04. Creating Programs

Before attempting to use the example programs, keep in mind that those will likely only work if you are using the EXACT same still setup that I'm using. Which is a Still Spirits boiler and T-500 column with an L&Z Technology LNZ-10000K analog SCR power controller on the boiler. I'm not sure if the fact that I'm using their water pressure regulator makes a difference. I'm on a well with a small pressure tank, so I absolutely need to have the regulator.

You should only use the example programs as a guide or reference point for creating programs for your still. If you are running a normal custom built still, it's more than likely that you are using 1/2" cooling water plumbing, whereas I'm using 1/4". So that fact in itself is more than enough reason that you shouldn't attempt to use the example programs with your custom built still.

Things that will affect the example programs:

1. Your water pressure
2. The diameter of your cooling lines
3. The length of your cooling lines
4. The number of hard right angles in your cooling lines
5. The speed at which your valves open and close
6. The efficiency of your boiler
7. The size of your column
8. The size of your dephlegmator

In order to create your own programs, you first need to do a run manually and make notes of your settings. Remember, programs are tuned to your specific still, they will only work with another 100% identical still. This is why the Genio and iStill work right out of the box. Their controllers and software are custom tailored to their stills.

If you are doing a reflux run, you should keep in mind that when things are running in automation, your dephleg range should use a 5C window with your desired temperature right in the middle. A 3C window is way too narrow and a 7C window leaves too much room for slop. Always use a 5C window so your target temperature is centered within it. For example, a program using 58C to 63C would mean that 61C is your target temperature because there are five 1C slots in this range. The system will use 0.1% or 0.25% dephleg valve micro steps to adjust into the range center. If things go outside of the program's temperature range, the system will use 1% steps to pull it back in and then use micro steps.

When creating a pot still mode program, keep in mind that the automation only maintains your boiler power. The thermal mass of your wash will cause temperature adjustments to be extremely lagged because there is no way to force cool it down if things go over temperature. It is extremely important that you pay close attention to your temperatures during your test runs to prevent this from causing problems for you in automation mode.

When in automation mode, all temperature adjustments are given time to take effect before another adjustment is imposed. Due to the thermal mass of the wash, boiler temperature adjustments are only imposed every 15 minutes. In pot still runs, boiler power changes are imposed every 5 minutes because vapor temperature changes are faster than wash temperature changes. In reflux runs, dephleg water flow changes are imposed every 2 minutes. All changes require time for them to have a measurable effect, so these delays are absolutely necessary.

You can adjust program settings in automation mode while a run is active. If you are in the middle of a reflux run, you should use the PAUSE RUN feature before making changes and then resume the run to restart the dephleg warm up routine. For example, if your dephleg is running too hot, manually adjust the cooling higher, wait for it to complete, then pause the run. This is because the pause function memorizes the current dephleg cooling valve position, opens it to 100%, then returns to that memorized position when you resume the run.

Pausing a pot still run is also possible, but there is no dephleg warm up restart period. The pause feature simply opens the dephleg cooling valve to 100% in order to stop all distillate output. There will still be a delay before distillate starts running again after the run is resumed because the water inside of your dephleg coil needs to return to the column temperature to stop the reflux action.

So, that's about all you need to know about creating your own programs. Do manual runs and make notes of your settings along the way. Create a new program using these settings as a starting point. Test the program in an automated run and fine tune the settings. From that point, all you ever have to worry about is your mash/wash recipe and fermentation process. Fill your boiler, start the run, and let 'er rip. You can also set your program to stop the run automatically based on output proof or flow rate, or just stop it manually.