup of the controller system.

Due to high overall wattage capabilities of the controller, the only way to obtain total isolation is to incorporate a line voltage isolation transformer. This would, however, prove to be extremely bulky and expensive.

SAFETY

and ACE Temperature Controllers

We at ACE take pride in producing a reliable, rugged and precise line of temperature control instruments. These controllers are designed and constructed utilizing state of the art components that are sized for long-term reliability and safety.

The standard laboratory controller, such as ACE Models 12102, 12103, 12105, 12106, 12108, 12110, 12125, 12126, 12127 and several of other manufacturers, has one component — a Solid State Relay, a Triac or a Mechanical Relay — that controls the output to the heated medium. If any of these or one of many auxiliary components were to fail and short out, which is usually the case, thermal runaway will occur, creating, at the very least, a dangerous situation such as a fire hazard. Therefore, no matter how reliable a controller might be, it should never be left running unattended for long periods of time; e.g., 1/2 hour to continuous.

If it is necessary to operate for extended periods of time, then for SAFETY, a second controller having ON OFF output should be utilized. This secondary controller’s limiting output should be adjusted by the setpoint to a temperature above the primary controller’s setpoint (+10°) and the secondary’s output used as a power source of 120 volts for the primary controller. Thus, using two controllers with two sensors and two Solid State

Relay components greatly reduces the chance of thermal runaway since both would have to fail.

ACE Controllers can be set to ON OFF output by adjusting the proportional band to zero as  described in the operating instructions furnished with the controllers.

Controllers with one temperature probe sensor thatwillprotectyourheatedmediumfromthermal runaway are available from ACE. Models 12107, 12111 and 12113 have Alarm HI and Alarm LO setpoints providing an alarm tracking band of ±15°C (user adjustable) around the setpoint. These alarm setpoints shut off the output to the heater by an additional relay in series with the main control relay. These alarm setpoints, when properly adjusted, provide over-temperature protection for a thermal runaway problem. This includes sensor-out-of-medium protection only after system does reach setpoint.

In addition, these controllers have a rear AL2 output that offers a 120 volt source for powering a sound device, motors, solenoid valve, etc., all of which may be utilized to react to a runaway temperature situation.

We can customize controllers for your needs.

Knowing the potential hazards of thermal run­ away, we at ACE have designed the safest and most reliable temperature controllers available.

WARNING: In any critical application where failure could cause product loss or endanger personnel, a second redundant limit controller is recommended

All ACE Temperature Control outputs are rated for resistive loads ONLY.

No transformers or autotransformers can be plugged into these outputs. Damage to the controller could result.

Helpful Hints

For Better General Laboratory Temperature Control Operation

1.Temperature medium must be stirred or agitated well for close control of temperatures.

2.Immersion temperature probe must be at least 1" into  medium for proper control.

3.Keep probe plug connectors clean by using fine emery paper and/or electrical cleaning fluid. Make sure plugs are fully inserted, especially phone jacks.

4.The selected voltage output of the temperature controller must NOT exceed the maximum voltage rating of the   heating element.

5.The average temperature rise time from starting temperature to setpoint temperature should be in the 2° to 3°C per minute range. Methods to achieve reduced overshoot:

a)Use controllers with multiple selection output voltages.

b)In some situations you can use a line voltage autotransformer to power the input to your temperature controller to 100 volts and even lower without affecting controller performance, thereby reducing the voltage to your heater.

WARNING! DO NOT plug autotransformer into   the output of your temperature controller to reduce voltage output. Repeated proportional switching of the autotransformer can and will cause damage to your controller circuitry in most cases.

c)Commercially available solid state line voltage controls such as ACE Cat. No. 13530-10 can be plugged into the output of a proportional temperature controller to reduce power to your heater.

d)Generally, properly sized heaters for the vessel being heated will normally achieve proper temperature rise time, such as ACE Instatherm®.

e)In some instances, trying to heat large vessels at low temperatures, above yet near room ambient, will necessitate using some of the previously mentioned voltageor power-reducing methods. Controller Models 12107, 12108, 12110, 12111, 12125, 12126, and 12127 have an automatic rate circuit which helps regulate rise-time, and the ramp and soak feature on these controllers can also help. The factory setting for SP1 output high limit is 68% for normal heating conditions. If you encounter a problem of overshooting the SP1 setpoint or if cycling around the SP1 setpoint becomes a problem, it is usually due to over-powered heaters or low setpoint temperatures. To adjust for this limited problem, reduce the SP1 output high limit setting (S1OH). See page 31 of the O.E.M. Manual. Adjust between 68% (factory setting) to 30% for better overall controller performance if this problem has been encountered.

A good guideline is to keep the maximum % output to no more than four times the power % needed to maintain the setpoint. Estimate % output by the Demand Light ON time out of the factory-set ten-second cycle time, or see page 25 of the O.E.M. Manual (PCTO).

Please note: Adjustment of (S1OH) could need increasing above 68% for high-temperature use. Contact Ace Glass Electronics Dept. if difficulty arises in making these changes. Remember, regulating the rise-time helps limit overshoot and reduces temperature differentials across glass vessel walls, which is good safety practice.

f)A good practice, especially on initial start ups, is to set the setpoint lower than the temperature needed (5° to 25°C less), then increase the setpoint after the lower set temperature is reached. This helps lessen overshoot, yet you still get good heat up rate which is sometimes a necessity. This practice of an initial lower setpoint is almost a must with standard proportional controllers, especially NON PID units (e.g. 12102, 12103, 12105 and 12106).

 6. Use of line filters and surge suppressors to power your temperature controller is recommended.

 7. Keep controller case in a clean, vented, room-ambient temperature area, if possible.

 8. Properly sized fuses for heater and temperature controller protection are a must. Very fast acting fuses are supplied with ACE Controllers and replacements are available  from ACE to protect your equipment investment; see ACE Temperature Controller Bulletin or contact your ACE  Salesperson. These fuses are higher cost than the regular blow fuse but they are worth it! Also, when constantly  heating small vessels with less than 10 amperes drain,

a 10 ampere very fast acting fuse would be appropriate. On most ACE Temperature Controllers1 the bottom rear  panel fuse would be the one to change from 15 amperes to 10 ampere value. The 15 ampere is standard since the majority of heaters used are rated so near 10 amperes that false blows would occur. The top rear 15 ampere  primary should not be changed.

1On the ACE Nos. 12107-20, 12111-15 and 12113 -17 Controllers, the top fuse is the one to change. The bottom fuse is a three ampere regular blow alarm output fuse. Check your controller instructions for the proper replacement of the output or secondary fuse and use proper fuse for the size of the heater amperes.

Since supplying these very fast acting fuses, we have   seen a reduction of approximately 90% in Instatherm heater burnout normally due to “over voltaging.” This is a big savings in time, money and product loss.

 9. Temperature control units with alarm bands must be set properly. The 12107, 12111 and 12113 ACE Controllers  automatically make the adjustment of the Alarm setpoints. Factory set at ±15°C; can be changed when necessary.

10.Allow sufficient time for Auto Tune type Controllers to tune themselves by doing a trial run or by having a Setpoint Temperature 25°C or more above the starting temperature.

11.Refer to ACE Quick Reference menu sheets to follow   OEM Manual.

12.Always read instructions first and call ACE GLASS INC. (Electronics Dept.) if any questions arise.

Operating Instructions for

12102-12 Temperature Controllers

(RTD INPUT SENSOR)

CONTROLS 120 VOLT HEATERS ONLY!

Before beginning, take some time to familiarize yourself with the features of your new ACE Temperature Controller.

FRONT PANEL:

Locate large CONTROL KNOB in upper center   of panel. In lower left corner is MAIN POWER SELECTOR, ON (A.C. Power)/OFF SWITCH.  Above power switch is the DETECTOR CONNECTION for connecting RTD Sensor.  

To the immediate right of the power switch is a   red INPUT POWER INDICATING LIGHT indicating   line power to controller. In lower right corner see   the front 0-120V OUTLET for connecting heater.   Above outlet is the OUTPUT POWER DEMAND LIGHT that indicates power output to heater.

REAR PANEL:

Lower left, locate two fuse holders: both are fast   acting 15 amp fuses for input (top) and output   (bottom) circuits. Note! Output can be changed to   10 amp for lower current heaters. Bottom center is a second output outlet for 120 volts, 15 amps maximum loads such as oil baths, mantles, etc. To the right   bottom is the power cord for 120 volts, 15 amps maximum power input.

Control

Knob

Input

Sensor

Jack

Main

Power

Selector

Switch

Input Power

Indicating Light 0-120v

Outlet

Output

Power

Demand

Light

OPERATION

CONTROLS 120 VOLT HEATERS ONLY!

1.Turn MAIN POWER SELECTOR SWITCH   to “Off” position.

2.Turn the CONTROL KNOB to position “0.”

3.Connect 120v heater to front or rear outlet, i.e.,   oil bath, mantle, etc. Watch heater voltage rating!

4.Connect sensor to DETECTOR CONNECTION   and immerse probe into liquid to be heated.   A convenient method of holding sensor in oil   baths is via 9601-30 Holder Clip.

5.Plug POWER CORD into line source.

6.Switch MAIN POWER SELECTOR SWITCH to   A.C. Power. INPUT POWER INDICATING LIGHT should light.

7.Turn CONTROL KNOB to desired temperature.  OUTPUT POWER DEMAND LIGHT will indicate heating.

Operating Instructions for

12103-05 Temperature Controllers

(RTD INPUT SENSOR)

CONTROLS 20, 40 & 120 VOLT HEATERS

Before beginning, take some time to familiarize yourself with the features of your new ACE Temperature Controller.

FRONT PANEL:

Locate large CONTROL KNOB   in upper center of panel.  

In lower left corner is MAIN POWER SELECTOR, ON (A.C. Power)/OFF SWITCH. Above   power switch is the DETECTOR CONNECTION for connecting RTD Sensor. To the immediate right of the power switch is a red INPUT POWER INDICATING LIGHT indicating line power to controller.   In lower right corner see the front

0-20v or 0-40v OUTLET for connecting heater. To the left of outlet is output voltage selector switch. Above outlet is the OUTPUT POWER DEMAND LIGHT that indicates power output to heater.

Control

Knob

Input

Sensor

Jack

Main

Power

Selector

Switch

Input Power

Indicating Light

		REAR PANEL:
		Lower left, locate two fuse
		holders: both are fast acting
		15 amp fuses for input (top)
		and output (bottom) circuits.
		Note! Output can be changed
		to 10 amp for lower current
		heaters. Bottom center is an
		output outlet for 120v, 15 amps
		maximum loads such as oil
		baths, mantles, etc. To the
		right bottom is the power
		cord for 120 volts, 15 amps
		maximum power input.
		Output Power
		Demand Light
	40v/Off/20v	0-20v/0-40v Outlet
	Selector Switch

OPERATION

FOR 0-20 OR 0-40 VOLTAGE LIMITS

1.Turn MAIN POWER SELECTOR SWITCH to “Off” position.

2.Turn the CONTROL KNOB to position “0.”

3.Connect FRONT OUTLET to heater, i.e., oil bath, mantle, etc.

4.Select desired voltage limit and switch front toggle, located   to left of front outlet, to proper position. Watch heater voltage rating!

5.Connect sensor to DETECTOR CONNECTION and immerse probe into liquid to be heated. A convenient method of holding sensor in oil baths is via 9601-30 Holder Clip.

6.Plug POWER CORD into 120v line source.

7.Switch MAIN POWER SELECTOR SWITCH to “Front Outlet.” INPUT POWER INDICATING LIGHT should light.  

(Note! If switch is accidentally turned to “Rear Outlet,”   the front outlet will not be activated.)

8.Turn CONTROL KNOB to desired temperature.   OUTPUT POWER DEMAND LIGHT will indicate heating,   blinks within proportional band, and goes out when set temperature is exceeded.

FOR 0-120 VOLTAGE LIMITS

1.Turn MAIN POWER SELECTOR SWITCH   to “Off” position.

2.Turn the CONTROL KNOB to position “0.”

3.Connect REAR OUTLET to heater, i.e., oil bath, mantle, etc. 120v type heaters, only.

4.Connect sensor to DETECTOR CONNECTION   and immerse probe into liquid to be heated.   A convenient method of holding sensor in oil   baths is via 9601-30 Holder Clip.

(IMPORTANT! To avoid damage, never disconnect sensor while MAIN POWER SELECTOR SWITCH   is energized.)

5.Plug POWER CORD into 120v line source.

6.Switch MAIN POWER SELECTOR SWITCH   to “Rear Outlet.” INPUT POWER INDICATING  

LIGHT should light. (Note! If switch is accidentally turned to “Front Outlet,” the rear outlet will not   be activated.)

7.Turn CONTROL KNOB to desired temperature. OUTPUT POWER DEMAND LIGHT will   indicate heating.