TDC5 Temperature Controller

Product Information: TDC5 Temperature Controller

Specifications:

• Manufacturer: Gamry Instruments, Inc.

• Model: TDC5

• Warranty: 2 years from the original shipment date

• Support: Free telephone assistance for installation, use, and
  simple tuning

• Compatibility: Not guaranteed to work with all computer
  systems, heaters, cooling devices, or cells

Product Usage Instructions:

1. Installation:

1. Ensure you have all the necessary components for
   installation.

2. Refer to the installation guide provided with the product for
   step-by-step instructions.

3. If you encounter any issues during installation, please refer
   to the troubleshooting section in the user manual or contact our
   support team.

2. Basic Operation:

1. Connect the TDC5 Temperature Controller to your computer system
   using the provided cables.

2. Power on the TDC5 and wait for it to initialize.

3. Launch the accompanying software on your computer.

4. Follow the software instructions to set up and control the
   temperature using the TDC5.

3. Tuning:

Tuning the TDC5 Temperature Controller allows you to optimize
its performance for your specific application. Follow these
steps:

1. Access the tuning settings in the software interface.
2. Adjust the parameters according to your requirements.
3. Test the controller’s response to different temperature changes
   and fine-tune as needed.

FAQ:

Q: Where can I find support for the TDC5 Temperature

Controller?

A: For support, visit our service and support page at https://www.gamry.com/support-2/.
This page contains installation information, software updates,
training resources, and links to the latest documentation. If you
can’t find the information you need, you can contact us via email
or telephone.

Q: What is the warranty period for the TDC5 Temperature

Controller?

A: The TDC5 comes with a limited warranty of two years from the
original shipment date of your purchase. This warranty covers
defects resulting from faulty manufacture of the product or its
components.

Q: What if I encounter issues with the TDC5 during installation

or use?

A: If you’re having problems with installation or use, please
call us from a telephone next to the instrument so that you can
change instrument settings while talking to our support team. We
offer a reasonable level of free support for TDC5 purchasers,
including telephone assistance for installation, use, and simple
tuning.

Q: Are there any disclaimers or limitations to be aware

of?

A: Yes, please note the following disclaimers:

• The TDC5 may not work with all computer systems, heaters,
  cooling devices, or cells. Compatibility is not guaranteed.

• Gamry Instruments, Inc. assumes no responsibility for errors
  that might appear in the manual.

• The limited warranty provided by Gamry Instruments, Inc. covers
  repair or replacement of the product and does not include other
  damages.

• All system specifications are subject to change without
  notice.

• This warranty is in lieu of any other warranties or
  representations, expressed or implied, including merchantability
  and fitness, as well as any other obligations or liabilities of
  Gamry Instruments, Inc.

• Some states do not allow for the exclusion of incidental or
  consequential damages.

TDC5 Temperature Controller Operator’s Manual
Copyright © 2023 Gamry Instruments, Inc. Revision 1.2 December 6, 2023 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 one of the following ways:

Internet Telephone

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 © 2019-2023, Gamry Instruments, Inc., all rights reserved. CPT Software Copyright © 1992­2023 Gamry Instruments, Inc. Explain Computer Language Copyright © 1989­2023 Gamry Instruments, Inc. Gamry Framework copyright © 1989-2023, Gamry Instruments, Inc., all rights reserved. TDC5, Explain, CPT, Gamry Framework, 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.
4

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…………………………………………………………………………………………………….. 19
Chapter 3: TDC5 Use ………………………………………………………………………………………………………………….. 21 Using Framework Scripts to Set Up and Control Your TDC5 ………………………………………………………… 21 Thermal Design of Your Experiment ………………………………………………………………………………………… 21 Tuning the TDC5 Temperature Controller: Overview …………………………………………………………………. 22 When to Tune …………………………………………………………………………………………………………………….. 22 Automatic versus Manual Tuning …………………………………………………………………………………………….. 23 Auto Tuning the TDC5 ………………………………………………………………………………………………………….. 23
Appendix A: Default Controller Configuration ………………………………………………………………………………….. 25 Initialization Mode menu ………………………………………………………………………………………………………. 25 Programming Mode Menu …………………………………………………………………………………………………….. 30 Changes that Gamry Instruments Has Made to Default Settings …………………………………………………….. 33
Appendix B: Comprehensive Index ………………………………………………………………………………………………… 35
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.
Warning: 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.
Warning: 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.
Warning: 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.
7

Safety Considerations
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.
Table 1­1 Line Cord Polarities and Colors

Region US European

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.

Warning: 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 very near 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.

8

Safety Considerations
Warning: 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.
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

Chapter 2: Installation

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.

Warning: 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
Line Cord Polarities and Colors

Qty Gamry P/N Omega P/N Description

1

990-00491 –

1

988-00072 –

Gamry TDC5 (modified Omega CS8DPT) Gamry TDC5 Operator’s Manual

1

720-00078 –

Main Power Cord (USA version)

2

–

–

Omega Output Cords

1

985-00192 –

1

–

M4640

USB 3.0 type A male/male cable, 6 ft Omega User’s Guide

1

990-00055 –

RTD Probe

1

720-00016 –

TDC5 Adapter for RTD cable

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.
Warning: 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. In Windows® 7, you can find the Device Manager
in the Control Panel. In Windows® 10, you can find it by searching in the Windows® search box. 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.
Warning: 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 a 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 only by made 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.
17

Installation
Warning: Modifications to the Omega output cables should only be made by a
qualified electrician. Improper modifications could create a significant electrical shock hazard.
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.
18

Installation
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.
19

Chapter 3: TDC5 Use

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. 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.

Tuning the TDC5 so that it works optimally on your experimental setup is very difficult using the front-panel controls of the TDC5. We strongly recommend that you use the scripts listed above to tune your TDC5.
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 a 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.
21

TDC5 Use
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.
· 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 FlexCellTMTM heated with a 300 W jacket and cooled using solenoid-valve controlling water-flow through a cooling coil. The tuning settings are described below:
22

TDC5 Use
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

Re-tune 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.
· 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.

Automatic versus Manual Tuning
Tune your TDC5 automatically whenever possible.
Unfortunately, the system response with many electrochemical cells is too slow for auto tuning. You cannot auto-tune if a 5°C increase or decrease in the system temperature takes more than five minutes. In most cases, auto-tune on an electrochemical cell will fail unless the system is actively cooled.
A full description of the manual tuning of PID controllers is beyond the scope of this manual. Refer to Table 3­3 and the tuning parameters for a Gamry Instruments Flex Cell used with a 300 W heating mantle and switched cooling using water flow though the standard cooling coil. The solution was stirred.

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.

23

TDC5 Use 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. 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 un 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 or try to manually tune the system.
24

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 Manual and Live Scaling submenu is the same for all PRoC ranges

MANL Rd.1

Low display reading

IN.1

Manual input for Rd.1

25

Default Controller Configuration

Level 2
tARE LINR RdG

Level 3
dSbL ENbL RMt N.PNt MANL LIVE dEC.P °F°C d.RNd

Level 4 Level 5 Level 6 Level 7 Level 8 Notes

Rd.2

High display reading

IN.2

Manual input for Rd.2

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 Manual / Live inputs repeat from 1..10, represented by n

Rd.n

Low display reading

IN.n

Manual input for Rd.n

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

26

Default Controller Configuration

Level 2
ECtN CoMM

Level 3 Level 4 Level 5 Level 6 Level 7 Level 8 Notes

FLtR

8

Readings per displayed value: 8

16

16

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, six 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

27

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
UNIt
No yES yES No CR SPCE

Level 8 Notes yES Includes lowest process reading No 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

PRty
dAtA StoP

9600 4800 2400 1200 57.6 115.2 odd EVEN NoNE oFF 8bIt 7bIt 1bIt 2bIt

28

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

Default Controller Configuration

Level 2 SFty
t.CAL SAVE LoAd VER.N

Level 3 PwoN RUN.M SP.LM SEN.M
OUT.M
NoNE 1.PNt 2.PNt ICE.P 1.00.0

Level 4 AddR RSM 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 Address for 485, placeholder for 232 RUN on power up if not previously faulted 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 Manual temperature calibration 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

29

Default Controller Configuration

Level 2 VER.U F.dFt I.Pwd
P.Pwd

Level 3 ok? ok? No yES No yES

Level 4

Level 5

Level 6

Level 7

Level 8 Notes ENTER downloads firmware update ENTER resets to factory defaults No required password for INIt Mode 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

30

Default Controller Configuration

Level 2 Level 3 Level 4 Level 5 Level 6 Notes

CtCL

N.o.

Output activated with Alarm

N.C.

Output deactivated with Alarm

A.P.oN

yES

Alarm active at power on

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

31

Default Controller Configuration

Level 2 Level 3 Level 4 Level 5 Level 6 Notes

oUt2 0-5 0-20 4-20 0-24

Output value for Rd2 0­5 Volts 0­20 mA 4­20 mA 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

GAIN

P

Manual Proportional Band setting

I

Manual Integral Factor setting

d

Manual Derivative Factor setting

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

32

Default Controller Configuration

Level 2

Level 3 S.PRG M.tRk
tIM.F E.ACt
N.SEG S.SEG

Level 4 Level 5 Level 6 Notes

RMt

M.RMP on, start with digital input

Select program (number for M.RMP program), options 1­99

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

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 · 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

33

Default Controller Configuration · Set Derivative factor Rate to 109 s · Set Cycle time to 1 s
34

Comprehensive Index

Appendix B: Comprehensive
Index
AC line cord, 7 AC Outlet Fuses, 8 Advanced Settings for COM, 16 Advanced…, 16 Auto Tuning the TDC5, 23 auto-tuning, 23 baseline temperature, 23 cable, 7, 13, 18 CEE 22, 7, 13 Cell Cables, 18 COM port, 16 COM port, 15 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, 24 electrical transients, 9 Error code 007, 24 Error code 016, 24 ExplainTM scripts, 21 FlexCell, 18, 22 FlexcellTM, 12 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 Omega CS8DPT, 11 oPER, 13 Output 1, 17 Output 2, 17 Parameters
Operating, 23
physical location, 11 PID, 12, 18, 22, 23 polarity, 8 Port Settings, 16

Ports, 14 potentiostat, 18, 21 power cord, 11 power line transient, 9 power switch, 13 Programming Mode, 30 Properties, 15 RFI, 9 RTD, 11, 12, 13, 18, 22 Runtime Warning window, 24 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, 19 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 USB cable, 11, 14 USB Serial Device, 15 USB Serial Device Properties, 15 Visual Inspection, 11 Warranty, 3 Windows, 4
35

References

• Omega Engineering | Sensing, Monitoring and Control Solutions
• Omega Engineering | Sensing, Monitoring and Control Solutions
• Service and Support Pages: FAQ-Electrochemical Training-Tech Support Gamry Instruments

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