Isotech Saturn 877 Operating instructions

Page 1 of 28
Saturn model 877 Iss.08–08/14
SATURN THERMOCOUPLE
CALIBRATION FACILITY
MODEL 877
User Maintenance Manual/Handbook
Isothermal Technology Limited, Pine Grove, Southport, PR9 9AG, England
Tel: [phone] Fax: [phone] Internet: www.isotech.co.uk E-mail: [email protected]
The company is always willing to give technical advice and assistance where appropriate. Equally, because of the programme of continual
development and improvement we reserve the right to amend or alter characteristics and design without prior notice. This publication is for
information only

Page 2 of 28
Saturn model 877 Iss.08–08/14
CONTENTS
CONTENTS ....................................................................................................................................................................................... 2
GUARANTEE...................................................................................................................................................................................... 3
CAUTIONARY NOTE........................................................................................................................................................................ 4
EMC INFORMATION................................................................................................................................................................ 5
ELECTRICAL SAFETY ............................................................................................................................................................... 5
Environmental Ratings.................................................................................................................................................................. 5
HEALTH AND SAFETY INSTRUCTIONS ................................................................................................................................ 6
IMPORTANT SATURN `SPIDER' UNPACKING NOTE .......................................................................................................... 7
INTRODUCTION .............................................................................................................................................................................. 8
THEORY OF OPERATION ................................................................................................................................................................ 9
SATURN HIGH TEMPERATURE CALIBRATION FURNACE 100°C TO 1300°C.......................................................................... 10
INTRODUCTION ........................................................................................................................................................................ 10
FEATURES .................................................................................................................................................................................... 10
HORIZONTAL CROSS SECTION THROUGH THE SATURN ...................................................................................................... 11
PRINCIPLE OF OPERATION....................................................................................................................................................... 11
NOMINAL DIMENSIONS................................................................................................................................................................ 12
SPECIAL FEATURES......................................................................................................................................................................... 14
EACH UNIT COMPRISES ................................................................................................................................................................ 15
PRECAUTIONS ................................................................................................................................................................................ 16
CAUTION................................................................................................................................................................................ 17
ON ARRIVAL .................................................................................................................................................................................... 18
COMMISSIONING ........................................................................................................................................................................... 19
SAMPLE RESULTS ........................................................................................................................................................................ 19
USING THE CONTROLLER............................................................................................................................................................ 20
FRONT PANEL LAYOUT ............................................................................................................................................................ 20
The Temperature Controller..................................................................................................................................................... 20
Altering the Setpoint ..................................................................................................................................................................20
ADVANCED CONTROLLER FEATURES.................................................................................................................................... 20
Setpoint Ramp Rate....................................................................................................................................................................20
Instrument Address.................................................................................................................................................................... 21
Monitoring the Controller Status ...............................................................................................................................................21
Units........................................................................................................................................................................................... 21
DIAGNOSTIC ALARMS................................................................................................................................................................ 22
USING THE PC INTERFACE ........................................................................................................................................................... 23
CONNECTIONS.......................................................................................................................................................................... 23
CAL NOTEPAD................................................................................................................................................................................ 24
DEVELOPMENT .......................................................................................................................................................................... 24
HOW TO INSTALL CAL NOTEPAD .......................................................................................................................................... 25
PROTOCOL ................................................................................................................................................................................. 25
GETTING THE BEST FROM YOUR SATURN ................................................................................................................................ 26
INTRODUCTION ........................................................................................................................................................................ 26
SATURN MODEL 877 PERFORMANCE REPORT - APPENDIX I.................................................................................................. 27

Page 3 of 28
Saturn model 877 Iss.08–08/14
GUARANTEE
This instrument has been manufactured to exacting standards and is guaranteed for twelve months against electrical
break-down or mechanical failure caused through defective material or workmanship, provided the failure is not the
result of misuse. In the event of failure covered by this guarantee, the instrument must be returned, carriage paid, to
the supplier for examination and will be replaced or repaired at our option.
FRAGILE CERAMIC AND/OR GLASS PARTS ARE NOT COVERED BY THIS GUARANTEE
INTERFERENCE WITH OR FAILURE TO PROPERLY MAINTAIN THIS INSTRUMENT MAY INVALIDATE THIS
GUARANTEE
RECOMMENDATION
The life of your ISOTECH Instrument will be prolonged if regular maintenance and cleaning to remove general dust
and debris is carried out.
ISOTHERMAL TECHNOLOGY LTD.
PINE GROVE, SOUTHPORT
PR9 9AG, ENGLAND
TEL: [phone]/544611
FAX: [phone]
The company is always willing to give technical advice and assistance where appropriate. Equally, because of the
programme of continual development and improvement we reserve the right to amend or alter characteristics and
design without prior notice. This publication is for information only.

Page 4 of 28
Saturn model 877 Iss.08–08/14
CAUTIONARY NOTE
ISOTECH PRODUCTS ARE INTENDED FOR USE BY TECHNICALLY TRAINED AND COMPETENT
PERSONNEL FAMILIAR WITH GOOD MEASUREMENT PRACTICES.
IT IS EXPECTED THAT PERSONNEL USING THIS EQUIPMENT WILL BE COMPETENT WITH THE
MANAGEMENT OF APPARATUS WHICH MAY BE POWERED OR UNDER EXTREMES OF TEMPERATURE, AND
ARE ABLE TO APPRECIATE THE HAZARDS WHICH MAY BE ASSOCIATED WITH, AND THE PRECAUTIONS
TO BE TAKEN WITH, SUCH EQUIPMENT.

Page 5 of 28
Saturn model 877 Iss.08–08/14
EMC INFORMATION
This product meets the requirements of the European Directive on Electromagnetic Compatibility (EMC)
89/336/EEC as amended by EC Directive 92/31/EEC and the European Low Voltage Directive 73/25/EEC, amended
by 93/68/EEC. To ensure emission compliance please ensure that any serial communications connecting leads are
fully screened.
The product meets the susceptibility requirements of EN 50082-1, criterion B.
Symbol Identification
Publication
Description
ISO3864
Caution (refer to manual)
IEC 417
Caution, Hot Surface
ELECTRICAL SAFETY
This equipment must be correctly earthed.
This equipment is a Class 1 Appliance. A protective earth is used to ensure the conductive parts cannot become live
in the event of a failure of the insulation.
The protective conductor of the flexible mains cable which is coloured green/yellow MUST be connected to a suitable
earth.
The blue conductor should be connected to Neutral and the Brown conductor to Live (Line).
Warning: Internal mains voltage hazard. Do not remove the panels.
There are no user serviceable parts inside. Contact your nearest Isotech agent for repair.
Voltage transients on the supply must not exceed 2.5kV.
Conductive pollution, e.g. Carbon dust, must be excluded from the apparatus. EN61010 pollution degree 2.
Environmental Ratings
Operating Temperature 0-50°C
Relative Humidity 5-95%, non condensing

Page 6 of 28
Saturn model 877 Iss.08–08/14
HEALTH AND SAFETY INSTRUCTIONS
1. Read this entire manual before use.
2. Wear appropriate protective clothing.
3. Operators of this equipment should be adequately trained in the handling of hot and cold items and liquids.
4. Do not use the apparatus for jobs other than those for which it was designed, i.e. the calibration of
thermometers.
5. Do not handle the apparatus when it is hot (or cold), unless wearing the appropriate protective clothing and
having the necessary training.
6. Do not drill, modify or otherwise change the shape of the apparatus.
7. Do not dismantle the apparatus.
8. Do not use the apparatus outside its recommended temperature range.
9. If cased, do not return the apparatus to its carrying case until the unit has cooled.
10. There are no user serviceable parts inside. Contact your nearest Isotech agent for repair.
11. Ensure materials, especially flammable materials are kept away from hot parts of the apparatus, to prevent
fire risk.

Page 7 of 28
Saturn model 877 Iss.08–08/14
IMPORTANT SATURN `SPIDER' UNPACKING NOTE
1. Cut open top of the outer box.
2. Remove the polystyrene and shredded material.
3. Carefully remove the inner case and stand it on its four screwed studding’s.
4. Carefully unscrew bolts and remove chipboard and Polystyrene Square, exposing ceramic spider.

Page 8 of 28
Saturn model 877 Iss.08–08/14
INTRODUCTION
This furnace has been uniquely designed for the accurate calibration of a number of thermocouples over a very wide
temperature range.
Introduced by Isothermal Technology in 1984, the full potential of the bath has yet to be realized. However, with
proper care, a thermocouple may be calibrated from 100°C up to 1250°C in as many steps as required.
A variety of special designs are available to customer’s requirements.
Special attention has been given in the design to the geometric layout of the sensors to enable up to 15
thermocouples, including their head assemblies to be housed and calibrated at the same time.

Page 9 of 28
Saturn model 877 Iss.08–08/14
THEORY OF OPERATION
The major problem of calibration furnace systems has been what is called "end effects".
This is the problem encountered in any tubular furnace due to the fact that the ends of the tube tend to be cooler
than the central part of the tube.
To compensate for this, windings that heat the tube are specially profiled to give a uniform area of constant
temperature in the central part of the tubular oven or furnace.
To further even out the temperature gradients, metal or ceramic equalising blocks are introduced.
With enough effort this fundamentally unsound device can be made to give fairly good results.
The theory behind the Isotech Saturn Furnace is that a solid conducting sphere suspended in the centre of a hollow
outer, heated sphere will take up the temperature of the outer hollow heated sphere by convection and radiation to
give a very stable temperature reference without end or edge effects.
The second step in the design of the sphere was the assumption that the point at the centre of the inner solid sphere
would be not only at a stable temperature, but would be virtually unaffected by short term fluctuations in the
temperature of the outer hollow heated sphere.
In practice, the above assumptions have proved correct and after considerable development have enabled a practical
realisation of the theory to become available.
A number, up to 16, of close ended pockets have been introduced into the central sphere along a circumference.
These pockets meet the very centre of the inner sphere, thus tapping the source of uniform unfluctuating
temperature.
The larger the number of pockets and the larger each pocket becomes the further from the centre of the inner
sphere are the ends of the pockets.
To compensate for this the central sphere is made larger so that there is a slower response to temperature changes
and a longer time to stabilise.
Unlike its competitors, the Saturn Furnace rewards the patience of its user. The longer the furnace is left, the more
any temperature gradients inside the inner sphere even out.

Page 10 of 28
Saturn model 877 Iss.08–08/14
SATURN HIGH TEMPERATURE CALIBRATION FURNACE 100°C TO 1300°C
INTRODUCTION
The Isotech Saturn Furnace has been designed for the accurate calibration of thermocouples over the temperature
range 100°C to 1300°C.
Most high temperature calibration furnaces are no more than specially profiled muffle or tube furnaces in which
thermocouples are placed in parallel tubes. These designs suffer from a number of problems, the major ones being
poor temperature stability and limited access, (usually only 3 or 4 thermocouples can be calibrated at one time).
Isotech's calibration furnace is revolutionary from a number of aspects:-
FEATURES
1. It is spherical and its design ensures a central zone of constant temperature.
2. Thermocouples are inserted around the circumference of the furnaces and when fully inserted, the measuring
junctions are within a few millimetres of each other and of the centre of the sphere.
3. 7 to 15 thermocouples can be calibrated simultaneously.
4. The accuracy (±0.25°C in 1000°C) of the furnace has only previously been achieved by using heat pipes.
5. Because of the design, the price is only half to one third of a bath with comparable accuracy and much smaller
capacity for calibration.
6. The temperature of the furnace is controlled from a microprocessor based controller which can incorporate
remote facilities, enabling the furnace temperatures to be pre-programmed from a computer. Thus, totally
automatic calibration becomes possible and easily realizable.
7. The use of newly developed modern ceramic materials has enabled high accuracy, low mass and high stability
to be obtained.
8. Each thermocouple is completely isolated in a gas tight closed end tube to prevent any contamination
problems during calibration.
9. Normally the windings will require replacing after 2 or 4 years of operating (dependant on work cycle) and so
the furnace has been designed with ease of maintenance in mind. A spare set of windings is provided free
with each furnace, as is a comprehensive manual.

Page 11 of 28
Saturn model 877 Iss.08–08/14
HORIZONTAL CROSS SECTION THROUGH THE SATURN
PRINCIPLE OF OPERATION
The Saturn comprises of a number of concentric shells. The outer layer of spun metal is for containment and support,
inside this is a layer of ceramic fibre. Within the fibre is a ceramic spherical mantle containing the heater windings.
Lastly, in the centre of the furnace is a solid ceramic sphere cast with 8 or 16 tubes* to be used for the
thermocouples requiring calibration.
*Depending on design requirements.

Page 12 of 28
Saturn model 877 Iss.08–08/14
NOMINAL DIMENSIONS

Page 13 of 28
Saturn model 877 Iss.08–08/14
SPECIFICATION
Size
425mm diameter sphere
Weight
25 kilos
Temperature Range
100°C to 1300°C
No. of Calibration Points
8 normal - 16 to special requirements
Diameter of Sensors
Up to 8mm (others by arrangement)
Depth of immersion
200mm
Accuracy
±0.25°C at 1000°C (Using comparison techniques)
Warm-up times*
1 hour to 700°C
3 hours to 1300°C
Stabilization time*
1 hour to ±0.25°C
Power supply
240V, 50Hz
3KW Typically
Single Phase
Ambient Operating Temp
0 –50°C
<70%RH
*These times may increase as the windings age or if the supply voltage is low.

Page 14 of 28
Saturn model 877 Iss.08–08/14
SPECIAL FEATURES
The Saturn is normally supplied 240V, 50Hz, 3 KW with 8 sensor insertion points, one of which is used to house the
control thermocouple. Eight tubes with a nominal internal diameter of 6mm have been found to give a very good and
stable performance. It is the configuration around which the specification has been written.
To special order, the following options are available:
1. 16 Thermocouple Inserts: Because of the extra thermal mass involved in offering this option to the same
accuracy, an extra 30 minutes should be allowed for full stabilization.
2. Larger thermocouple inserts: Inserts of up to 10mm diameter can be accommodated in the furnace. Please
contact ISOTECH for details.
3. APC interface is included.

Page 15 of 28
Saturn model 877 Iss.08–08/14
EACH UNIT COMPRISES
1. Saturn Furnace Model 877
2. Saturn Spider
3. Controller
4. Spare set of Windings
5. Thermocouple
6. User Maintenance Manual/Guarantee

Page 16 of 28
Saturn model 877 Iss.08–08/14
PRECAUTIONS
Some precautions should be noted as follows:-
1. Due to the nature that the furnace is used the outer surface will become hot during operation at elevated
temperatures.
2. Thermal Shock: - The materials used in the furnace have been especially selected for their purity and ability to
withstand Thermal Shock. However, if a cold sensor is introduced into the furnace at high temperatures it
should be inserted slowly, allowing the sensor to warm-up in, say 1cm steps. Failure to observe the above
can cause fracture of the tube into which it was being inserted. If this happens, it will not impair the accuracy
of the rest of the system, but will reduce its capacity. New central equalising spheres are available from
ISOTECH.
3. Over Temperature: - All the materials used in the construction of the furnace have been rated to 1,400°C.
However, at these temperatures the life expectancy of the heater windings for example are very short. We
therefore recommend an upper temperature of 1300°C for the bath.
4. Electrical Noise Pick-Up:- At high temperatures all ceramics have a reduced insulation value and hence
conduct more electricity. This means that at temperatures from in excess of 700°C an increasing amount of
‘noise' or electrical interference can be noticed on thermocouple outputs.
Three techniques can be used to eliminate this problem.
The first is to use a filter circuit; the second is to momentarily switch off the furnace heater whilst the
thermocouple reading is taken. Alternatively an isolation transformer can be used to reduce the electrical
leakage.
5. The furnace must be mounted on a suitable solid flat surface, horizontal to within ±5°.

Page 17 of 28
Saturn model 877 Iss.08–08/14
CAUTION
Before switching on, check that there is approximately 20Ωbetween the furnace heater windings and greater than
5Megohms between windings and outer furnace case.
Assuming this is so you may now commission the furnace.
Please read the operating instructions carefully before proceeding.

Page 18 of 28
Saturn model 877 Iss.08–08/14
ON ARRIVAL
On unpacking the Saturn you will find 4 parts:-
1. The Controller.
2. The furnace.
3. The equalizing sphere complete with its pockets.
4. A packet containing the control thermocouple, a spare set of windings and this instruction book.
To assemble the furnace, use the following procedure:-
a. Carefully remove all the packing material.
b. Stand the furnace on a flat surface and carefully unscrew the upper half of the outer sphere.
c. Lift off the upper half of the sphere and the ceramic fibre insulation –dust precautions should be taken at this
point.
d. You will then see the hollow half of the inner sphere containing the heater windings.
e. Two wires come from the top of the hollow sphere. Without disturbing these wires, carefully lift the upper
hemisphere from its locating pegs and slide in the equalising block with its pockets. This normally requires
two people.
Carefully position the equalising block until its sits correctly in the grooves provided and is symmetrically
placed inside the furnace. Use some small pieces of insulation (supplied) to pack underneath the pockets so
they sit on a soft bed of insulation rather than the ceramic heater support. This protects the pockets and
improves the performance.
Beneath the furnace is an adjustment which will allow you to adjust the height of the heater winding ceramic.
Adjust so that the sphere re-assembles without undue pressure on the equalizing block.
f. Reassemble the furnace.
g. Unpack the controller and connect the white cable with the IP65 connector to the white cable from the
lower half of the furnace using the colour coded connector.
h. Connect to a suitable electrical supply. Check the ratings plate on the controller for details.
i. Push the control thermocouple into one of the pockets 150mm to the mark on the thermocouple and
connect to the thermocouple input of the controller.
It is important not to fully immerse the control sensor into the equalising block pocket. Doing this will create
a large thermal lag between the controller and the heaters thus introducing instability and the very long delay
in reaching the setpoint.

Page 19 of 28
Saturn model 877 Iss.08–08/14
COMMISSIONING
During its trip to you, the package containing the furnace may have become damp, therefore, we recommend the
following initial procedure:-
1. Switch on the furnace/controller and set the temperature to 100°C. Allow the temperature to reach 100°C
and stabilise there for 2 hours.
2. Increase the set temperature to 200°C. Allow 2 hours for stabilisation.
3. Increase the temperature in 100°C steps allowing 1 to 2 hours between each change until the furnace has
reached 1,000°C.
Your Saturn is now ready for use!
SAMPLE RESULTS

Page 20 of 28
Saturn model 877 Iss.08–08/14
USING THE CONTROLLER
FRONT PANEL LAYOUT
The Temperature Controller
The controller has a dual display, the upper display indicates the nominal block temperature, and the lower display
indicates the desired temperature or setpoint.
Altering the Setpoint
To change the setpoint of the controller simply use the UP and DOWN keys to raise and lower the setpoint to the
required value. The lower display changes to indicate the new setpoint.
ADVANCED CONTROLLER FEATURES
Setpoint Ramp Rate
By default the bath is configured to heat and cool as quickly as possible. There may be some calibration applications
where it is advantageous to limit the heating or cooling rate.
An example might be when testing bimetallic thermostats, by forcing the bath to heat at a controlled rate it is easier
to determine the temperature at which the thermostat changes state.
The bath can have its heating rate limited with the Setpoint Ramp Rate feature. This feature is accessed from the
Scroll key. Depress the key until the display shows,
SPrr