Model 150 & 150/Timer Manual - J
Contents
1. 3 1 Front Panel Description Front Back 1 ka e e JKL ne J KEM Scientific Inc 2 St Louis Missouri 120 Vac 60 Hz 10 amps 1200 watts 4 OFF ON 5 6 7 10 11 13 12 Figure 1 1 Temperature Display Shows temperature of the process as the default display Shows set point 10 11 12 13 temperature i e desired temperature when button is held in Shows state of the heating outlet Indicates outlet 13 is on when light is lit conditional on the State of the timer switch 7 see Section 3 4 Control Key When held in the display shows the set point temperature To decrease or increase the set point press the W key 4 or M key 5 while simultaneously holding in the control key The set point appears as a blinking number in the display Lowers set point when button 3 is simultaneously pressed Raises set point when x button 3 is simultaneously pressed Controller On Off switch WARNING Due to the nature of solid state relays a small amount of output power 7 5 mA 120 VAC 0 9 watts is present at outlet 13 even when the controller is turned off Take appropriate precautions to avoid electrical shock Timer Switch This switch in conjunction with the timer determines if power is present at outlet 13 See Section 3 4 The label When time 0 turn outlet has reference to the time remaining2. button press the 48 button to change the display to on then release both buttons 9 Press and hold both the AN 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 3 8 and 9 except in step 8 press the VW button until off is displayed New tuning EN values loaded into memory SOG ee o Point Heatto set point after entering The autotune sequence pee During autotune the controller heats 75 of a e 052 N to 75 of the set point temperature set point where it oscillates for several cycles before loading the new tuning parameters After the tuning parameters are loaded it heats to the Start Th ep oe 44 set point temperature Tuning below During T1 4 the controll i AT measures heating delays and Quarter cycle times the ser Po Preven ony damage rates of heating and cooling that might occur from overheating Time Autotuning the Controller for Very Fine Control This procedure is not recommended for heating mantles see Section 2 3 In the majority of cases the procedure above results in stable temperature control with any heater A second ve
3. Inductive loads lt 4 amps 480 watts solenoids transformers motors The Model 150 Timer can be used with any 120 volt heater such as heating mantles hot plates ovens etc but with small equipment heating mantels less than 100 ml in size or equipment that heats up and cools down slowly some hot plates a large amount of over shoot of the entered temperature may result during initial warm up The problem is not with the controller which has the best heating algorithm in the industry it s with the over powered heaters some pieces of equipment have A simple example will clarify this point Consider the example of trying to control the temperature of a pot of water at 80 C on a simple electric stove by manually turning it ON and OFF This is the way the Model 150 controls temperature by rapidly turning ON and OFF the heater for just the right amount of time to maintain the reaction at the desired temperature Now in the first case if you were heating 4 liters of water in a large pan the stove would do a pretty reasonable job because the amount of heat the stove generates is appropriate for the amount of water being heated Now imagine you attempted to use the same stove to regulate the temperature of a teaspoon 1 ml of water You would have predictably disastrous temperature control because the heater the stove has substantially more power than is needed to heat a teaspoon of water This is the case wi
4. Controuler 2 04 eee Shae ted owes heen ed 5 2 2 Auto Tuning Procedure nnsssennnns nennu re nenn r ennnen 6 2 3 Tuning for Heating Mantles A Special Case 8 24 Ser PACEME vredens DAS SES Sed 8 3 OPERATIONS GUIDE 45 0 300004 os Sati oe bated sg oe beta doe bend ss 9 3 1 Front Panel Description 23 2 2624 ck beta ees beet ohh ee kresne 9 DZ HERA ae PL RD ee Des 10 3 3 Over Temperature Protection Circuit 0 0 0 cece eee 11 IA MTCS regera ie eb em ae AE pe eee eee 12 3 5 Temperature Sensor Input 20000r searkdek sandete enne 12 3 6 Do s and Don ts When Using Your Controller 13 3 7 Resetting the Controller for Use With Heating Mantles Resiorins Factory DENS ard sake nhir Sed boomed ean 13 3 8 Changing between PID and ON OFF Operating Modes 14 3 9 Using the Temperature Ramp Feature 0 0 0 eee eee 15 310 IrOuBleshOOune 2244 arr Anar E eed ht caer Geo wed tes 17 TABLE As ae Sos eta hae teat cs Bose els ea eo es Babe els Ema eo cs Pane ee ee 17 AFPENDIS 02055 tiaras sees onus eae ene DD 18 I Using the Controller With an Oil Bath Application Note 1 18 II Safety Considerations and Accurate Temperature Control 19 IMI How to Set Up a Reaction Using J KEM s Digital Controller 20 VI Resetting the Controller to Original Factory Settings 24 Section I Quick Operating Instructions The fo
5. I N until the value __ appears in the display Let go of all the keys 22 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 4 keys N N N NO 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 Nn 24
6. below 10 C above the setpoint the circuit is reset and the controller begins to operate normally An over temperature condition is indicated by the display blinking the message AL The over temperature feature acts to prevent accidents in situations where something has gone wrong or when the Model 150 is used in an application that it s not capable of controlling For applications requiring more versatile and accurate temperature regulation consider J KEM s 200 series controllers read the last paragraph of Section 3 2 for a comparison of J KEM s 150 Series and 200 Series controllers There may be situations where it s desirable to disable the over temperature protection circuit for example if the controller is often used as a digital thermometer The two procedures below give directions on disabling and re enabling the over temperature circuit In reality the over temperature alarm can t be turned off because it s hard wired in the controller but what you can do is program an over temperature condition so high i e 999 9 C that it has the effect of disabling the alarm What you ll do in the procedure to deactivate the over temperature circuit is enter the number of degrees that the reaction temperature must exceed the set point to cause the over temperature circuit to come on If you enter a small number such as 10 C which is the factory default the alarm will turn off heating when the reaction exceeds the set point by 1
7. 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 7 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 rise in temperature isn t sensed by the controller within a reasonable period of time Several examples follow that show the type of consideration that should be given to sensor placement Use With Place the sensor in the solution Stir vigorously so that heat is homogeneously mixed Solutions throughout the solution Tape a thin wire thermocouple directly to the HPLC column Place several layers 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
8. heating coil or an air vent A small thermocouple 1 16 or 1 8 thermocouple that responds rapidly to changes in air temperature is better than a larger one Section 3 Operations Guide
9. in the display 8 Displays the time remaining in the timer in the format of Hr Min Increases the time remaining in the timer when pressed Decreases the time remaining in the timer when pressed Indicates whether the timer section will allow power to be ON or OFF at outlet 13 This LED is lit when the timer section will allow power to be present at outlet 13 and off when the timer section has turned power off at outlet 13 Temperature Sensor Input Use the same type of sensor probe as the sensor plug installed on the controller see Section 3 2 The correct sensor type will have the same color plug as the receptacle 12 on the front of the controller Power Outlet Plug only 120 VAC devices into this outlet see Section 3 2 3 2 Heater Restrictions The controller delivers 10 amps of current at 120 VAC into resistive loads heating mantles hot plates ovens etc Use only resistive loads that are safely operated at 120 VAC and require less than 10 amps or damage to the controller and a safety hazard may result e Do not plug oil baths into your controller Oil baths are not 120 VAC devices and become a fire hazard unless properly connected to the controller See Appendix for an application note describing the use of oil baths with this controller e Devices other than resistive loads can be used with your controller but certain restrictions Device Type Incandescent lamps lt 700 watts Infrared heaters apply
10. 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 Oil bath 10 ml heating mantle 21 Classes of J KEM Scientific Temperature Controllers J KEM s 200 Series Apollo and Gemini controllers are compatible with any size heating mantle from 5 ml to 50 liter and any 120 Vac oil bath do not use with oil baths rated less than 120 Vac J KEM s 150 Series economy controllers are compatible with 500 ml heating mantles and larger and 120 Vac oil baths do not use with oil baths rated less than 120 Vac J KEM s 230 Vac controllers are compatible with any 230 Vac heating mantle 100ml and larger They are not compatible with any size oil bath Shown is a typical set up for a 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 t
11. it First hold in the button while holding in the button press the YW 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 While holding in the button press the button to change the display to At SP and release both buttons Press and hold both the 4 and Y buttons for 3 seconds until the temperature appears in the display The controller is now in its autotune mode While in autotune the display alternates between tunE for autotune and the process temperature When the autotune sequence is done this may take in excess of an hour the controller stops displaying tunE and only displays the process temperature To abort autotune manually repeat steps 3 8 and 9 except in step 8 press the W button until off is displayed 7 2 3 2 4 Autotune Errors The most frequent reason for autotune errors is that the over temperature protection circuit turns heating off during autotune which results in a tunE FAIL message in the temperature meter During autotune it s not unusual for the reaction temperature to exceed the set point by enough to trigger the over temperature protection circuit In this case
12. min is set unless the heater is powerful enough to impart heat at such a high rate the reaction temperature will not track the ramp temperature Likewise a reaction can t cool faster than natural cooling by ambient air 4 Once the Ramp to Setpoint feature is activated in programming mode it remains on until it s deactivated in programming mode The Ramp to Setpoint feature remains activated even if power is turned off to the controller Activating amp Programming the Ramp to Setpoint Feature I Press and hold in both the and V keys on the front of the temperature meter until the word tunE appears in the display then release both keys Press the A 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 V or A key until the desired ramp rate appears in the display then let go of all the keys Units are in degrees hour Press the A 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 V or A 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 t
13. reaction on Channel I 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 20 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 is a type J The color of the thermocouple the thermocouple extension cord and the thermocouple receptacle on the face of the controller must all be the same color 1 e thermocouple type or the controller will not read the correct temperature Thermocouples are available in many different styles As long as the thermocouple has the same color connector as the connector on the controller they are 100 compatible Stainless steel no Teflon coating 12 inch length Teflon coated Bend Teflon coated 6 inch length Teflon coated Temperature sensitive end hypodermic needle of the thermocouple When a thermocouple is placed in solution often it is desirable to bend the thermocouple slightly so that more of the tip extends into the solution It does not hurt a thermocouple to be bent slightly The temperature sensitive portion of a thermocouple is the first 4 of the tip It s good for the first 2 to be
14. the over temperature protection circuit must be inactivated before the autotune procedure is tried again see Section 3 3 If the autotune sequence failed due to the over temperature protection circuit the timer display will show the word help If the word help is not showing in the timer window autotune must have failed for a different reason To remove the tunE FAIL 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 under powered 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
15. 0 C If you enter a large number such as 999 9 C you ll for all practical purposes turn the over temperature circuit off since with this setting the reaction must exceed the set point by 999 9 C before the alarm would come on Procedure to DEACTIVATE Over Temp Alarm Procedure to RE ACTIVATE Over Temp Alarm Press and hold in both the 8 and W keys on the front Press and hold in both the 48 and W keys on the front of the temperature meter until the word tunE of the temperature meter until the word tunE appears in the display then release both keys This appears in the display then release both keys This places the controller in programming mode places the controller in programming mode 2 Press the key until SEt 2 appears in the display Press the key until SEt 2 appears in the display and release all keys then release all keys Press and hold in the key When the key is held Press and hold in the key While holding in the in the display shows the number of degrees that the key press the VW key until the display shows 10 0 set point must be exceeded by to cause the over then release both keys temperature alarm to activate To effectively disable the over temperature alarm while holding in the key press the 8 key until a very large value like 100 is entered When you re done let go of all the keys Whatever number you entered at this point is the number of degrees that the reac
16. ABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL J KEM SCIENTIFIC INC BE LIABLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES THE BUYER S SOLE REMEDY FOR ANY BREACH OF THIS AGREEMENT BY J KEM SCIENTIFIC INC OR ANY BREACH OF ANY WARRANTY BY J KEM SCIENTIFIC INC SHALL NOT EXCEED THE PURCHASE PRICE PAID BY THE PURCHASER TO J KEM SCIENTIFIC INC FOR THE UNIT OR UNITS OF EQUIPMENT DIRECTLY AFFECTED BY SUCH BREACH Service J KEM Scientific maintains its own service facility and technical staff to service all parts of the controller usually in 24 hours For service contact J KEM Scientific Inc 6970 Olive Boulevard St Louis MO 63130 314 863 5536 Fax 314 863 6070 Web site amp On Line Catalog www jkem com E Mail jkem911 jkem com This manual contains parameters specific to temperature controller Serial When calling with a technical question please have the controller s serial number available You ve purchased the most versatile controller available to the research community We re confident it can regulate ANY heating cooling situation you ll ever encounter If the information in this manual isn t adequate to make your application work call our Engineering Department for assistance INDEX SECTION PAGE 1 QUICK OPERATING INSTRUCTIONS 4 2 ADJUSTING THE CONTROLLER FOR STABLE CONTROL WITH VARIOUS HEATERS 5 21 Howto Tune tie
17. Temperature Control for Research and Industry Model 150 amp 150 Timer Manual KEM Scientific Inc Instruments for Science from Scientists 2 g Sem SSCS SST S SPST PSST CCST SSS TST CSC PSS EEE STE PERC CPPCC PCP Te Tee ere eer BEE EEE EEE EEE EEE EE EEE EEE EEE I EE EEE WE Er Evan HESEEETENEEETEEEEETETEEETET EEE TETEETTETEEETEEEEETEREE EEETEEETTTTETTTTTET TET KEETTTTEETTTSTENETTTEETTTTTENTTTETEE TETTE EEE DEE MTT Tr TETT TT TETTE TET Tiree eri tera 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 aresult 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 MERCHANT
18. aced in a 100 ml heating mantle the always set to the Volume of 100 ml heating mantle the power control input should be solution being heated not the power control input should be set to the 10 100 ml setting size of the flask or heater set to the 50 500 ml setting When the power control computer is set to the correct power level your Test System Set Point 115 C 2 Lof N N dimethylformamide p 3 L Round Bottomed Flask controller can regulate virtually any heater to 0 1 C with less than 1 C overshoot on initial warming 3 L Heating Mantle 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 Time min 30 For a detailed explanation of the Power Control Computer see Section Two in the controller s User manual 23 VI 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 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 t
19. 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 M 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 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 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 M key until the value 3 0 appears in the display Let go o
20. be bent without harming them If you re heating a corrosive liquid use Teflon coated thermocouples 3 Enter the setpoint i e the desired temperature Hold in the button and simultaneously press the Ay key to increase or the W key to decrease the setpoint The setpoint can be seen at anytime by holding in i j the button the setpoint appears as a blinking j i number in the display 4 Set the timer For units with digital __ timers the timer turns the heating outlet OFF Lj T F E F E E E T T F LENKE ol al ll Tol ll la Val a i J The position of the timer switch determines if the heating or ON depending on the p outlet is ON or OFF when TIME 0 When the switch is position of the timer 4 amp J or ON set to OFF the heating outlet is off when Time 0 and on when Time 0 When the switch is set to ON the switch and whether any When time 0 heating outlet is on when Time 0 and off when turn outlet Time 0 The normal switch position 1s ON since the time is present in the OD timer resets to zero when the controller 1s first turned on display Section 2 Adjusting The Controller For 2 1 Stable Control With Various Heaters What is Tuning The controller s most powerful feature is its ability to regulate virtually any heater with stable temperature control But what s required for stable control is that the controller be tuned to the heater being us
21. e 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 cower heaters that transfer heat rapidly such as heat to heater ore ven SE 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 PID Mode of the heating curve during initial warm up and a port decreases power to the heater before the set men point is reached so that the solution reaches the y set point with minimal over shoot Notice that the heater turns off for varying periods of time F power before the set point temperature is reached JE The second feature of PID mode is that it adjusts the percent of time the heater is on so that the set PT point is maintained precisely The advantage of gt _ gt Time 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 o
22. eceptacle of the controller and connect the oil bath to the variac C Adjust the variac to deliver a voltage slightly above the voltage you normally would use to heat D gt the oil bath Enter the desired temperature into the controller The controller will now regulate the temperature of the oil bath In some unusual cases the controller may need to be autotuned for the oil bath see User s Manual but this is discouraged unless yov ll be using the oil bath frequently 2 If the reason for using an oil bath is that a small volume is being heated you have a second option Your Model 150 controller can be upgraded to a J KEM 200 series which can heat volumes as small as I ml in a 5 ml round bottomed flask using a 5 ml heating mantle Contact J KEM for upgrade information the advantage of this option is that it eliminates the mess and safety hazards associated with oil baths Accessories for regulating the temperature of small volumes are available from J KEM including small volume heating mantles and micro thermocouples Call if you have any concerns or would like to discuss your application with a technical representative Accessories for Heating Small Volumes Available From J KEM All sizes from 5 ml to 50 L Teflon Coated Micro scale Thermocouples See Catalog Thermocouples hermetically sealed in various See Catalog size hypodermic needles 18 II Safety Considerations and Accurate Temperature Control For safety critica
23. ed 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 turned off it stops heating instantaneously In contrast a hot plate may take several minutes to begin heating when electricity is applied and even longer to start cooling when electricity is turned off Your controller can regulate both a heat lamp and a hot plate to I 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
24. emperature 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 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 7 Resetting the Controller for Use With Heating Mantles Restoring Factory Defaults 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 This procedure takes about 2 minutes to perform 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 2 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 VW or key until the value 10 appears in the display then let go of all the keys J 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 N key until the value 10 appears in the dis
25. f all the keys Press the y key once and the word CyC t will appear in the display Next hold in the key then while holding in the key press the 8 key until the value 30 appears in the display Let go of all the keys 4 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 VW 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 changing this will be 0 or 50 or 199 9 depending on thermocouple type Let go of all the keys 19 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 W or key N Oo jun
26. f the time The controller can be set back to PID mode by following Procedure I in Section 3 7 Temp Set ERE Point i i 1 Press and hold in both the 8 and 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 2 Press until the word CyC t appears in the display The controller can be set 3 While holding in the key press the W key until the word on of appears back to PID control by in the display NOTE if the display shows the letter A when the keys i ae j following Procedure 1 in is held in press the N key until on of is in the display then let go of all Section 3 7 To the keys 4 Press the W key until the word bAnd appears in the display While KE holding in the key press the W key until the value 0 1 appears in the controller to original display then let go of all the keys factory settings follow the 5 Press and hold in both the and keys on the front of the controller until procedure in the the temperature is displayed then release both keys Appendix Section II completely reset the 14 Nn CD ao 2 5 Ramp to Setpoint amp Soak Feature A new feature of J KEM s controllers called Ramp To Setpoint allows you to enter a specific heating rate e g heat to 120 C at a rate of 5 C Hour a second feature ca
27. 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 heating mantle gt 100 ml can be used without the need to retune When changing from 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 a heating mantle yields stable temperature control Plot 1 but poor control results when the same tuning parameters are used with an oven Plot 2 Curve 1 However after tuning the controller to the oven stable temperature control results Plot 2 Curve 2 Plot 1 Plot 2 80 80 70 Curve 2 Controller loaded with 60 tuning parameters for Temp drying oven C Conditions 400 ml Toluene 50 IR flask ae a Se ae i Curve 1 Controller loaded with 8 40 tuning parameters for heating mantles 30 20 10 20 30 40 50 60 0 10 20 30 40 50 60 Time min 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 8 Rather it s a predictive controller Based on the shape slope of the heating curve the con
28. he first 14 1 2 is better is covered by the fluid in the reaction flask Heater power cord 22 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 i 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 the setpoint appears as a blinking number 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 300 ml2 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 pl
29. he heater doesn t have enough Replace with a more powerful heater For assistance contact J power KEM The controller does not come Internal 2 amp fuse has blown Not user serviceable Have qualified electrician replace on Circuit breaker on back has tripped Allow to cool then reset circuit breaker The controller comes on but The heater is broken To verify that the controller is functioning properly enter a set does not heat point of 100 C Plug a light into the outlet of the controller then wait I minute Ifthe light comes on the controller is working properly The timer controls are set Change the position of switch 7 or enter a time into the timer See incorrectly Section 3 4 The temperature sensor is Clean or replace broken sensor unplugged excessively corroded or broken SAL The process temperature is hotter Correct the over temperature condition than the alarm temperature PArk Controller has been placed in 1 Hold in both the AN and VW keys on the front of the J KEM Park mode temperature meter until tunE appears in the display 2 First hold in the key then while holding in the x key press the W key until oFF appears 3 Hold in the AN and keys until the temperature appears in the display tunE FAIL Displayed temperature is The controller has not warmed up The display temperature reads low when the controller is first incorrect turned on but will se
30. his setting is one below 0 First hold in the key then while holding in the key press the V or A 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 5 To exit programming mode press and hold in both the W and A keys until the temperature appears in the display then release both keys Deactivating the Ramp to Setpoint Feature I Press and hold in both the and VW keys on the front of the temperature meter until the word tunE appears in the display then release both keys 2 Press the A 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 A key until OFF appears in the display then let go of all the keys 3 To exit programming mode press and hold in both the A and V keys until the temperature appears in the display then release both keys 16 3 10 Troubleshooting Corrective Problem Cause Action Large over shoot of the set point Controller is not tuned for process Tune the controller as outlined in Section 2 gt 39 during initial warm up or being heated unstable temperature control The process heats too slowly T
31. ir type Blue type T Yellow type K Black type J The color of the thermocouple plug must match the color of the receptacle on the front of the controller If the temperature sensor is broken or becomes unplugged the error message FAIL inPt appears in the display and the controller stops heating 12 3 6 Do s and Don ts When Using Your Controller The controller heater and thermocouple form a closed loop feedback system 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 lowering the set point 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 If the thermocouple or heater is removed from solution unplug the heater or preferably lower the set point below the room temperature so no heat is called for 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 manner 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 t
32. l 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 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 cons
33. lf 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 Wrong type of thermocouple is Thermocouples are color coded Thermocouple plug and temperatures but are not plugged into controller thermocouple receptacle must be the same color see Section 3 2 calibrated for them connections sandpaper or steel wool discard thermocouple Temperature display offset needed Call J KEM for assistance Controller blinks inPt FAIL Table 1 Tuning Parameters for Various Heaters Fill in values determined for your equipment for quick reference Proportional Integral Time Derivative Time Derivative Band Reset Rate Approach Cont Cycle Time Instrument bAnd Int t dEr t dAG CyG t Heating Mantles Factory Default 10 10 50 5 30 HeatLamp PP em PP Vacum Oven 1 PP Hot Plate PP 17 Appendix I Using the Controller With an Oil Bath Application Note 1 Using your controller with an oil bath is usually not recommended but can be done safely 1f the instructions in this application note are followed An alternative to oil baths is outlined in Point 2 below i The following procedure allows your controller to regulate the temperature of an oil bath Place the thermocouple in the oil bath not too close to the heating coil B Plug a variac into the heating r
34. lled Soak then lets you specify how long to stay at that temperature before turning off Examples of Program Ramps Ramp Temperature Power Off Soak YN a ge 5 Power Off Temperature 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 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
35. n of switch 7 is the ON position with no time in the timer window 8 If switch 7 is set to When time 0 turn outlets ON outlet 13 is on since the time does equal zero The effect of the position of switch 7 on outlet 13 is summarized in the table below Switch 7 Time Remaining Outlet 13 LED 11 Position in Timer 1S 1S Comment When time y mm fom o turn outlet Outlet 13 will remain ON until the OFF gt Zero ON ON timer counts down to zero at which point the outlet will turn OFF and stay off indefinitely 0 Zero ON ON turn outlet Outlet 13 will remain OFF until the ON gt Zero OFF OFF timer counts down to zero at which point the outlet will turn ON and stay on indefinitely WARNING A potential danger exists when using the timer to turn outlet 13 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 that turns outlet 13 ON Therefore only processes that pose no danger when heated indefinitely should be set up to turn on when the timer counts to zero 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 1 412 All thermocouples are color coded to show the
36. play 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 First hold in the key then while holding in the key press the W or key until the value 5 0 appears in the display then let go of all the keys Press the key once and the word CyC t will appear in the display First hold in the key then while holding in the key press the W or N key until the value 30 appears in the display then let go of all the keys R Press and hold in both the W and 8 keys until the temperature appears in the display then release both keys 13 3 8 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 pen spar ON OFF Mode and OFF when above The disadvantage of this Temp S 2 a Tae 4 mode is a large over shoot of the set point pe 5 30 on initial warm up and oscillation of temperature around the set point thereafter The reason for th
37. rsion 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 In most cases if the over temperature protection circuit is active it must be inactivated before starting this procedure see Section 3 3 k 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 Turn the controller and heater on For Model 150 Timer units make sure the timer switch is set so that heating is on 1 e LED 11 is lit see Section 3 4 Enter the desired set point temperature Press and hold in both the 8 and Y buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons Press the 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
38. tant depends on the physical characteristics of the process being heated For example for the same amount of input power the rate of heat transfer is twice as high for hexane as compared to water since the coefficient of heat for hexane is 0 54 calories g C and water is 1 0 calorie gram C That means that 1000 watt seconds of input power will raise the temperature of 10 g of hexane 44 C while the same amount of power causes a 24 C rise in water In theory the tuning constants needed to heat hexane are different from those to heat water Fortunately your J KEM controller is self adaptive and is able to adapt it s heating characteristics for different solvents such as hexane and water Even with the controller s self adaptive algorithms the tuning constants have to be reasonably close to a proper set or the controller will not produce stable temperature control see Section 2 1 When a controller is shipped the default set of tuning constants loaded into the controller are those appropriate for heating typical organic reactions 1 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 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 con
39. th most heaters used in research Large heaters tend to be powered appropriately for their intended heating applications but small heaters are generally highly over powered For example a 5 liter heating mantle has 0 12 watts per ml while a 5 ml heating mantle has 9 6 watts per ml a 80 fold greater amount of power To heat small applications with reliable temperature control power needs to be adjusted to the heater with millisecond precision The Model 150 lacks this sophistication which is present only in J KEM s 200 Series controllers To compensate for the excess power small heaters tend to have J KEM s 200 Series controllers have a patented power control computer that adjusts power to the heater 2048 times per second The Model 150 should give outstanding results with larger pieces of equipment where heating power and heat required are closely matched The Model 150 is the second best controller in the industry the very best is J KEM s 200 series which has none of the limitations listed above If the Model 150 doesn t deliver the performance you need for a particular application call J KEM and inquire about upgrading your current controller to a 200 Series unit 10 3 3 Over Temperature Protection Circuit The temperature controller is equipped with an over temperature protection circuit that turns off heating any time the temperature of the reaction goes 10 C above the entered setpoint When the temperature of the reaction cools
40. this procedure see Section 3 3 1 Set the equipment up in the exact configuration it will be used For example to tune to a vacuum oven place the thermocouple in the room temperature oven and plug the oven into the controller If the oven or heater has its own thermostat or power control turn both as high as they Il go 2 Turn the controller and heater on For Model 150 Timer units make sure the timer switch 1s set so that heating is on 1 e LED I I is lit see Section 3 4 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 Press and hold in both the 48 and Y buttons for 3 seconds on the front of the temperature meter until the word tunE appears in the display then release both buttons 4 Press the button 5 times until CyG t appears in the display if you go past this setting press the V button until you get back to it 5 First hold in the button while holding in the button press the W button Continue to hold both buttons in until the display reads A or A where HE 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 8 While holding in the
41. 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 15 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 If this controller is equipped with a digital 100 hour timer the digital timer and the Ramp to Setpoint feature are completely independent of each other For example if the digital timer is set to turn heating OFF after 5 hours heating is turned off even if a ramp step is in progress Likewise if a Soak time turns heating off after 3 hours and the digital timer is set to turn heating off after 10 hours the digital timer has no effect since the expired Soak time already has turned heating off To avoid confusion and conflicts between the meters Hold feature and the front panel digital timer it s recommended that the Soak Time feature be set to in the meters setup menu and not changed 3 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 1 e 20 deg
42. tion temperature must exceed the set point before the alarm comes on To return to normal display press and ij To return to normal temperature display press and 1 2 4 hold in both the AN and WV keys about 3 seconds until the temperature appears in the display hold in both the X and keys about 3 seconds until the temperature appears in the display 11 3 4 3 5 Timer Controls Model 150 Timers only The timer section turns outlet 13 either ON or OFF in an unattended operation when the time in the timer counts to zero To adjust the time in the timer press the UP arrow or DOWN arrow buttons 9 amp 10 to increase or decrease the displayed time The format of the display is Hr Min A simple way to know whether outlet 13 is on or off is by the state of LED 11 which is lit when the outlets are on and not lit when they re off The position of switch 7 determines whether outlet 13 is ON or OFF depending on whether there is any time present in the timer To understand the effect of switch 7 take the example where switch 7 is set to the OFF position In this case its effect would be When time 0 zero turn outlet OFF If there is time present in timer 8 then outlet 13 would be ON since time 0 When the timer counts down to zero then outlet 13 would go OFF because this fills the requirements of the position of switch 7 1 e When time 0 turn outlet OFF When not using the timer the normal positio
43. trol 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 19 III How to Set Up a Reaction with J KEM Scientific s Digital Temperature Controller This application note shows how to set up a typical heated reaction using J KEM Scientific s digital temperature controller For this example the Model Gemini controller is used but the application note applies equally well to all J KEM temperature controller models If you have 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
44. troller 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 I 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 In most cases if the over temperature protection circuit is active it must be inactivated before starting
45. ur 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 non polymeric reactions in solvents such as THF toluene DMF etc If the controller is used with this type of reaction the 4 steps below will help you get started For a primer on how to set up a reaction with your temperature controller See Appendix III To use heaters other than heating mantles See Section 2 Do not use the controller to heat oil baths See Section 3 2 amp Appendix I For polymer synthesis atypical expensive or safety critical reactions See Appendix II Use with appropriately sized equipment The Model 150 can be used with most common laboratory heaters including heating mantles larger than 100 ml in size but is not suited for small scale reactions see Section 3 2 For small scale equipment J KEM s 200 Series controller which are capable of heating any application or any volume 1ml 100L to 0 1 C are recommended J 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
46. ype 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 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 ACE Yellow type K tc B Black type J te 4 First hold in the key then while holding in the key press the key until 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
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