TDC5 Temperature Controller
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Product Information
Specifications
- Product: TDC5 Temperature Controller
- Manufacturer: Gamry Instruments, Inc.
- Warranty: 2 years from original shipment date
- Support: Free telephone assistance for installation, use, and
tuning
Product Usage Instructions
Installation
Ensure you have the instrument model and serial numbers
available for reference.
Visit the support page at https://www.gamry.com/support-2/ for
installation information.
Operation
If experiencing issues, contact support via phone or email with
necessary details.
For immediate assistance, call from a telephone next to the
instrument for real-time troubleshooting.
Maintenance
Regularly check for software updates on the support page
provided.
Keep instrument model and serial numbers handy for any support
requests.
FAQ
Q: What is the warranty period for the TDC5 Temperature
Controller?
A: The warranty covers defects resulting from faulty manufacture
for two years from the original shipment date.
Q: How can I reach customer support?
A: You can contact support via phone at 215-682-9330 or
toll-free at 877-367-4267 during US Eastern Standard Time.
Q: What is covered under the limited warranty?
A: The warranty covers repair or replacement for defects in
manufacture, excluding other damages.
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TDC5 Temperature Controller Operator’s Manual
Copyright © 20192025 Gamry Instruments, Inc. Revision 1.5.2 July 28, 2025 988-00072
If You Have Problems
If You Have Problems
Please visit our service and support page at https://www.gamry.com/support-2/. This page contains information on installation, software updates, and training. It also contains links to the latest available documentation. If you are unable to locate the information you need from our website, you can contact us via email using the link provided on our website. Alternatively, you can contact us in one of the following ways:
Internet Phone
https://www.gamry.com/support-2/
215-682-9330 9:00 AM-5:00 PM (US Eastern Standard Time) 877-367-4267 (Toll-free US & Canada Only)
Please have your instrument model and serial numbers available, as well as any applicable software and firmware revisions.
If you are having problems with installation or use of the TDC5 Temperature Controller, please call from a telephone next to the instrument, where you can change instrument settings while talking to us.
We are happy to provide a reasonable level of free support for TDC5 purchasers. Reasonable support includes telephone assistance covering the normal installation, use, and simple tuning of the TDC5.
Limited Warranty
Gamry Instruments, Inc. warrants to the original user of this product that it shall be free of defects resulting from faulty manufacture of the product or its components for a period of two years from the original shipment date of your purchase.
Gamry Instruments, Inc. makes no warranties regarding either the satisfactory performance of the Reference 3020 Potentiostat/Galvanostat/ZRA including the software provided with this product or the fitness of the product for any particular purpose. The remedy for breach of this Limited Warranty shall be limited solely to repair or replacement, as determined by Gamry Instruments, Inc., and shall not include other damages.
Gamry Instruments, Inc. reserves the right to make revisions to the system at any time without incurring any obligation to install same on systems previously purchased. All system specifications are subject to change without notice.
There are no warranties which extend beyond the description herein. This warranty is in lieu of, and excludes any and all other warranties or representations, expressed, implied or statutory, including merchantability and fitness, as well as any and all other obligations or liabilities of Gamry Instruments, Inc., including but not limited to, special or consequential damages.
This Limited Warranty gives you specific legal rights and you may have others, which vary from state to state. Some states do not allow for the exclusion of incidental or consequential damages.
No person, firm or corporation is authorized to assume for Gamry Instruments, Inc., any additional obligation, or liability not expressly provided herein except in writing duly executed by an officer of Gamry Instruments, Inc.
Disclaimers
Gamry Instruments, Inc. cannot guarantee that the TDC5 will work with all computer systems, heaters, cooling devices, or cells.
The information in this manual has been carefully checked and is believed to be accurate as of the time of release. However, Gamry Instruments, Inc. assumes no responsibility for errors that might appear.
3
Copyrights
Copyrights
TDC5 Temperature Controller Operator’s Manual copyright © 2019-2025, Gamry Instruments, Inc., all rights reserved. CPT Software Copyright © 19922025 Gamry Instruments, Inc. Explain Computer Language Copyright © 19892025 Gamry Instruments, Inc. Gamry Framework copyright © 1989-2025, Gamry Instruments, Inc., all rights reserved. Interface 1010, Interface 5000, Interface Power Hub, EIS Box 5000, Reference 620, Reference 3000TM, Reference 3000AETM, Reference 30K, EIS Box 5000, LPI1010, eQCM 15M, IMX8, RxE 10k, TDC5, Gamry Framework, Echem Analyst 2, Echem ToolkitPy, Faraday Shield, and Gamry are trademarks of Gamry Instruments, Inc. Windows® and Excel® are a registered trademark of Microsoft Corporation. OMEGA® is a registered trademark of Omega Engineering, Inc. No part of this document may be copied or reproduced in any form without the prior written consent of Gamry Instruments, Inc.
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Table of Contents
Table of Contents
If You Have Problems ……………………………………………………………………………………………………………………. 3
Limited Warranty ………………………………………………………………………………………………………………………….. 3
Disclaimers ………………………………………………………………………………………………………………………………….. 3
Copyrights …………………………………………………………………………………………………………………………………… 4
Table of Contents………………………………………………………………………………………………………………………….. 5
Chapter 1: Safety Considerations……………………………………………………………………………………………………… 7 Inspection …………………………………………………………………………………………………………………………….. 7 Line Voltages ………………………………………………………………………………………………………………………… 8 Switched AC OutletsFuses ……………………………………………………………………………………………………… 8 TDC5 Electrical Outlet Safety …………………………………………………………………………………………………… 8 Heater Safety ………………………………………………………………………………………………………………………… 8 RFI Warning………………………………………………………………………………………………………………………….. 9 Electrical Transient Sensitivity …………………………………………………………………………………………………… 9
Chapter 2: Installation………………………………………………………………………………………………………………….. 11 Initial Visual Inspection………………………………………………………………………………………………………….. 11 Unpacking Your TDC5 ………………………………………………………………………………………………………….. 11 Physical Location …………………………………………………………………………………………………………………. 11 Differences Between an Omega CS8DPT and a TDC5 ………………………………………………………………… 12 Hardware Differences ……………………………………………………………………………………………………. 12 Firmware Differences …………………………………………………………………………………………………….. 12 AC Line Connection ……………………………………………………………………………………………………………… 12 Power-up Check ………………………………………………………………………………………………………………….. 13 USB Cable ………………………………………………………………………………………………………………………….. 14 Using Device Manager to Install TDC5 …………………………………………………………………………………….. 14 Connecting the TDC5 to a Heater or Cooler ……………………………………………………………………………… 17 Connecting the TDC5 to an RTD Probe ……………………………………………………………………………………. 18 Cell Cables from the Potentiostat …………………………………………………………………………………………….. 18 Setting up the TDC5 Operating Modes …………………………………………………………………………………….. 18 Checking TDC5 Operation…………………………………………………………………………………………………….. 18
Chapter 3: TDC5 Use ………………………………………………………………………………………………………………….. 19 Using Framework Scripts to Set Up and Control Your TDC5 ………………………………………………………… 19 Thermal Design of Your Experiment ………………………………………………………………………………………… 19 Tuning the TDC5 Temperature Controller: Overview …………………………………………………………………. 20 When to Tune …………………………………………………………………………………………………………………….. 20 Auto Tuning the TDC5 ………………………………………………………………………………………………………….. 21
Appendix A: Default Controller Configuration ………………………………………………………………………………….. 23 Initialization Mode menu ………………………………………………………………………………………………………. 23 Programming Mode Menu …………………………………………………………………………………………………….. 28 Changes that Gamry Instruments Has Made to Default Settings …………………………………………………….. 31
Appendix B: Index ………………………………………………………………………………………………………………………. 33
5
Safety Considerations
Chapter 1: Safety Considerations
The Gamry Instruments TDC5 is based on a standard temperature controller, the Omega Engineering Inc. Model CS8DPT.. Gamry Instruments has performed slight modifications of this unit to allow easier incorporation of it into an electrochemical test system. Omega provides a User’s Guide that covers safety issues in detail. In most cases, the Omega information is not duplicated here. If you do not have a copy of this document, contact Omega at http://www.omega.com. Your TDC5 Temperature Controller has been supplied in a safe condition. Consult the Omega User’s Guide to ensure continued safe operation of this device.
Inspection
When you receive your TDC5 Temperature Controller, inspect it for evidence of shipping damage. If you note any damage, please notify Gamry Instruments Inc. and the shipping carrier immediately. Save the shipping container for possible inspection by the carrier.
A TDC5 Temperature Controller damaged in shipment can be a safety hazard. The protective grounding can be rendered ineffective if the TDC5 is damaged in shipment. Do not operate damaged apparatus until a qualified service technician has verified its safety. Tag a damaged TDC5 to indicate that it could be a safety hazard.
As defined in IEC Publication 348, Safety Requirements for Electronic Measuring Apparatus, the TDC5 is a Class I apparatus. Class I apparatus is only safe from electrical shock hazards if the case of the apparatus is connected to a protective earth ground. In the TDC5 this protective ground connection is made via the ground prong in the AC line cord. When you use the TDC5 with an approved line cord, the connection to the protective earth ground is automatically made prior to making any power connections.
If the protective ground is not properly connected, it creates a safety hazard, which could result in personnel injury or death. Do not negate the protection of this earth ground by any means. Do not use the TDC5 with a 2-wire extension cord, with an adapter that does not provide for protective grounding, or with an electrical outlet that is not properly wired with a protective earth ground.
The TDC5 is supplied with a line cord suitable for use in the United States. In other countries, you may have to replace the line cord with one suitable for your electrical outlet type. You must always use a line cord with a CEE 22 Standard V female connector on the instrument end of the cable. This is the same connector used on the US standard line cord supplied with your TDC5. Omega Engineering (http://www.omega.com) is one source for international line cords, as described in their User’s Guide.
If you replace the line cord, you must use a line cord rated to carry at least 15 A of AC current. If you replace the line cord, you must use a line cord with the same polarity as that supplied with the TDC5. An improper line cord can create a safety hazard, which could result in injury or death.
The wiring polarity of a properly wired connector is shown in Table 11 for both US line cords and European line cords that follow the “harmonized” wiring convention.
7
Region US European
Safety Considerations
Table 11 Line Cord Polarities and Colors
Line Black Brown
Neutral White Light Blue
Earth-Ground Green Green/Yellow
If you have any doubts about the line cord for use with your TDC5, please contact a qualified electrician or instrument service technician for assistance. The qualified person can perform a simple continuity check that can verify the connection of the TDC5 chassis to earth and thereby check the safety of your TDC5 installation.
Line Voltages
The TDC5 is designed to operate at AC line voltages between 90 and 240 VAC, 50 or 60 Hz. No modification of the TDC5 is required when switching between US and international AC line voltages.
Switched AC OutletsFuses
Both of the switched outlets on the back of the TDC5 have fuses above and to the left of the outputs. For Output 1, the maximum allowed fuse rating is 3 A; for Output 2, the maximum allowed fuse is 5 A.
The TDC5 is provided with 3 A and 5 A, fast-blow, 5 × 20 mm fuses in the switched outlets.
You may wish to tailor the fuses in each outlet for the expected load. For example, if you are using a 200 W cartridge heater with a 120 VAC power line, the nominal current is a bit less than 2 A. You may want to use a 2.5 A fuse in the switched outlet to the heater. Keeping the fuse rating just above the rated power can prevent or minimize damage to an improperly operated heater.
TDC5 Electrical Outlet Safety
The TDC5 has two switched electrical outlets on the rear panel of its enclosure. These outlets are under the control of the TDC5’s controller module or a remote computer. For safety considerations, whenever the TDC5 is powered, you must treat these outlets as being on.
In most cases, the TDC5 powers one or both outlets when it is first powered up.
The switched electrical outlets on the TDC5 rear panel must always be treated as on whenever the TDC5 is powered. Remove the TDC5 line cord if you must work with a wire in contact with these outlets. Do not trust that the control signals for these outlets, when off, remains off. Do not touch any wire connected to these outlets unless the TDC5 line cord has been disconnected.
Heater Safety
The TDC5 Temperature Controller is often used to control an electrical heating apparatus that is located on or close to an electrochemical cell filled with electrolyte. This can represent a significant safety hazard unless care is taken to ensure that the heater has no exposed wires or contacts.
An AC-powered heater connected to a cell containing electrolyte can represent a significant electrical-shock hazard. Make sure that there are no exposed wires or connections in your heater circuit. Even cracked insulation can be a real hazard when salt water is spilled on a wire.
8
Safety Considerations
RFI Warning
Your TDC5 Temperature Controller generates, uses, and can radiate radio-frequency energy. The radiated levels are low enough that the TDC5 should present no interference problem in most industrial laboratory environments. The TDC5 may cause radio-frequency interference if operated in a residential environment.
Electrical Transient Sensitivity
Your TDC5 Temperature Controller was designed to offer reasonable immunity from electrical transients. However, in severe cases, the TDC5 could malfunction or even suffer damage from electrical transients. If you are having problems in this regard, the following steps may help:
· If the problem is static electricity (sparks are apparent when you touch the TDC5: o Placing your TDC5 on a static control work surface may help. Static-control work surfaces are now generally available from computer supply houses and electronics tool suppliers. An antistatic floor mat may also help, particularly if a carpet is involved in generating static electricity. o Air ionizers or even simple air humidifiers can reduce the voltage available in static discharges.
· If the problem is AC power-line transients (often from large electrical motors near the TDC5): o Try plugging your TDC5 into a different AC-power branch circuit. o Plug your TDC5 into a power-line surge suppressor. Inexpensive surge suppressors are now generally available because of their use with computer equipment.
Contact Gamry Instruments, Inc. if these measures do not solve the problem.
9
Installation
Chapter 2: Installation
This chapter covers normal installation of the TDC5 Temperature Controller. The TDC5 was designed to run the experiments in the Gamry Instruments CPT Critical Pitting Test System, but it is also useful for other purposes. The TDC5 is an Omega Engineering Inc., Model CS8DPT Temperature Controller. Please review the Omega User’s Guide to familiarize yourself with the operation of the temperature controller.
Initial Visual Inspection
After you remove your TDC5 from its shipping carton, check it for any signs of shipping damage. If any damage is noted, please notify Gamry Instruments, Inc., and the shipping carrier immediately. Save the shipping container for possible inspection by the carrier.
The protective grounding can be rendered ineffective if the TDC5 is damaged in shipment. Do not operate damaged apparatus until its safety has been verified by a qualified service technician. Tag a damaged TDC5 to indicate that it could be a safety hazard.
Unpacking Your TDC5
The following list of items should be supplied with your TDC5: Table 22
Packing list for Gamry TDC5 (modified Omega CS8DPT) with Gamry P/N 992-00143
Qty 1 1
4 1
1 1 1 1 1 2 1
Gamry P/N 988-00072 990-00481
630-00018 990-00491
720-00078 721-00016 952-00039 985-00192 990-00055 –
Omega P/N M4640
Description Gamry TDC5 Operator’s Manual Fuse Kit – 5X20, 250V, 5A Fast-Blow Fuse – 5X20, 250V, 5A Fast-Blow Gamry TDC5 (modified Omega CS8DPT) Main Power Cord (USA version) TDC5 Adapter for RTD cable Omega CS8DPT USB 3.0 type A male/male cable, 6 ft RTD Probe Omega Output Cords Omega User’s Guide
Contact your local Gamry Instruments representative if you cannot find any of these items in your shipping containers.
Physical Location
You can place your TDC5 on a normal workbench surface. You will need access to the rear of the instrument because power connections are made from the rear. The TDC5 is not restricted to operation in a flat position. You can operate it on its side, or even upside-down.
11
Installation
Differences Between an Omega CS8DPT and a TDC5
Hardware Differences
A Gamry Instruments TDC5 has one addition compared to an unmodified Omega CS8DPT: A new connector is added to the front panel. It is a three-pin connector used for a three-wire 100 platinum RTD. The RTD connector is wired in parallel with the input terminal strip on the Omega CS8DPT. You can still make use of the full range of input connections.
If you make other input connections: · Be careful to avoid connecting two input devices, one to the 3-pin Gamry connector and one to the terminal strip. Unplug the RTD from its connector if you connect any sensor to the input terminal strip. · You must reconfigure the controller for the alternate input. Consult the Omega manual for additional details.
Firmware Differences
The firmware configuration settings for the PID (proportional, integrating and derivative) controller in the TDC5 are changed from the Omega defaults. See Appendix A for details. Basically, Gamry Instruments’ controller setup includes:
· Configuration for operation with a three-wire 100 platinum RTD as the temperature sensor · PID tuning values appropriate for a Gamry Instruments FlexCellTM with a 300 W heating jacket and active
cooling through the FlexCell’s heating coil.
AC Line Connection
The TDC5 is designed to operate at AC line voltages between 90 and 240 VAC, 50 or 60 Hz. You must use a suitable AC power cord to connect the TDC5 to your AC power source (mains). Your TDC5 was shipped with a USA-type AC power input cord. If you need a different power cord, you may obtain one locally or contact Omega Engineering Inc. (http://www.omega.com).
12
Installation
The power cord using with the TDC5 must terminate with a CEE 22 Standard V female connector on the instrument end of the cable and must be rated for 10 A service.
If you replace the line cord you must use a line cord rated to carry at least 10 A of AC current. An improper line cord can create a safety hazard, which could result in injury or death.
Power-up Check
After the TDC5 is connected to an appropriate AC voltage source, you can turn it on to verify its basic operation. The power switch is a large rocker switch on the left side of the rear panel.
Power
Make sure that a newly installed TDC5 has no connection to its switched OUTPUT outlets when it is first powered. You want to verify that the TDC5 powers up correctly before you add the complexity of external devices. When the TDC5 is powered up, the temperature controller should light up and display a couple of status messages. Each message will be displayed for a few seconds. If you connected an RTD to the unit, the upper display should show the current temperature at the probe (the units are degrees Celsius). If you do not have a probe installed, the upper display should show a line containing the characters oPER, as shown below:
13
Installation
After the unit has powered up correctly, turn it off before making the remaining system connections.
USB Cable
Connect the USB cable between the USB Type-A port on the front panel of the TDC5 and a USB Type-A port on your host computer. The supplied cable for this connection is a dual-ended USB Type-A cable. Type A is a rectangular connector whereas Type B is an almost square USB connector.
Using Device Manager to Install TDC5
1. After the TDC5 is plugged into an available USB port on the host computer, turn on the host computer. 2. Log into your user account. 3. Run the Device Manager on your host computer. 4. Expand the Ports section in the Device Manager as shown.
14
Installation
5. Turn on the TDC5 and look for a new entry that suddenly appears under Ports. This entry will tell you the COM number associated with the TDC5. Take note of this for use during installation of the Gamry Instruments software.
6. If the COM port is higher than number 8, decide on a port number less than 8. 7. Right-click on the new USB Serial Device that appears and select Properties. A USB Serial Device
Properties window like the one shown below appears. Port Settings
Advance 15
Installation 8. Select the Port Settings tab and click the Advanced… button. The Advanced Settings for COMx dialog
box appears as shown below. Here, x stands for the particular port number you chose.
9. Select a new COM Port Number from the drop-down menu. Select a number of 8 or less. You do not need to change any other settings. After you have made a selection, remember this number to use during the Gamry Software Installation.
10. Click the OK buttons on the two open dialog boxes to close them. Close the Device Manager. 11. Proceed with the Gamry Software Installation. Select Temperature Controller in the Select Features
dialog box. Press Next to continue the installation process.
12. In the Temperature Controller Configuration dialog box, select the TDC5 in the drop-down menu under Type. Choose the COM port that you noted down earlier.
16
Installation
The Label field must contain a name. TDC is a valid, convenient choice.
Connecting the TDC5 to a Heater or Cooler
There are many ways to heat an electrochemical cell. These include an immersible heater in the electrolyte, heating tape surrounding the cell, or a heating mantle. The TDC5 can be used with all these types of heaters, as long as they are AC-powered.
An AC-powered heater connected to a cell containing electrolyte can represent a significant electrical-shock hazard. Make sure that there are no exposed wires or connections in your heater circuit. Even cracked insulation can be a hazard when salt water is spilled on a wire.
The AC power for the heater is drawn from Output 1 on the rear panel of the TDC5. This output is an IEC Type B female connector (common in the USA and Canada). Electrical cords with the corresponding male connector are available worldwide. An Omega-supplied output cord ending in bare wires was shipped with your unit. Connections to this output cord should be made only by a qualified electrical technician. Please check that the fuse on Output 1 is appropriate for use with your heater. The TDC5 is shipped with a 3 A Output 1 fuse already installed. In addition to controlling a heater, the TDC5 can control a cooling device. The AC power for the cooler is drawn from the outlet labeled Output 2 on the rear of the TDC5. An Omega-supplied output cord ending in bare wires was shipped with your unit. Connections to this output cord should only be made by a qualified electrical technician. The cooling device can be as simple as a solenoid valve in a cold-water line leading to a water jacket surrounding the cell. Another common cooling device is the compressor in a refrigeration unit. Before connecting a cooling device to the TDC5, verify that the Output 2 fuse is the correct value for your cooling device. The TDC5 is shipped with a 5 A Output 2 fuse already installed.
Modifications to the Omega output cables should only be made by a qualified electrician. Improper modifications could create a significant electrical shock hazard.
17
Installation
Connecting the TDC5 to an RTD Probe
The TDC5 must be able to measure the temperature before it can control it. The TDC5 uses a platinum RTD to measure the cell temperature. A suitable RTD is supplied with the TDC5. This sensor plugs into adapter cable supplied with your TDC5:
Contact Gamry Instruments, Inc. at our US facility if you need to substitute a third-party RTD into a CPT system.
Cell Cables from the Potentiostat
A TDC5 in your system does not affect the cell cable connections. These connections are made directly from the potentiostat to the cell. Please read your potentiostat’s Operator’s Manual for cell cable instructions.
Setting up the TDC5 Operating Modes
The PID controller built into the TDC5 has a number of different operating modes, each of which is configured by means of user-entered parameters.
Please refer to the Omega documentation supplied with your TDC5 for information about the various controller parameters. Do not change a parameter without some knowledge of that parameter’s effect on the controller.
The TDC5 is shipped with default settings appropriate for heating and cooling a Gamry Instruments FlexCell using a 300 W heating jacket and a solenoid-controlled cold-water flow for cooling. Appendix A lists the factory TDC5 settings.
Checking TDC5 Operation
To check the TDC5 operation, you must set up your electrochemical cell completely, including a heater (and possibly a cooling system). After you have created this complete setup, run the TDC Set Temperature.exp script. Request a Setpoint temperature slightly above room temperature (often 30°C is a good setpoint). Note that the observed temperature on the display will wander slightly above and below the setpoint temperature.
18
TDC5 Use
Chapter 3: TDC5 Use
This chapter covers normal use of the TDC5 Temperature Controller. The TDC5 is intended primarily for use in the Gamry Instruments CPT Critical Pitting Test System. It should also prove useful in other applications.
The TDC5 is based on the Omega CS8DPT temperature controller. Please read the Omega documentation to familiarize yourself with the operation of this apparatus.
Using Framework Scripts to Set Up and Control Your TDC5
For your convenience, the Gamry Instruments FrameworkTM software includes several ExplainTM scripts that simplify setup and tuning of the TDC5. We strongly recommend that you use the scripts to tune your TDC5. These scripts include:
Script TDC5 Start Auto Tune.exp TDC Set Temperature.exp
Description
Used to start the controller auto-tune process Changes the Set Point of a TDC when other scripts are not running.
There is one downside to using these scripts. They only run on a computer that has a Gamry Instruments potentiostat installed in the system and is currently connected. If you do not have a potentiostat in the system, the script will show an error message and terminate before it outputs anything to the TDC5.
You cannot run any TDC5 script on a computer system that does not include a Gamry Instruments potentiostat.
Thermal Design of Your Experiment
The TDC5 is used to control the temperature of an electrochemical cell. It does so by turning on and off a heat source that transfers heat to the cell. Optionally, a cooler can be used to remove heat from the cell. In either case, the TDC5 switches AC power to the heater or cooler to control the direction of any transfer of heat.
The TDC5 is a closed-loop system. It measures the temperature of the cell and uses feedback to control the heater and cooler.
Two major thermal problems are present to some degree in all system designs:
· The first problem is temperature gradients in the cell which are invariably present. However, they can be minimized by proper cell design:
o Stirring the electrolyte helps a great deal.
o The heater should have a large area of contact with the cell. Water jackets are good in this regard. Cartridge type heaters are poor.
o Insulation surrounding the cell may minimize inhomogeneities by slowing the loss of heat through the walls of the cell. This is especially true near the working electrode, which may represent the major pathway of escaping heat. It is not unusual to find the electrolyte temperature near the working electrode 520°C lower than that of the bulk of the electrolyte.
o If you cannot prevent thermal inhomogeneities, you can at least minimize their effects. One important design consideration is the placement of the RTD used to sense the cell temperature. Place the RTD as close as possible to the working electrode. This minimizes the error between the actual temperature at the working electrode and the temperature setting.
19
TDC5 Use
· A second problem concerns the rate of temperature change. o You would like to have the rate of heat transfer to the cell’s contents high, so that changes in the cell’s temperature can be made quickly.
o A more subtle point is that the rate of heat loss from the cell should also be high. If it is not, the controller risks gross overshoots of the set point temperature when it raises the cell temperature.
o Ideally, the system actively cools the cell as well as heats it. Active cooling can consist of a system as simple as tap water flowing through a cooling coil and a solenoid valve.
o Temperature control via an external heater such as a heating mantle is moderately slow. An internal heater, such as a cartridge heater, is often quicker.
Tuning the TDC5 Temperature Controller: Overview
Closed-loop control systems such as the TDC5 must be tuned for optimal performance. A poorly tuned system suffers from slow response, overshoot, and poor accuracy. The tuning parameters depend greatly on the characteristics of the system being controlled.
The temperature controller in the TDC5 can be used in an ON/OFF mode or a PID (proportional, integral, derivative) mode. The ON/OFF mode uses hysteresis parameters to control its switching. The PID mode uses tuning parameters. The controller in PID mode reaches the set-point temperature quickly without much overshoot and maintains that temperature within a closer tolerance than the ON/OFF mode.
When to Tune
The TDC5 is normally operated in PID (proportional, integrating, derivative) mode. This is a standard method for process-control equipment that allows for rapid changes in the set parameter. In this mode the TDC5 must be tuned to match it to the thermal characteristics of the system that it is controlling.
The TDC5 is shipped in a default for PID-control mode configuration. You must explicitly change it to operate in any other control mode.
The TDC5 is initially configured with parameters appropriate for a Gamry Instruments FlexCellTM heated with a 300 W jacket and cooled using solenoid-valve controlling water-flow through a cooling coil. The tuning settings are described below:
Table 33 Factory-set tuning parameters
Parameter (Symbol) Proportional Band 1 Reset 1 Rate 1 Cycle Time 1 Dead Band
Settings 9°C 685 s 109 s 1 s 14 dB
Retune your TDC5 with your cell system before you use it to run any real tests. Retune whenever you make major changes in the thermal behavior of your system. Typical changes that may require retuning include:
· Changing to a different cell.
· Addition of thermal insulation to the cell.
· Addition of a cooling coil.
20
TDC5 Use · Changing the position or power of the heater. · Changing from an aqueous electrolyte to an organic electrolyte. In general, you do not have to retune when switching from one aqueous electrolyte to another. Tuning is therefore only an issue when you first set up your system. After the controller has been tuned for your system, you may ignore tuning as long as your experimental setup remains relatively constant.
Auto Tuning the TDC5
When you auto-tune your cell, it must be fully setup to run tests. But there is one exception. You do not need the same working electrode (metal sample) used in your testing. You may use a similar-sized metal sample.
1. Fill your cell with electrolyte. Connect all heating and cooling devices in the same manner used in your tests.
2. The first step in the tuning process is to establish a stable baseline temperature: a. Run the Framework software. b. Select Experiment > Named Script… > TDC Set Temperature.exp c. Set a baseline temperature. If you are uncertain what temperature to enter, choose a value slightly above the room temperature of your laboratory. Often a reasonable choice is 30°C. d. Click the OK button. The script terminates after changing the TDC Setpoint. The Setpoint display should change to the temperature you entered. e. Observe the TDC5 process temperature display for a couple of minutes. It should approach the Setpoint and then cycle to values both above and below that point. On an untuned system, the temperature deviations around the Setpoint can be 8 or 10°C.
3. The next step in the tuning process applies a temperature step to this stable system: a. From the Framework software, select Experiment > Named Script… > TDC5 Start Auto Tune.exp. On the resulting Setup box, click the OK button. After a few seconds, you should see a Runtime Warning window like the one below.
b. Click the OK button to continue. c. The TDC5 display may blink for several minutes. Do not interrupt the auto-tune process. At the
end of the blinking period, the TDC5 eithers display doNE, or an error code. 21
TDC5 Use 4. If auto-tune is successful, the TDC5 displays doNE. Tuning can fail in several ways. Error code 007 is
displayed when the Auto Tune is unable to raise the temperature by 5°C within the 5 minutes allowed for the tuning process. Error code 016 is displayed when auto-tune detects an unstable system prior to applying the step. 5. If you do see an error, repeat the process of setting the baseline and try auto-tune a couple more times. If the system still does not tune, you may need to change the thermal characteristics of your system.
22
Default Controller Configuration
Appendix A: Default Controller Configuration
Initialization Mode menu
Level 2 INPt
Level 3 t.C.
Rtd
tHRM PRoC
Level 4 Level 5 Level 6 Level 7 Level 8 Notes
k
Type K thermocouple
J
Type J thermocouple
t
Type T thermocouple
E
Type E thermocouple
N
Type N thermocouple
R
Type R thermocouple
S
Type S thermocouple
b
Type B thermocouple
C
Type C thermocouple
N.wIR
3 wI
3-wire RTD
4 wI
4-wire RTD
A.CRV
2.25k 5k 10k
420
2 wI 385.1 385.5 385.t 392 391.6
2-wire RTD 385 calibration curve, 100 385 calibration curve, 500 385 calibration curve, 1000 392 calibration curve, 100 391.6 calibration curve, 100 2250 thermistor 5000 thermistor 10,000 thermistor Process input range: 4 to 20 mA
Note: This Live Scaling submenu is the same for all PRoC ranges
MANL Rd.1
Low display reading
23
Default Controller Configuration
Level 2
tARE LINR RdG
Level 3
dSbL ENbL RMt N.PNt MANL LIVE dEC.P °F°C d.RNd FLtR
Level 4 Level 5 Level 6 Level 7 Level 8 Notes
Rd.2
High display reading
LIVE
Rd.1
Low display reading
IN.1
Live Rd.1 input, ENTER for current
Rd.2
High display reading
IN.2 024
Live Rd.2 input, ENTER for current Process input range: 0 to 24 mA
+-10
Process input range: -10 to +10 V
Note: +- 1.0 and +-0.1 support SNGL, dIFF and RtIO tYPE
+-1
tYPE
SNGL
Process input range: -1 to +1 V
dIFF
Differential between AIN+ and AIN-
RtLO
Ratio-metric between AIN+ and AIN-
+-0.1
Process input range: -0.1 to +0.1 V
Note: The +- 0.05 input supports dIFF and RtIO tYPE
+-.05
tYPE
dIFF
Differential between AIN+ and AIN-
RtLO
Ratiometric between AIN+ and AIN-
Process input range: -0.05 to +0.05 V
Disable tARE feature
Enable tARE on oPER menu
Enable tARE on oPER and Digital Input
Specifies the number of points to use
Note: The Live inputs repeat from 1..10, represented by n
Rd.n
Low display reading
Rd.n
Low display reading
IN.n
Live Rd.n input, ENTER for current
FFF.F
Reading format -999.9 to +999.9
FFFF
Reading format -9999 to +9999
FF.FF
Reading format -99.99 to +99.99
F.FFF
Reading format -9.999 to +9.999
°C
Degrees Celsius annunciator
°F
Degrees Fahrenheit annunciator
NoNE
Turns off for non-temperature units
Display Rounding
8
Readings per displayed value: 8
16
16
24
Default Controller Configuration
Level 2
ECtN CoMM
Level 3 Level 4 Level 5 Level 6 Level 7 Level 8 Notes
32
32
64
64
128
128
1
2
2
3
4
4
ANN.n
ALM.1 ALM.2
Note: Four-digit displays offer 2 annunciators, 6-digit displays offer 6 Alarm 1 status mapped to “1” Alarm 2 status mapped to “1”
oUt#
Output state selections by name
NCLR
GRN
Default display color: Green
REd
Red
AMbR
Amber
bRGt HIGH
High display brightness
MEd
Medium display brightness
Low
Low display brightness
5 V
Excitation voltage: 5 V
10 V
10 V
12 V
12 V
24 V
24 V
0 V
Excitation off
USb
Configure the USB port
Note: This PRot submenu is the same for USB, Ethernet, and Serial ports.
PRot
oMEG ModE dAt.F
CMd CoNt StAt
Waits for commands from other end
Transmit continuously every ###.# sec
No
yES Includes Alarm status bytes
RdNG
yES Includes process reading
No
PEAk
No
yES Includes highest process reading
VALy
No
yES Includes lowest process reading
UNIt
No
25
Default Controller Configuration
Level 2
Level 3
EtHN SER
Level 4
AddR PRot AddR PRot C.PAR
Level 5
M.bUS bUS.F bAUd
Level 6 _LF_ ECHo SEPR RtU ASCI
232C 485 19.2
Level 7
No yES yES No _CR_ SPCE
Level 8 Notes yES Send unit with value (F, C, V, mV, mA)
Appends line feed after each send Retransmits received commands
Carriage Return separator in CoNt Space separator in CoNt Mode Standard Modbus protocol Omega ASCII protocol USB requires Address Ethernet port configuration Ethernet “Telnet” requires Address Serial port configuration Single device Serial Comm Mode Multiple devices Serial Comm Mode Baud rate: 19,200 Bd
9600 4800 2400
1200 57.6
115.2
PRty
odd
EVEN
NoNE
oFF
dAtA
8bIt
7bIt
StoP
1bIt
2bIt
AddR
SFty
PwoN
RSM
26
9,600 Bd 4,800 Bd 2,400 Bd 1,200 Bd 57,600 Bd 115,200 Bd Odd parity check used Even parity check used No parity bit is used Parity bit is fixed as a zero 8-bit data format 7-bit data format 1 stop bit 2 stop bits gives a “force 1” parity bit Address for 485, placeholder for 232 RUN on power up if not previously faulted
Default Controller Configuration
Level 2
SAVE LoAd VER.N VER.U F.dFt I.Pwd
Level 3 RUN.M SP.LM SEN.M
OUT.M
1.PNt 2.PNt ICE.P _____ _____ 1.00.0
ok? ok? No
Level 4 wAIt RUN dSbL ENbL SP.Lo SP.HI
LPbk
o.CRk
E.LAt
oUt1
oUt2 oUt3 E.LAt
R.Lo R.HI ok? dSbL
Level 5
dSbL ENbL ENbl dSbL ENbl dSbL o.bRk
ENbl dSbL
Level 6
dSbL ENbl
Level 7
P.dEV P.tME
Level 8 Notes Power on: oPER Mode, ENTER to run RUN’s automatically on power up ENTER in Stby, PAUS, StoP runs ENTER in modes above displays RUN Low Setpoint limit High Setpoint limit Sensor Monitor Loop break timeout disabled Loop break timeout value (MM.SS) Open Input circuit detection enabled Open Input circuit detection disabled Latch sensor error enabled Latch sensor error disabled Output Monitor oUt1 is replaced by output type Output break detection Output break detection disabled Output break process deviation Output break time deviation oUt2 is replaced by output type oUt3 is replaced by output type Latch output error enabled Latch output error disabled Set offset, default = 0 Set range low point, default = 0 Set range high point, default = 999.9 Reset 32°F/0°C reference value Clears the ICE.P offset value Download current settings to USB Upload settings from USB stick Displays firmware revision number ENTER downloads firmware update ENTER resets to factory defaults No required password for INIt Mode
27
Default Controller Configuration
Level 2 P.Pwd
Level 3 yES No yES
Level 4 _____
_____
Level 5
Level 6
Level 7
Level 8 Notes Set password for INIt Mode No password for PRoG Mode Set password for PRoG Mode
Programming Mode Menu
Level 2 Level 3 Level 4 Level 5 Level 6 Notes
SP1
Process goal for PID, default goal for oN.oF
SP2
ASbo
Setpoint 2 value can track SP1, SP2 is an absolute value
dEVI
SP2 is a deviation value
ALM.1 Note: This submenu is the same for all other Alarm configurations.
tyPE
oFF
ALM.1 is not used for display or outputs
AboV
Alarm: process value above Alarm trigger
bELo
Alarm: process value below Alarm trigger
HI.Lo.
Alarm: process value outside Alarm triggers
bANd
Alarm: process value between Alarm triggers
Ab.dV AbSo
Absolute Mode; use ALR.H and ALR.L as triggers
d.SP1
Deviation Mode: triggers are deviations from SP1
d.SP2
Deviation Mode: triggers are deviations from SP2
CN.SP
Tracks the Ramp & Soak instantaneous setpoint
ALR.H
Alarm high parameter for trigger calculations
ALR.L
Alarm low parameter for trigger calculations
A.CLR
REd
Red display when Alarm is active
AMbR
Amber display when Alarm is active
dEFt
Color does not change for Alarm
HI.HI
oFF
High High / Low Low Alarm Mode turned off
GRN
Green display when Alarm is active
oN
Offset value for active High High / Low Low Mode
LtCH
No
Alarm does not latch
yES
Alarm latches until cleared via front panel
botH
Alarm latches, cleared via front panel or digital input
RMt
Alarm latches until cleared via digital input
CtCL
N.o.
Output activated with Alarm
N.C.
Output deactivated with Alarm
A.P.oN
yES
Alarm active at power on
28
Default Controller Configuration
Level 2 Level 3 Level 4 Level 5 Level 6 Notes
No
Alarm inactive at power on
dE.oN
Delay turning off Alarm (sec), default = 1.0
dE.oF
Delay turning off Alarm (sec), default = 0.0
ALM.2
Alarm 2
oUt1
oUt1 is replaced by output type
Note: This submenu is the same for all other outputs.
ModE
oFF
Output does nothing
PId
PID Control Mode
ACtN RVRS Reverse acting control (heating)
dRCt Direct acting control (cooling)
RV.DR Reverse/Direct acting control (heating/cooling)
PId.2
PID 2 Control Mode
ACtN RVRS Reverse acting control (heating)
dRCt Direct acting control (cooling)
RV.DR Reverse/Direct acting control (heating/cooling)
oN.oF ACtN RVRS Off when > SP1, on when < SP1
dRCt Off when < SP1, on when > SP1
dEAd
Deadband value, default = 5
S.PNt
SP1 Either Setpoint can be used of on/off, default is SP1
SP2 Specifying SP2 allows two outputs to be set for heat/cool
ALM.1
Output is an Alarm using ALM.1 configuration
ALM.2
Output is an Alarm using ALM.2 configuration
RtRN
Rd1
Process value for oUt1
oUt1
Output value for Rd1
Rd2
Process value for oUt2
RE.oN
Activate during Ramp events
SE.oN
Activate during Soak events
SEN.E
Activate if any sensor error is detected
OPL.E
Activate if any output is open loop
CyCL
RNGE
0-10
PWM pulse width in seconds Analog Output Range: 010 Volts
oUt2 0-5 0-20
Output value for Rd2 05 Volts 020 mA
29
Default Controller Configuration
Level 2 Level 3 Level 4 Level 5 Level 6 Notes
4-20
420 mA
0-24
024 mA
oUt2
oUt2 is replaced by output type
oUt3
oUt3 is replaced by output type (1/8 DIN can have up to 6)
PId
ACtN RVRS
Increase to SP1 (i.e., heating)
dRCt
Decrease to SP1 (i.e., cooling)
RV.DR
Increase or decrease to SP1 (i.e., heating/cooling)
A.to
Set timeout time for autotune
tUNE
StRt
Initiates autotune after StRt confirmation
rCg
Relative Cool Gain (heating/cooling mode)
oFst
Control Offset
dEAd
Control Dead band/Overlap band (in process unit)
%Lo
Low clamping limit for Pulse, Analog Outputs
%HI
High clamping limit for Pulse, Analog Outputs
AdPt
ENbL
Enable fuzzy logic adaptive tuning
dSbL
Disable fuzzy logic adaptive tuning
PId.2 Note: This menu is the same for PID menu.
RM.SP
oFF
oN
420
Use SP1, not remote Setpoint Remote analog Input sets SP1; range: 420 mA
Note: This submenu is the same for all RM.SP ranges.
RS.Lo
Min Setpoint for scaled range
IN.Lo
Input value for RS.Lo
RS.HI
Max Setpoint for scaled range
024 010
IN.HI
Input value for RS.HI 024 mA 010 V
M.RMP R.CtL
No
Multi-Ramp/Soak Mode off
yES
Multi-Ramp/Soak Mode on
RMt S.PRG
M.RMP on, start with digital input Select program (number for M.RMP program), options 199
M.tRk
RAMP 01
Guaranteed Ramp: soak SP must be reached in ramp time 01 V
SoAk CYCL
Guaranteed Soak: soak time always preserved Guaranteed Cycle: ramp can extend but cycle time can’t
30
Default Controller Configuration
Level 2
Level 3 tIM.F E.ACt
N.SEG S.SEG
Level 4 Level 5 Level 6 Notes
MM:SS
HH:M M
StOP
Note: tIM.F does not appear for 6-digit display that use a HH:MM:SS format “Minutes : Seconds” default time format for R/S programs “Hours : Minutes” default time format for R/S programs Stop running at the end of the program
HOLd
Continue to hold at the last soak setpoint at program end
LINk
Start the specified ramp & soak program at program end
1 to 8 Ramp/Soak segments (8 each, 16 total)
Select segment number to edit, entry replaces # below
MRt.#
Time for Ramp number, default = 10
MRE.# oFF Ramp events on for this segment
oN Ramp events off for this segment
MSP.#
Setpoint value for Soak number
MSt.#
Time for Soak number, default = 10
MSE.#
oFF Soak events off for this segment
oN Soak events on for this segment
Changes that Gamry Instruments Has Made to Default Settings
· Set Omega Protocol, Command Mode, No Line Feed, No Echo, Use <CR> · Set Input Configuration, RTD 3 Wire, 100 ohms, 385 Curve · Set Output 1 to PID Mode · Set Output 2 to On/Off Mode · Set Output 1 On/Off Configuration to Reverse, Dead Band 14 · Set Output 2 On/Off Configuration to Direct, Dead Band 14 · Set Display to FFF.F degrees C, Green Color · Set Point 1 = 35 degrees C · Set Point 2 = 35 degrees C · Set Proportional Band to 9C · Set Integral factor to 685 s · Set Derivative factor Rate to 109 s · Set Cycle time to 1 s
31
Appendix B: Index
AC line cord, 7 AC Outlet Fuses, 8 Advanced Settings for COM, 16 Advanced…, 16 Auto Tuning the TDC5, 23 baseline temperature, 23 cable, 7, 13, 18 CEE 22, 7, 13 Cell Cables, 18 COM port, 15, 16 COM Port Number, 16 computer, 3 Control Panel, 14 cooler, 17 cooling device, 17 CPT Critical Pitting Test System, 11, 21 CS8DPT, 7, 12, 21 CSi32, 11 Device Manager, 14, 16 doNE, 23 electrical transients, 9 Error code 007, 24 Error code 016, 24 ExplainTM scripts, 21 FlexCell, 12, 18, 22 FrameworkTM software, 21 fuse
cooler, 17
heater, 17
Gamry Software Installation, 16 heater, 8, 17, 21, 23 host computer, 14 Initialization Mode, 25 inspection, 7 Label, 17 line voltages, 8, 12 oPER, 13 Output 1, 17 Output 2, 17 Parameters
Operating, 22
part list, 11 physical location, 11 PID, 12, 18, 22 polarity, 7 Port Settings, 16 Ports, 14 potentiostat, 18, 21 power cord, 11 power line transient, 9
Index
power switch, 13 Programming Mode, 30 Properties, 15 RFI, 9 RTD, 11, 12, 13, 18, 21 Runtime Warning window, 23 safety, 7 Select Features, 16 shipping damage, 7 static electricity, 9 support, 3, 9, 11, 18 TDC Set Temperature.exp, 21, 23 TDC5
Cell Connections, 17 Checkout, 18 Operating Modes, 18 Tuning, 22 TDC5 adapter for RTD, 11 TDC5 Start Auto Tune.exp, 21 TDC5 Use, 21 telephone assistance, 3 Temperature Controller, 16 Temperature Controller Configuration, 16 Thermal Design, 21 Type, 16 unpacking, 11 USB cable, 11, 14 USB Serial Device, 15 USB Serial Device Properties, 15 Visual Inspection, 11 Warranty, 3 Windows, 4
33
Documents / Resources
 |
GAMRY TDC5 Temperature Controller [pdf] Instruction Manual TDC5 Temperature Controller, TDC5, Temperature Controller, Controller |