I'm surprised you see any temp differential in your setup. I don't at all. I set my HLT to the temp I want to mash at and the mash always follows at the same temp. both my HLT and MLT probes are at the kettle outputs. The HLT probe is used to heat the water in the HLT, the MLT probe just displays the temp of the wort leaving the HLT. It's passive (doesn't control anything).
I did a test during my last brew on the weekend which was a light lager mashed at 148F. The test went like this:
1. Heated 20 gallons of water in the HLT to 148F.
2. Moved 6 gallons over the MLT.
3. Turned on the HERMS recirc with the pump 100% open, waited for both vessels to equalize as the MLT is initially cold.
4. Both vessles now contain 148F water. Dough in with 14 lbs of grain. The MLT temp drops from 148 to 138 because of the cold grain.
5. Turn recirc back on with the pump 100% open again. It took exactly 9 mins for the temp of the wort exiting the MLT to rise from 138F to 148F.
This quick rise time is one reason why I never bother trying to overshoot with my strike water.
I continued my test during my mash out from 148F to 168F. To do the mash out I simply turn the HLT PID from 148F to 168F and watch the MLT temp reading rise. It took exactly 21 minutes for the wort exiting the MLT to rise from 148F to 168F.
Again, maybe what helps is that I pump at 100% open without any issues with 1/2" ID hose. The wort is really moving and never gets stuck. This batch was 30% corn and rise flakes which cause lots of problems for some people requiring rice hulls (I don't need to use rice hulls). The Blichmann false bottom most certainly helps. Hats off to John for a great piece of engineering.
Kal
I never did calibrate my MLT dial thermometer, maybe that would explain the small differential? Maybe I'll pull it out of the tun and try a two point calibration.
Sometimes I try to over shoot my HLT to get a bigger delta T, for a quicker ramp. I certainly could do it the way you mentioned. I'm still getting acquainted with my system, so I'm open to trying alterations in my process (actually, no two batches of the 5 so far went exactly the same).
I'll keep this thread updated as I dial in my process.
TB