Chemglass CG-1972-65 User Manual

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Temperature Control for Research and Industry

High Power

Temperature Controllers

User Manual for Models

HCC-130 HCC-215 HCC-230

Warranty

J-KEM Scientific, Inc. warrants this unit to be free of defects in materials and workmanship and to give satisfactory service for a period of 12 months from date of purchase. If the unit should malfunction, it must be returned to the factory for evaluation. If the unit is found to be defective upon examination by J-KEM, it will be repaired or replaced at no charge. However, this WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of being damaged as a result of excessive current, heat, moisture, vibration, corrosive materials, or misuse. This WARRANTY is VOID if devices other than those specified in Section 3.2 are powered by the controller. Components which wear or are damaged by misuse are not warranted. This includes contact points, fuses and solid state relays.

THERE ARE NO WARRANTIES EXCEPT AS STATED HEREIN. THERE ARE NO 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. We’re confident it can regulate ANY heating/cooling situation you’ll ever encounter. If the 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. ADJUSTING THE CONTROLLER FOR STABLE

CONTROL WITH DIFFERENT HEATERS . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 What is Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Autotuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Tuning for Heating Mantles: A Special Case . . . . . . . . . . . . . . . . . . . 8

2.4 Sensor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3. OPERATIONS GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Heater Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Setting the Controller for Safe Operation . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Ramp-to-Setpoint & Soak Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Timer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.6 Temperature Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.7 Power Reduction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.8 Affect of Power Setting on Heating Profile . . . . . . . . . . . . . . . . . . . . . 16

3.9 Do's and Don't's When Using Your Controller . . . . . . . . . . . . . . . . . . . 17

3.10 Resetting the Controller for Use With Heating Mantles . . . . . . . . . . . . 18

3.11 Changing the Temperature Display Resolution . . . . . . . . . . . . . . . . . . 18

3.12 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.13 Changing between PID and ON/OFF Operating Modes . . . . . . .. . . . . 19

3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. APPLICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1 Theory of How the Controller Works – Simply . . . . . . . . . . . . . . . . . . . . 21

4.2 Controlling the Heating Mantle Temperature Directly . . . . . . . . . . . . . . 22

4.3 Automatic Storage of Min/Max Temperatures . . . . . . . . . . . . . . . . . . . . 23

TABLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I. Safety Considerations and Accurate Temperature Control . . . . . . . . . . . 25

II. Resetting the Controller to Original Factory Settings . . . . . . . . . . . . . . . 26

WARNING: Adhere to the restrictions of SECTION 3.2. Failure to do so may create a

significant safety hazard and will void the warranty.

Section 1: Quick Operating Instructions

The three steps below are the 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., nonpolymeric 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.

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

2 3

Enter the Over Temperature Limit.

This meter, labeled “Limit Controller”, is the back-up meter for the setpoint

controller. Set this meter about 5 higher than the temperature entered into the Setpoint Controller in Step 5 If the reaction reaches this temperature limit for any reason, heating is 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.

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.

Set the power level switch to the volume of solution being heated

(not the size of the flask being used). The power level switch can be thought of as a solid state variac. Volume ranges are printed above this switch as a guide to select the correct power level since it’s easier to guess the volume being heated than the appropriate “percent power” to apply to a heater. ‘Heat Off’ turns off the heater so the controller displays temperature only. All new users should read Section 3.5.

Enter the setpoint (i.e., the desired reaction temperature) into the setpoint controller by holding in the *

button and simultaneously pressing the ▲ key to increase or the ▼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.

Limit

Controller

80.

To enter a temperature into either of the digital meters, hold the *

button and simultaneously press

the ▲ key to increase or the ▼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.

10-100 ml 50-500 ml

1-10 ml

Heat

Off

Output

Pow er L evel

300 ml-2 L

> 2 L

A power is equivalent to

setting of..... a variac setting of:

1-10 ml 3% 10-100 ml 10% 50-500 ml 25% 300 ml - 2 L 50% > 2 L 100%

TIP: Because the power switch acts like a variac, if the reaction is heating too slowly or you need more power (e.g., heating to high temperatures), give the heater more power by turning the power level up one setting. If the reaction needs less power than normal (e.g., heating to low temperatures (<60 temperature overshoots the set point excessively, turn the power down one setting. DO NOT set the power switch on a setting too high initially to heat the reaction quickly and then lower it to the correct setting, this degrades heating performance.

C) or the

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 programmed with values telling it how fast the heater warms up, cools off, and how efficiently it transfers heat. For example, consider the difference between a heat lamp and a hot plate. When electricity is applied to a heat lamp it begins to heat instantaneously, and when it's 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 controller is tuned to one type of heater, heating mantles

for example, any size-heating mantle can be used without the need to retune. When changing from heating mantles to a different type of heater, an oven for example, the controller should be tuned with values describing the oven’s heating characteristics. The effect of tuning is seen below. When the controller is tuned for heating mantles, using it with any size-heating mantle yields stable temperature control (Plot 1), but poor control results when the same tuning parameters are used with an oven (Plot 2, Curve 1). However, after tuning the controller to the oven, stable temperature control results (Plot 2, Curve 2).

Temp.

Plot 1

Conditions:

100 ml Toluene 250 ml Round bottomed flask 250 ml Heating mantle Power Setting = 50 - 500 ml

Temp.

Plot 2

Curve 2:

Curve 1:

Controller loaded with tuning parameters for drying oven

Controller loaded with tuning parameters for heating mantles

010

Time (min)

50 60

0102030405060

Time (min)

It’s important to understand that this controller isn’t a simple ON/OFF type controller (i.e. ON when

below the set point, OFF when above [though it can be made to work this way, see Section 3.13]). 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 to the heater now

to control the shape of the heating curve minutes in advance. The importance of the tuning parameters is that they are constants in the equation the temperature meter uses to perform its predictive calculations. If the temperature meter is programmed with tuning 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).

2.2 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.

1. Set the equipment up in the exact configuration it will be used. For example, to tune a vacuum oven, place the thermocouple in the room temperature controller. If the oven has its own thermostat or power control, turn both as high as they’ll go.

oven then plug the oven into the

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

ambient, skip this procedure and go to the next procedure, “Autotuning Fine

3. Enter a temperature into the limit controller about 25

Control”

into the setpoint controller.

C higher than the set point entered

the Controller for Very

C above

4. Press and hold in both the ▲ and ▼ 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 ▼ button until you get back to it).

6. First, hold in the ‘*’ button, while holding in the ‘ hold both buttons in until the display reads “A --”, or “A ##” where “##” is some number.

7. Release the ‘*’ button and press the ▼ button until “tunE” once again appears in the display.

’ button press the ▼ button. Continue to

8. Press and hold the ‘*’ button and “tunE” will change to “off” indicating that autotune is off.

9. While holding in the ‘*’ button, press the ▲ button to change the display to “on”, then release

both buttons.

10. Press and hold both the ▲ and ▼ 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 ▼ button until “off” is displayed].

Temp

Set

Point

75% of

set point

OS1

New tuning

values loaded

into memory

OS2

Heat to set point after entering new parameters

The autotune sequence.

During autotune the controller heats to 75% of the set point temperature, where it oscillates for several cycles before loading the new tuning parameters. After the tuning parameters are loaded it heats to the set point temperature. Tuning below the set point prevents any damage

Start

During T1 - 4 the controller measures heating delays and rates of heating and cooling

T1 T2 T3 T4

Quarter cycle times

that might occur from overheating.

Time

Autotuning the Controller for Very Fine Control.

This procedure is not recommended for heating mantles (see Section 2.3).

In the majority of cases, the procedure above results in stable temperature control with any heater. A

second version of the autotune routine is available and can be used when the heater is already at or close to the set point, is being tuned at a temperature close to room temperature, or for very fine control in demanding situations. If stable temperature control doesn’t result after performing the first autotune routine, the procedure below should be performed. Before performing the ‘fine tune’ autotune procedure, the ‘regular’ autotune procedure that precedes this should normally be performed.

1. Set the equipment up in the exact configuration it will be used. If the heater has its own thermostat or power controls, turn both as high as they’ll go. With this procedure it’s not necessary for the equipment to start at room temperature. This procedure can be performed at

any time and any temperature. Only tune the never tune the limit controller.

setpoint controller (i.e., the meter on the left),

2. 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

the setpoint controller.

C higher than the set point entered into

4. Press and hold in both the ▲ and ▼ 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 ▼ 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 “##” is some number.

7. Release the ‘*’ button and press the ▼ button until “tunE” once again appears in the display.

8. 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 ▲ button to change the display to “At.SP”, then

release both buttons.

10. Press and hold both the ▲ and ▼ buttons (≈ 3 seconds) until the temperature appears in the

in step 9 press the ▼ button until “off” is displayed].

Autotune Errors. The autotune routine can fail for several reasons. If it fails, the controller displays

the error message “tunE” “FAiL”. To remove this message, turn the controller off for 10 seconds. Try the procedure titled “Autotuning the Controller for Very Fine Control” above. If autotune fails again, call and discuss your application with one of our engineers. A common problem when tuning at high temperatures or with large volumes is for the heater to be underpowered. A more powerful heater may be needed (contact J-KEM for assistance).

2.3 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

(i.e., don’t autotune to the heating mantle)

by following the step-by-step instructions given in Procedure 1 of Section 3.10.

2.4 Sensor Placement. Placement of the sensor is basically common sense. The sensor should be positioned to sense the average temperature of the medium being heated. That means the thermocouple should be shielded from direct exposure to the heater but not so distant that 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:

Solutions

HPLC column heated with a heating tape

Oven

Place the sensor in the solution. Stir vigorously so that heat is homogeneously mixed throughout the solution. Tape a thin wire thermocouple directly to the HPLC column. Place several layers of paper over the thermocouple to insulate it from the heating tape (the thermocouple should sense the column column completely with heating tape. The thermocouple needs to be shielded from transient hot and cold air currents. Don’t place the thermocouple near the heating coil or an air vent. A small thermocouple (1/16” or 1/8” thermocouple) that responds rapidly to changes in air temperature is better than a larger one.

temperature, not the heater temperature). Wrap the HPLC

Section 3: Operations Guide

3.1 Front Panel Description.

Figure 1

1. Temperature Display. Shows temperature of the process as the default display. Shows set point temperature (i.e. desired temperature) when ‘*’ button is pressed.

2. Control Key. When pressed, the display shows the set point temperature. To decrease or increase

the set point, press the ‘▼’ key (3) or ‘▲’ key (4), while simultaneously depressing the control key.

The set point appears as a blinking number in the display.

3. Lowers set point when ‘*’ button (2) is simultaneously pressed.

4. Raises set point when ‘*’ button (2) is simultaneously pressed.

5. Limit Controller. This controller sets the temperature that causes the over temperature circuit to activate disconnecting power from outlets 8 (see Section 3.3).

6. Indicates an over temperature condition and heating has stopped when lit. See Section 3.3.

7. 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 limit controller) must each have a thermocouple attached.

8. 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.

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. Increases or decreases the time remaining in the timer when pressed.

13. This switch, in conjunction with the timer, determines when power is present at the heating outlets. See Section 3.5. The label ‘When time = 0 turn outlet:’ has reference to the time remaining in the display 15.

14. Indicates whether the timer section has turned power ON or OFF at the heating outlets. This LED is lit when the timer will allow power to be present at the heating outlets and off when the timer has turned the heating outlets off.

15. Displays the time remaining in the timer in the format of ‘Hr:Min’.

3.2 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 HCC-215 HCC-230

120 VAC 30 Amps 220-240 VAC 15 Amps 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 Restrictions Comments

Incandescent lamps Infrared heaters

Inductive loads: * solenoids * transformers

≤ 3000 watts

≤ 10 amps

≤ 1 horsepower

Set the power reduction circuit to the > 2 L position. The controller must be programmed for this use. Request application note AN5.

* motors

3.3 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.

Setpoint

Controller

80.0

The meter on the far left, labeled Setpoint Controller is the main process controller and 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.

Limit

Controller

80.0

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 into the limit controller (for example 85 heat the process to 80 into play is if, for whatever reason, the temperature of the process rises to 85

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 results in the same scenarios as above. The Model HCC provides complete, 100% redundant control of the heating process for maximum safety of unattended operations.

The meter on the right, labeled Limit Controller has no influence on the heating 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 process heats to the temperature entered into the limit controller, power is physically

C) above the temperature entered into the setpoint controller. If the

disconnected from outlets 8 and remains disconnected until the controller is manually reset.

C where it will maintain it indefinitely. The only time the limit controller comes

C). Press the reset button (9). The setpoint controller begins to

C) then a slightly higher temperature

C at which point power is

3.4 Ramp-to-Setpoint & 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 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).

C at a rate of 5o C/Hour), a second

Examples of Program Ramps

Soak

Setpoint

Ramp

Power Off

Ramp

Setpoint

Temperature

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:

Temperature

Time

Soak

Power Off

SPrr SetPoint Ramp Rate. Allowable Values: 0 to 9990 deg/Hr.

This specifies the desired rate of heating (cooling). Note, this parameter specifies the desired rate of heating (cooling), but in cases of extremely high ramp rates the reaction will not actually heat faster than the power of the heater will allow.

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.

Important Points to Know

1. While the Ramp-to-Setpoint feature in activated, the display alternates between the current reaction

temperature and the word “SPr” to indicate that a “SetPoint Ramp” is active.

2. Setting a ramp rate 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 (i.e., 20 deg/min) is set, unless the heater is powerful enough to impart heat at such a high rate, the reaction temperature will not track the ramp temperature. Likewise, a reaction can’t cool faster than natural cooling by ambient air.

3. Once the Ramp-to-Setpoint feature is activated in programming mode, it remains on until it’s deactivated in programming mode. The Ramp-to-Setpoint feature remains activated even if power is turned off to the controller.

Activating & Programming the Ramp-to-Setpoint Feature

5. To exit programming mode, press and hold in both the ▼ and ▲ keys until the temperature appears in the display, then

Press and hold in both the ▼ 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 ▼ or ▲ 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 ▼ or ▲ key until the desired setting appears in the display, then let go of all the keys.

Press the ▲ 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 ▼ or ▲ key until the desired time

appears in the display, then let go of all the keys. If a soak time is set, the controller display will alternate between showing the current reaction temperature and the word “StoP” when the soak time has expired to indicate that power has been turned off.

release both keys.

Deactivating the Ramp-to-Setpoint Feature

3. To exit programming mode, press and hold in both the ▼ and ▲ keys until the temperature appears in the display, then

Press and hold in both the ▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the

display, then release both keys.

Press the ▲ key (9 times) until the word “SPrn” appears in the display.

This function turns the ramping feature ON and OFF. First hold in the ‘*’ key, then while holding in the *’ key press

the ▼ or ▲ key until OFF appears in the display, then let go of all the keys.

release both keys.

3.5 Timer Controls. The timer section turns the heating outlets either ON or OFF in an unattended operation when the time in the counter expires. To enter a value into the timer press the up or down buttons (12) to increase or decrease the displayed time. The format of the display is ‘Hr : Min’. A simple way to know whether the heating outlets are ON or OFF is by the state of LED 14 which is lit when the outlets are ON and not lit when they’re OFF. The heating outlets will be ON or OFF depending on the position of switch 13 as outlined in the table below.

Switch 13 Time Remaining Outlets LED 14

Position on Clock are: is Comment

[When time =

Zero

OFF

turn outlet:]

OFF

[When time =

>Zero

Zero

Heating remains ON until the timer counts down to zero, at which point the outlets turn OFF and stay off until reset.

turn outlet:]

> Zero

OFF

Heating remains OFF until the timer counts down to zero, at which point the outlets turn ON and stay on indefinitely.

WARNING: A potential danger exists when using the timer to turn heating outlets ON when the

timer counts to zero. During a power failure, the time remaining in the timer is lost. When the power

comes back on the timer resets to zero, which turns outlets ON. Therefore, only processes that pose no danger when heated indefinitely should be set up to turn on when the timer counts to zero.

3.6 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.

3.7 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 intermediate

(50 - 500 mL), medium (300 mL - 2 L), or high (>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 controller to the heater depending on the position of the power switch. A new power setting was added to this circuit that is not labeled on the front of the cabinet. The new setting is 1 ‘click’ to the left of the 1-10 ml setting and is “power off”. In this position the controller doesn’t heat but acts as a digital thermometer. The correct setting for this switch is the setting that supplies adequate power for the heater to heat to the set point in a reasonable period of time while at the same time not overpowering it.

(1-10 mL), low (10 - 100 mL),

Front Panel Approx. % of Volume Range Full Power

[New setting to the left of the “1-10 ml” setting] 0

1 - 10 mL 3 10 - 100 mL 10 50 - 500 mL 25 300 ml - 2 L 50 ≥ 2 L 100

Heating Liquids. Each power level is associated with a volume range, which acts as a guide when heating solutions with heating mantles. When solutions are heated with heating mantles set the power switch to the range that includes the volume of solution being heated [Note: this switch is set to the volume of solution

, not the size of the flask]. For example to heat 250 ml of toluene to 80o C in a 1 L round bottomed flask choose the third power setting (50 - 500 ml) since the solution volume falls within this range. There are situations when a power level other than that indicated by the front panel should be used:

Example Power Setting Explanation

80 ml toluene 100 ml flask 100 ml heating mantle SP = 80

C 80 ml collidine 100 ml flask 100 ml heating mantle SP = 170

C 80 ml water 100 ml flask 100 ml heating mantle SP = 80

C 125 ml toluene 1 L flask 1 L heating mantle SP = 80

150 ml toluene 250 ml flask 250 ml heating mantle SP = 35

Avoid switching between the different power levels while the controller is heating. Specifically, do not initially 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 (i.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 >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.

50 - 500 ml (25% power)

300 ml - 2 L (50% power)

10 - 100 ml (10% power)

Organic solvents heated to ≈ 50 - 110 range on the front panel. When choosing between 2 power

C are set to the volume

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.

3.8 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 contains 1 optimal and 1 or 2 less optimal settings demonstrating use of the power reduction circuit.

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 a smooth heating curve. The > 2L power setting is too much power and results in oscillation around the set point.

C and thus results in

Temp

0 10203040506070

Conditions: Set point = 75 C

Laboratory oven

Power Setting = 50 - 500 ml Power Setting = > 2L

Conditions: Set point = 45 C

HPLC Column wrapped with heating tape Power Setting = 50 - 500 ml

Time (min)

Temp.

Conditions: Set point = 70

0 10203040506070

Power Setting = 10-100 ml (i.e., 10% power) Power Setting = 50-500 ml (i.e., 25% power) Power Setting = 300 ml - 2 L (i.e., 50% power)

Time (min)

50 ml Toluene 100 ml Round bottomed flask

Graph 2

This graph shows the affect of different power settings when heating liquids with heating mantles. The 10 - 100 ml setting (10% power) is underpowered and results in slow heating. The 300 ml - 2 L setting (50% power) is too much power and results in sporadic control. The controller adapts to a wide range of power settings. In this example the power is varied by a factor of 5X, nevertheless, reasonable control is maintained in each case.

170

145

Set point = 155 C Power = > 2 L (100% power)

Graph 3

Another factor affecting the choice of power setting is the set point temperature. For set points

Temp

120

Set point = 100 C Power = 300 ml - 2 L (50% power)

near room temperature a low power level is adequate. For average temperatures (50 - 100 the volume is printed on the front of the controller is a good guide.

010203040506070

Conditions:

300 ml collidine 500 ml flask 500 ml heating mantle

Time (min)

Set point = 45 C Power = 50 - 500 ml (25% power)

For high temperatures, the next higher power setting might be needed to supply the heater with

additional power

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.

3.9 Do's and Don'ts When Using Your Controller. The controller, heater and thermocouple form a closed loop feedback system (see Fig. 2 in Section 4.1). When the controller is connected to a heater, the feedback loop should not be broken at any point.

Don't remove either the thermocouple or heater from the solution without setting the power level to the

"Heat Off". With the thermocouple or heater separated from the solution, as the thermocouple cools the controller turns the heater on. Since this heat is never fed back to the controller it heats continuously.

Don't use the controller to regulate an exothermic process.

The controller has no capacity for cooling. If an exotherm is expected, it must be controlled in another way.

Do use an appropriate size flask and heater for the volume being heated.

Use the smallest flask and heating mantle that accommodates the reaction. This ensures that the heating power of the heating mantle closely matches the volume being heated. This also allows the solution to radiate excess heat to minimize temperature overshoots.

Do place the thermocouple directly in the solution.

Place at least the first 1/4” of the 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).

Do avoid exposure of the controller to corrosive gases and liquids.

The atmosphere of a research hood is corrosive to all electronics. Place the controller outside the hood away from corrosive gases.

)

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 takes about 2 minutes to perform]

7. Press and hold in both the ▼ and ▲ keys until the temperature appears in the display, then release both keys.

Press and hold in both the both keys.

▲ key once and the word “bAnd” will appear in the display.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the all the keys.

▲ key once and the word “int.t” will appear in the display.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the all the keys.

▲ key once and the word “dEr.t” will appear in the display.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the all the keys.

▲ key once and the word “dAC” will appear in the display.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the all the keys.

▲ key once and the word “CyC.t” will appear in the display.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the all the 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 1o C resolution by following the procedure below (the

display can also be changed to read in resolution:

1) To enter a setpoint faster (the display scrolls 10X faster in 1

2) To display temperatures above 999.9

1. Press and hold in both the Ð and Ï keys on the front of the temperature meter until the word “tunE” appears in the display, then release

2. Press the Ð key once and “LEVL” appears in the display.

3. Press the Ï key repeatedly until the word “diSP” appears in the display.

4. Press and hold in both the Ð and Ï 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

both keys.

First hold in the ‘*’ key, then while holding in the ‘*’ key press the the keys.

First hold in the ‘*’ key, then while holding in the ‘*’ key press the Ð or Ï key until the value “1” [not “0.1”] appears in the display, then let go of all the keys.

the controller. None of the fuses are user serviceable and should be replaced by a qualified electrician If fuses are replaced THEY MUST BE REPLACED BY AN EXACT EQUIVALENTS Littlefuse #L15S 15). Fuses can be obtained from electrical supply houses or from J-KEM.

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

▼ or ▲ key until the value “10” appears in the display, then let go of

▼ or ▲ key until the value “50” appears in the display, then let go of

▼ or ▲ key until the value “3.0” appears in the display, then let go of

▼ or ▲ key until the value “30” appears in the display, then let go of

F, call for information). There are two reasons to change the display

mode than in 0.1o mode).

Ï key until “2” appears in the display then let go of all

(such as a

3.13 Changing Between PID and ON/OFF Operating Modes. The controller can heat in either of 2 operating modes, PID (P

roportional, 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 and OFF when above. The disadvantage of this mode is a large over shoot of the set point (5 -

) on initial warm up and oscillation of temperature around the set point thereafter. The reason for the overshoot is because the heater turns off only after crossing the set point and until the heater cools down the temperature continues to rise. This method works well for heaters that transfer heat rapidly (such as heat

lamps), it’s acceptable for heaters such as heating mantles (≈ 5o 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 the heating curve during initial warm up and decreases power to the heater before

the set point is reached so that the solution reaches the set point with minimal over shoot. [Notice that the heater turns off for varying periods of time before the set point temperature is reached]. The 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 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 ▲ and ▼ keys on the front of the temperature

meter until the word “tunE” appears in the display, then let go of the buttons.

2. Press ▲ until the word “CyC.t” appears in the display.

3. While holding in the ‘*’ key, press the ▼ key until the word “on.of” appears

in the display. NOTE: if the display shows the letter “A” when the ‘*’ keys

is held in, press the ▲ key until “on.of” is in the display, then let go of all

the keys.

4. Press the ▼ key until the word “bAnd” appears in the display. While holding in the ‘*’ key, press the ▼ key until the value “0.1” appears in the

display, then let go of all the keys.

5. Press and hold in both the ▲ and ▼ keys on the front of the controller until

the temperature is displayed, then release both keys.

Procedure to change controller to ON/OFF mode

The controller can be set back to PID control by following the procedure in Section 3.10. To completely reset the controller to original factory settings, follow the procedure in the Appendix, Section II.

3.14 Troubleshooting.

Problem Cause Corrective Action

Large over shoot of the set point (> 3o) during initial warm-up or

unstable temperature control. Controller is not tuned for process

The process heats too slowly. Output power level is set too low. Increase the output power level to the next higher setting (Section

The heater doesn’t have enough

The controller comes on, but does not heat.

An internal power fuse has blown Must be serviced by a qualified electronics technician. The over temperature protection

The switch on the bottom of the

Controller blinks: “

“-AL-”

“

“tunE” “FAiL” Displayed temperature is

incorrect.

[Note: Types ‘K’ & ‘J’ Thermocouples display negative

temperatures, but are not calibrated for them]

Corroded thermocouple

Corroded thermocouple. If the temperature-measuring end of the thermocouple is corroded,

inPt” “FAiL”

PArk”

Output power level is set too high. Set the output power level to a lower setting (see Section 3.7).

being heated.

power.

The heater is broken.

circuit is engaged.

Input/Output board must on the ‘inactive’ position.

The temperature sensor is unplugged, excessively corroded or broken. The process temperature is hotter than the alarm temperature.

Controller has been placed in “Park” mode.

Autotune routine failed. Turn off controller for 10 seconds. See Section 2.2.

The controller has not warmed-up.

Wrong type of thermocouple is plugged into controller.

connections.

Temperature display offset needed.

Tune the controller as outlined in Section 2.

3.7). Replace with a more powerful heater. For assistance contact J-

KEM. To verify that the controller is functioning properly, place the power level switch on the >2L setting and enter a set point of 100

C. Plug a light into the outlet of the controller, and wait 1 minute. If the light comes on the controller is working properly.

Set the limit controller to a temperature higher than that shown on the setpoint controller, then press the reset button (see Section 3.3). Move switch back to the inactive position. If accessories are attached, see User’s Manual for the accessory.

Clean or replace broken sensor.

Correct the over temperature condition.

1. Hold in both the temperature meter until ”

2. First hold in the “ the

▼ key until “oFF” appears.

3. Hold in the display.

The display temperature reads low when the controller is first 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 of heating.

Thermocouples are color-coded. Thermocouple plug and thermocouple receptacle must be the same color (see Section 3.6).

Clean plug on thermocouple and receptacle on controller with sandpaper or steel wool.

discard thermocouple. To enter a controller display offset:

1. Turn on controller. Allow unit to warm up for 30 minutes.

2. Record displayed temperature.

3. Press both the meter until “tunE” appears, then let go of the keys.

4. Press the

5. First hold in the “ press the go of all keys.

6. Press the

7. Note the current display offset (this is the number blinking in the display).

8. Calculate the new offset temperature using the equation:

New Current Display = display offset - Displayed + Correct Offset blinking in display temperature temperature

9. First hold in the “ press the showing, then let go of all the keys.

10. Press the

▲ and ▼ keys on the front of the J-KEM

tunE” appears in the display.

*” key, then while holding in the “*” key press

▲ and ▼ keys until the temperature appears in the

▲ and ▼ keys on the front of the temperature

▼ key until “LEVL” appears.

*” key, then while holding in the “*” key

▲ key until “3” is showing in the display, then let ▲ key until “ZEro” is showing in the display.

*” key, then while holding in the “*” key

▲ or ▼ keys until the new offset temperature is ▲ and ▼ keys until the temperature is displayed.

Section 4: Application Notes

Supplemental application notes on the following topics are available by contacting J-KEM.

Application Note

AN1 How to heat oil baths with your controller. (Included in Appendix) AN2 Changing the controller’s thermocouple type. AN3 Changing the heating outlet into a cooling outlet. AN4 Using the controller for unattended fractional distillations. AN5 Using the controller with inductive (motors, valves) loads.

4.1 Theory of How the Controller Works – Simply. For the purpose of explaining how the controller works, the example of a solution heated with a heating mantle is used. The principles are the same for all heater types.

Subject

Thermocouple

J-KEM Scien tific

Instrument s f or Science

80.0

Power

10-100 ml

50-500 ml

Outpu t

Power Level

300 ml-2 L

> 2 L

1-10 ml

Heat

Off

120 vac

Power to heater

Model 210

120 Vac, 840 watts

Temperature of process from the thermocouple

Heating mantle

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 this can be seen in a simple example.

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 warmedup. 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

would continue to rise – even though all power had been disconnected

– until the range coil cooled down.

C the temperature

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 the final temperature probably would not exceed 82 the volume of water is so large. In most situations a 2

C by the time the range coil cooled down, because

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 this case, the final temperature would probably approach 100

C before the range cooled down. A 20

C. In

overshoot is no longer acceptable. Unfortunately, this is the situation in most research heating applications. That is, small volumes (< 2 L) heated by very high efficiency heating mantles that contain large amounts of heat even after the power is turned off. Your controller handles the problem of ‘latent heat’ in the heating mantle in two ways:

1) The controller measures the rate

of temperature rise during the initial stages of heating. It then uses this information to determine the temperature at which heating should be stopped to avoid exceeding the set point. Using the range analogy, this might mean turning the power off when the water temperature reached 60 temperature from 60 to 80

C and allowing the latent heat of the burner to raise the water

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 (> 2 L). The proper power setting becomes instinctive after you've used your controller for a while. For additional information see Section 3.7.

4.2 Controlling the Heating Mantle Temperature Directly. In a normal heating setup, the thermocouple is placed in the solution being heated. The controller then regulates the temperature of the solution directly. The thermocouple could alternately be placed between the heating mantle and the flask so that the controller regulates the temperature of the heating mantle directly, which indirectly 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.

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 contact 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.

Heating Power Mantle Size Level 5 & 10 ml 1-10 ml 25 ml 10-100 ml 50 ml - 22 L 50 - 500 ml

For temperatures over ≈ 120 oC, the next higher power level may be necessary

Procedure to Load Tuning Parameters for External Thermocouples.

7. Press and hold in both the ▼ and ▲ keys until the temperature appears in the display, then release both keys.

Press and hold in both the both keys.

Press the “ Press the “ Press the “ Press the “ Press the “

▲ key once and the word “bAnd” will appear in the display. While holding in the ‘*’ key press the ▼ or ▲ key until the value

5” appears in the display, then release all keys.

▲ key once and the word “int.t” will appear in the display. While holding in the ‘*’ key press the ▼ or ▲ key until the value

2” appears in the display, then release all keys.

▲ key once and the word “dEr.t” will appear in the display. While holding in the ‘*’ key press the ▼ or ▲ key until the value

5” appears in the display, then release all keys.

▲ key once and the word “dAC” will appear in the display. While holding in the ‘*’ key press the ▼ or ▲ key until the value

5.0” appears in the display, then release all keys.

▲ key once and the word “CyC.t” will appear in the display. While holding in the ‘*’ key press the ▼ or ▲ key until the value

5.0” appears in the display, then release all keys.

To return to using thermocouples in

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.

4. Hold in both the ▼ and ▲ keys until the temperature appears in the display, and release both keys. Automatic temperature logging is now

Press and hold in both the both keys.

Press the appears in the display, then release all keys.

Press the display, then release all keys.

on and will remain on until the controller is turned off or logging is turned off manually by repeating this procedure except in Step 3 pressing the

▼ key once and the word “LEUL” appears in the display. While holding in the ‘*’ key press the ▲ key until the value “3” ▲ key until the word “ChEy” appears in the display. While holding in the ‘*’ key press the ▲ key until “on” appears in the

▲ key until the word “off” appears.

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

solution, perform Procedure 1 in Section 3.10.

Procedure to Start Temperature Logging

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

Procedure to Read Minimum and Maximum Temperatures

4. Press and hold in both the ▼ and ▲ keys until the temperature appears in the display, then release both keys.

Press and hold in both the both keys.

Press the appears in the display, then release all keys.

Press the

1. Variance (the difference between the highest and lowest logged temperatures) Hold in the ‘*’ key and the display will alternate

2. High Temperature (the highest temperature since the logging option was turned on). While holding in the ‘*’ key press the

3. Low Temperature. While holding in the ‘*’ key press the

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.

▼ key once and the word “LEUL” appears in the display. While holding in the ‘*’ key press the ▲ key until the value “3” ▲ key until the word “rEAd” appears in the display. The “rEAd” screen displays 3 parameters.

between “

once and the display will alternate between “

recorded temperature.

UAr

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

” and number of degrees of variance.

” and the highest recorded temperature.

▲ key once and the display will alternate between “Lo

” and the lowest

▲ key

Table 1 Tuning Parameters for Various Heaters

Fill in values determined for your equipment for quick reference.

Instrument

Heating Mantles (Factory Default)

Heat Lamp

Oven

Vacuum Oven

Oven

Hot Plate

Proportional

Band

“bAnd”

Integral Time

(Reset)

“int.t”

Derivative Time

(Rate)

“dEr.t”

Derivative

Approach Cont.

“dAC”

Cycle Time

“CyC.t”

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 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 (P

roportional, Integral, Derivative) algorithm to regulate heating. Each of the terms in the PID equation has a constant that scales the equation to the process being heating. These constants (plus two other related terms) are collectively known as the ‘tuning constants’ and for the most part they are expressed in units of time, since they represent delay times, rate of heat transfer times, and rate of error accumulation. The relative value of each constant depends on the physical characteristics of the process being heated. For example, for the same amount of input power, the rate of heat transfer is twice as high for hexane as compared to water, since the coefficient of heat for hexane is 0.54 calories/g/ temperature of 10 g of hexane 44

C and water is 1.0 calorie/gram/o C. That means that 1000 watt-seconds of input power will raise the

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 (< 160 solvents) using heating mantles, since this is the most common application for J-KEM controllers. Since it’s

impossible for J-KEM to predict the application the controller will be used for, the researcher must be aware of the possibility that the tuning constants loaded into the controller may not be a set that results in stable temperature control. It’s the researcher’s responsibility to monitor the temperature regulation of a reaction. If you encounter a process that your J-KEM controller does not heat with stability, you have two

resources.

Autotune Feature. Your controller has and autotune feature that when turned on (see Sections 2.1 & 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.

C if the controller is

C) organic

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 (i.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 control 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.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Press and hold in both the both keys.

▼ key until “LEVL” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▲ key until “3”

Press the appears in the display. Let go of all the keys.

▲ key until “rSEt” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▲ key until the

Press the

All” appears in the display. Let go of all the keys.

word “ Press and hold in both the

The value that needs to be entered depends of the type of thermocouple receptacle your controller was shipped with. Determine the thermocouple type below.

Blue (type T) “ Yellow (type K) “ Black (type J) “

First hold in the ‘*’ key, then while holding in the ‘*’ key press the go of all the keys.

▲ key once and “unit” will appear in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▲ key

Press the

until the value “ Press the

▲ key until the value “SSd” appears in the display. Let go of all the keys.

Press in both the Press and hold in both the

both keys. Press the

▲ key until the value “10” appears in the display. Let go of all the keys.

the Press the

▲ key until the value “10” appears in the display. Let go of all the keys.

Press the Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the keys. Press the

▲ key until the value “3.0” appears in the display. Let go of all the keys.

Press the

▲ key until the value “30” appears in the display. Let go of all the keys.

the Press the

▲ key until the word “OFF” is displayed. Let go of all the keys.

Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the Press the

Dvhi” appears in the display. Let go of all the keys.

word “ Press the

the value “ Press the the number in the display stops changing (this will be “ Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the Press the

until the value ________________ appears in the display. Let go of all the keys. Press the First hold in the ‘*’ key, then while holding in the ‘*’ key press the Press the until the value 10.0 is entered. Press and hold in both the

display will go away when a set point is entered.

▲ key once and the word “SP1.d” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key 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 ▲ 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 ▲ key once and the word “dEr.t” will appear in the display.

▲ key once and the word “dAC” will appear in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▲ key once and the word “CyC.t” will appear in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press ▲ key until the word “SPrn” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▼ or ▼ key until the word “LEVL” appears in the display.

▲ key until “SP2.A” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▲ key until the ▲ key until “diSP” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▼ or ▲ key until

0.1

” appears in the display. Let go of all the keys.

▲ key until “Lo.SC” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key hold in the ▼ key until ▼ key until the word “LEVL” appears in the display.

▲ key until “ZEro” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▼ or ▲ key

▼ key until the word “LEVL” appears in the display.

▲ key until “SEt.2” appears in the display. Next, hold in the ‘*’ key, then while holding in the ‘*’ key press the ▼ or ▲ keys

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

▼ and ▲ keys until the word “inPt” appears in the display, then release both keys.

Color of thermocouple receptacle (Fig 1; # 7) Value to enter:

NOTE: Many of the patterns for this parameter look similar, be careful to select the exact pattern shown above.

” appears in the display,. Let go of all the keys.

▼ and ▲ keys until the temperature appears in the display (the word “PArk” also appears), then release both keys.

▼ and ▲ keys on the front of the temperature meter until the word “tunE” appears in the display, then release

0” or “-50” or “-199.9” depending on thermocouple type). Let go of all the keys.

▼ and ▲ keys until the temperature appears in the display, then release both keys. The word “PArk” in the

▲ key until the value from the table above appears in the display. Let

▲ key until the value “50” appears in the display. Let go of all the

▲ key until “2” appears in the display. Let go of all the keys.

▲ key until “3” appears in the display. Let go of all the keys.

▼ key until “1” appears in the display. Let go of all the keys.

”

tc ” tc ”

Chemglass CG-1972-65 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual