TDC2 Temperature Controller Operator`s Manual
Contents
1. File Edt Experiment Analysis Options Window Help 8 x ix ejeje de rr sia mmis F1 ABORT F2 Skip FS ACTIV Pt Time Temp 627 6363s 53 2 54 00 _0 0 6 363k 53 20 53 00 52 00 Temp 51 00 50 00 0 000k 1 000k 2 000k 3 000k 4 000k 5 000k 6 000k 7 000k Time sec Remaining 1 Wait until some curvature is seen in the temperature versus time curve Figure 3 1 shows a good quality curve Select F2 Skip to terminate the experiment g Turn off the heater by setting the power to 0 h Close the CPT110 Runner Window by pressing F2 Skip Graphing the Temperature versus Time Curve a Run Microsoft Excel b Select File Open from the Excel menu In the resulting dialog box select the TUNE DTA file in your Gamry Framework data directory Select Ok NOTE The data curve resulting from the TDCTUNE experiment is normally stored in the file TUNE DTA If you stored the data in a different file open that file c The TUNE DAT file is not in an Excel format so a series of dialog boxes will pop up on the screen Each dialog box asks a question concerning the format of the file Select Next gt or Finish in each box to accept the default answer to each question d The Excel window should eventually look something like Figure 3 2 Figure 3 2 TUNE DTA File in Excel X Microsoft Excel Tune dta Iof x 587 File Edit View Insert Format Tools Data Window Help l8 x JOSH GRY2. 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 Ventilation Your TDC2 Temperature Controller was designed to operate at ambient temperatures between 0 C and 40 C Be careful when operating the TDC2 in an enclosed space such as an enclosed relay rack or NEMA enclosure The temperature within the enclosure must not exceed 40 C You may need to provide ventilation holes or even forced air cooling for the enclosure if excessive temperature rise occurs Defects and Abnormal Stresses You should treat your TDC2 Temperature Controller as potentially hazardous if any of the following is true of the unit e Itshows visible damage e lt does not operate properly e t has been stored for a long period of time under unfavorable conditions e thas been dropped or subject to severe transport stress e It has been subjected to environmental stress corrosive atmosphere fire etc Do not use your TDC2 or any other apparatus if you think it could be hazardous Have it checked by qualified service personnel Note that there are limit conditions on the storage shipping and operation of this equipment The TDC2 has not been designed for outdoor use Storage Ambient Temperature 20 C to 60 C Relative H
3. Earth Ground Light Blue Green Yellow If you have any doubts about the line cord for use with your TDC2 please contact a qualified electrician or instrument service technician for assistance They can perform a simple continuity check that can verify the connection of the TDC2 chassis to earth and thereby check the safety of your TDC2 installation Line Voltages The TDC2 can be wired at the factory for either 120 VAC or 240 VAC operation The voltage range cannot be modified in the field If your unit is set to the incorrect voltage range for the line voltage in your area you must return it to the factory The line voltage setting is shown on the rear panel of the unit There are two AC range labels below the line cord receptacle Each label is proceeded by a white circle The circle corresponding to the line voltage wiring has a black dot within the circle Figure 1 1 shows the appearance of the line voltage labels on a unit wired for 120 VAC operation Figure 1 1 Line Voltage Range Label 120 VAC LINE 50 60 Hz 240 VAC 15A 120 VAC 15A Before plugging in your TDC2 Temperature Controller you must check that its AC line voltage setting matches the voltage of your AC power line Table 1 2 shows the range of acceptable line voltages for each TDC2 voltage range setting Table 1 2 AC Voltage Ranges for Each Nominal Line Voltage Setting Allowed Range 120 85 to 132 VAC 240 170 to 264 VAC Gamry Instruments has atte
4. a Cycle the controllers display until it shows the output power setting out Note this number b At your computer run the CPT110 script TDCTUNE EXP This script can be run by selecting Experiment Named Script In the resulting dialog box there will be a box displaying the names of experimental scripts Select Tdctune exp Select Open This script simply records a temperature versus time curve Do not select Ok to start the experiment yet c Put the controller into MANUAL mode d Enter a power output that is about 1 5 times higher than that recorded in Step 3a For example if the previous power level was 7 increase it to 11 Note the size of the increase it will be needed in later calculations e As quickly as possible after Step 3d Select Ok on the Gamry Framework s Runner Window This starts the data acquisition portion of the TDCTUNE script f Allow the TDCTUNE script to acquire at least 1 2 hour of data The temperature versus time curve should start out linear then begin to curve See Figure 3 1 This Figure was generated using a Flex Cell heated with a 200 W heating jacket with slow stirring The jump in output was from 6 to 10 As you can see in this figure the temperature resolution of the measurement is fairly poor so the temperature versus time curve can consist of just a few levels Figure 3 1 Typical Real Time Plot from TDCTUNE EXP ge CMS100 t tdctune exp C cms95 data tune dta
5. close as possible to the working electrode This will minimize the error between the actual temperature at the working electrode and the temperature setting A second problem is in rates of temperature change 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 A more subtle point is that the rate of heat loss from the cell should also be high Ifit is not the controller risks gross overshoots of the set point temperature when it raises the cell temperature Ideally the system will actively cool the cell as well as heat it Active cooling can consist of a system as simple as a cooling coil and a solenoid valve Temperature control via an external heater such as a heating mantle is moderately slow An internal heater such as a cartridge heater is the quicker Tuning the TDC2 Temperature Controller Overview Closed loop control systems such as the TDC2 must be tuned for optimal performance A poorly tuned system will suffer from slow response overshoot and or poor accuracy The tuning parameters depend greatly on the characteristics of the system being controlled The temperature controller in the TDC2 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 wit
6. eee m tee 1 4 Heater Sate by os is scott aste tac eed e t OI D REND CD ERR 1 4 Ventilation it reti mo EH m ee eat b dire eiie 1 5 Defects and Abnormal Stressesi u a te e bg tite ig ege 1 5 GEN O 1 5 STNA E E pci labia 1 6 RELVWVarnINg ska san RAR BESTER una Al aan 1 6 Electrical Transient Sensitivity siss nde stetit see odes eiii et drei pee DER si 1 6 Chapter 2 Installation sa oe a an Lent nea E IR Re Aha 2 1 Initial Visual Inspection unit A eere eed n teo np ere re dpt 2 1 Physical Eocatiofix oni UE ET RR 2 1 Power Cord dieit ae eee nee e RE HDi De 2 1 LineVoltise Selector Re ote a 2 1 PowerUp Checks atia tmt te eee te OR re eere RD pene erbe 2 2 RS232Cable ELE S 2 2 Connecting the TDC2 to a Heater and or Cooler sse 2 3 Connecting the TDC2 to an RTD Probe an nun ee 2 3 CelliGables fromthe Potentiostat ette eO eed inel 2 4 Setting up the TDC2 Operating Modes sa cientos teretes hn tos etaed do 2 4 Calibrating the TDC2 Temperature Controller i oa een au 2 6 CheekingTDC2 Operations sso etel ont tech 2 6 Chapter 3 US esse D Rete ea ihn e Eee RA Dor ue d e Lei RU Ree pig 3 1 Thermal Design of Your Experiment staka seinni ph le dam ete i tn ak 3 1 Tuning the TDC2 Temperature Controller Overview eene 3 1 When to TUNG iet ora tt rptu tede t do a RO ee e E ue da tala s ba ege eds 3 2 Automatic versus Manual Tuning 3 2 Auto Turing the TIG sos sa aa eth AS ne RR Sig Cad Rt eu oc
7. 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 If You have Problems Contact us at your earliest convenience We can be contacted via Telephone 215 682 9330 8 00 AM 6 00 PM US Eastern Standard Time Fax 215 682 9331 Email techsupport gamry com Mail Gamry Instruments Inc 734 Louis Drive Warminster PA 18974 USA If you write to us about a problem provide as much information as possible If you are having problems in installation or use of this TDC2 Temperature Controller it would be helpful if you Called from a phone next to the instrument where you can change instrument settings while talking to us We will be happy to provide a reasonable level of free support for TDC2 purchasers Reasonable support includes telephone assistance covering the normal installation use and simple tuning of the TDC2 Disclaimers Gamry Instruments Inc cannot guarantee that the TDC2 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 printing However Gamry Instruments Inc assumes no responsib
8. BAS O wersrstu Arial 10 B ff JI 228 Hi 9 A Ra mj El TUNING mt 9 45 47 1 5 TOTALPTE 4000 B SAMPLET 10 GETTEMP F 8 STIRRATE 6 00E 01 9 INITTEMP 49 1 10 SETPOINT 10 Pt Time Temp1 Temp2 0 0 4 91E 01 0 00E 00 0 00E 00 1 11 4 90E 01 0 00E 00 0 00E 00 2 21 4 80E401 0 00E 00 0 00E 00 BE I4 4 MN TUNE Ready Highlight the first hundred points or so of the two data columns labeled Time and Temp1 These are the point to be included on the graph You may have to experiment with the number of points that you graph If you select too many points you lose resolution in determination of the deadtime see below If you select too few points the slope can be difficult to determine Select Insert Chart On This Sheet from the Excel menu Drag the cursor over a blank area of the sheet to define the chart area The area should be at least 4 columns wide by 10 rows tall In the next dialog box select Next gt to accept the data range because you have already highlighted the appropriate data ranges In the next dialog box select an XY Scatter chart then select Next gt Select any of the linear chart options then select Next gt Select the default for each of the next dialog boxes Your chart should something like Figure 3 3 In this figure the Excel line drawing tool has been used to draw a line on the chart This line is helpful in the next step of this p
9. C2 The cooling device can be as simple as a solenoid valve in a cold water line leading to a water jacket surrounding the cell More often the cooling device is the compressor in a refrigeration unit Before connecting a cooling device to the TDC2 verify that the Output 2 fuse is the correct value for your cooling device The TDC2 is shipped with a 5 amp Output 2 fuse Connecting the TDC2 to an RTD Probe The TDC2 must be able to measure the temperature before it can control it The TDC2 uses a platinum RTD to measure the cell temperature A suitable RTD is supplied with the TDC2 This sensor simply plugs into the rear panel RTD jack on the TDC2 Contact Gamry Instruments Inc at our US facility if you need to substitute a third party RTD into a CPT110 system The active end of the RTD should be located as close as possible to the working electrode in your cell This will minimize the effect of thermal gradients on the control accuracy Cell Cables from the Potentiostat A TDC2 in your system does not affect the cell cable connections These connections are made directly from the potentiostat to the cell Please read the your potentiostats Operator s Manual for cell cable instructions Setting up the TDC2 Operating Modes The Watlow Temperature Controller built into the TDC2 has a number of different operating modes each of which is configured by means of user entered parameters Note Please refer to the Watlow User s Manual supplied
10. Instruments Inc for assistance If the input voltage breaker does trip remove the source of the problem then simply switch the TDC2 back on to restore normal operation Switched AC Outlet Fuses Both of the switched outlets on the back of the TDC2 has a fuse to the left of the output There is no standard fuse rating printed on the panel Instead the panel is marked with an exclamation point within a triangle A directing the user to look in this manual The fuse rating can be selected by the user of the TDC2 The maximum allowed fuse rating is 10 amps Warning The AC line fuses are important components for safe operation of the TDC2 The switched outlet fuses must be rated at 10 amps or less Use of higher rated fuses could damage the TDC2 and or create a safety hazard which could result in personnel injury or death Do not replace the fuses with incorrect values or types or in any way circumvent the fuse action If your system routinely suffers from blown fuses it indicates a serious problem Contact Gamry Instruments Inc for assistance The TDC2 uses 5x20 mm fuses for the switched outlets You can use either fast or slow blow fuses at your option Representative fuses are Bussman GDA or Littlefuse 216 series fast blow and Bussman GDC or Littlefuse 218 series slow blow 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 no
11. TDC2 Temperature Controller Operator s Manual Copyright 2001 Gamry Instruments Inc All rights reserved Printed in the USA Revision 4 2 May 10 2003 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 date of shipment Gamry Instruments Inc makes no warranties regarding either the satisfactory performance of the TDC2 Temperature Controller including the software used with this product or the fitness of TDC2 based systems for any particular purpose The remedy for breach of this Limited Warranty shall be limited solely to repair or by replacement as determined by Gamry Instruments Inc and shall not include other damages Gamry Instruments Inc reserves the right to make revisions to the TDC2 at any time without incurring any obligation to install same on TDC2s 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
12. he TDC2 s proportional band Pb1 is calculated from Pb 100 Output K in our example Pb1 100 Output 17 Output C 5 8 C In the TDC2 the integral reset rate Re1 is specified in reciprocal minutes It is calculated from the deadtime in seconds using Rel 60 4 L using the numbers above Rel 60 4 300 0 05 min The derivative time dE1 is specified in minutes It is calculated from the deadtime in seconds using dEl L 2 60 seconds min using the numbers above dEl 300 seconds 120 seconds min 2 5 minutes Entering and Checking the New Tuning Parameters Enter the values calculated above into the TDC2 Select AUTO on the controller Enter a setpoint that is 10 to 20 C above the current temperature Rerun the TDCTUNE EXP script A smooth rise in temperature should be seen A overshoot of 1 or 2 C is acceptable 3 10 Appendix A RS232 Connector Pinout Any pin not listed is not connected Data directions are from the point of view of the computer Note that this is a classical 3 wire connection with jumpered control signals The TDC2 does not use or generate any of the modem control signals CTS RTS etc The computer s modem control outputs are jumpered to its inputs within the TDC2 Table A 1 RS232 Connector Pinout Data from computer to peripheral TDC2 ESE EA input Data from Data from peripheral to computer to computer Output Computer Pan ne _ data to send Jumpered
13. hout much overshoot and maintains that temperature within a closer tolerance than the ON OFF mode When to Tune The TDC2 is normally operated in PID mode In this mode it must be tuned to match it to the thermal characteristics of the system that it is controlling It is shipped in its default mode proportional control You must explicitly change it to operate in any other control mode The TDC2 is shipped with the tuning settings described below FACTORY SET TUNING PARAMETERS Parameter Symbol Proportional Band 1 1426 Pb1 Reset 1 rl Rate 1 dEl Cycle Time 1 Ct1 Dead Band db You should retune your TDC2 with your cell system before you use it to run any real tests The system should be retuned whenever you make major changes in the thermal behavior of your system Typical changes that would require retuning include e Addition of thermal insulation to the cell e Addition of a cooling coil e _ Changing the position or wattage of the heater or e 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 Once the controller has been tuned for your system you can ignore tuning as long as your experimental setup remains relatively constant Automatic versus Manual Tuning You should automatically tune your TDC2 whenever possible Unfortunate
14. ility for errors that might appear Copyrights and Trademarks TDC2 Operator s Manual Copyright 1997 2003 Gamry Instruments Inc All rights reserved Printed in USA Gamry Framework Software Originally CMS100 Software Copyright 1989 2003 Gamry Instruments Inc CPT110 Software Originally CMS110 Software Copyright 1992 2003 Gamry Instruments Inc Explain Computer Language Copyright 1989 2003 Gamry Instruments Inc Gamry Explain Gamry Framework CPT110 and TDC2 are trademarks of Gamry Instruments Inc Microsoft is a trademark and Windows is a registered trademark of Microsoft Corporation DOS as used herein refers to the MS DOS and PC DOS operating systems which are trademarks of Microsoft Corporation and IBM respectively No part of this document may be copied or reproduced in any form without the prior written consent of Gamry Instruments Inc Table of Contents Limited Way iii is i If You have Problems saitinin tede tee lab diia 2 A e RnB a ARR 3 Copyrights and Trademarks t basti eis nisse 3 Chapter 1 Safety Considerations esses emen eee nene em eren eene 1 1 Intro UC id td 1 1 1 1 Protective Grounding and Product Safety i icu iter en 1 1 line Voltages meer ders rit ett cette darte na a aka epe da 1 2 AG Line Circuit Breaker 2 51 iren te tt t omnet io eie pete 1 3 Switched AG Outlet FUSES ins oe ote IA A AAA AAA Seda 1 3 TDC Electrical Outlet Safety ee
15. ly the system response with many electrochemical cells is too slow for autotuning You cannot auto tune if a 5 C increase or decease in the system temperature takes more than ten 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 However a later section of this chapter does give a relatively simple step by step procedure for manually tuning the TDC2 The following table contains the tuning parameters for a Gamry Instruments Flex Cell used with a 200 W heating mantle and no active cooling The solution was stirred Parameter Symbol Setting Proportional Band 1 6 7 C Pb1 Reset L rEl dm Cycle TE 1 Ct1 Dead Band db O0 Auto Tuning the TDC2 This section briefly describes the temperature controllers auto tune feature which automatically sets the PID tuning parameters It is recommended that you read the Watlow Series 989 User s Manual before proceeding with this section Use this procedure to autotune the controller 1 The controller must be completely installed The system should be tuned using the same cell that will be used for real experiments You should try to duplicate your experimental conditions fairly closely 2 Enter a set point 10 to 20 C above the current system temperature 3 Press the MODE key until the Autotune Response message AUt ap
16. minal current is a bit less than 2 amps You may want to use a 2 5 amp 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 The TDC2 is shipped with a 5 amp fuse in the heater and cooler switched outlets The kit supplied with the TDC2 includes three spare 5 amp fuses TDC2 Electrical Outlet Safety The TDC2 has several switched electrical outlets on the rear panel of its enclosure These outlets are under the control of the TDC2 s controller module or a remote computer For safety considerations whenever the TDC2 is powered you must treat these outlets as being on Do not trust that the control signals for these outlets when off will remain off Do not touch any wire connected to these outlets unless the TDC2 line cord has been disconnected In most cases the TDC2 will power one or both of these outlets when it is first powered up Warning The switched electrical outlets on the TDC2 rear panel must always be treated as on whenever the TDC2 is powered Remove the TDC2 line cord if you must work with a wire in contact with these outlets Heater Safety The TDC2 Temperature 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 insure that the heater has no exposed wires or contacts
17. mpted to ship your TDC2 wired for the line voltage in your area If an error was made in the line voltage wiring please contact your local sales representative distributor or Gamry directly AC Line Circuit Breaker The TDC2 is protected by a AC line voltage circuit breaker This circuit breaker also functions as the main power switch It is located on the left side of the TDC2 Front Panel Regardless of the AC input voltage range this line voltage circuit breaker trips at 15 amps of line current The TDC2 internal circuitry draws very little current less than 0 2 amp If the line voltage circuit breaker trips it is therefore most likely the result of excessive current drawn from several of the TDC2 s switched AC outlets The sum of the currents drawn by the switched outputs must be less than 15 amps As is discussed below each outlet must be individually fused at 10 amps or less Therefore excessive current drawn from one switched AC output is unlikely to trip the line voltage circuit breaker Warning The circuit breaker is an important component for safe operation of the TDC2 Do not in any way circumvent the circuit breaker action In the unlikely event that the circuit breaker should fail it must be replaced by the exact same model and rating device Do not substitute other circuit breakers without express consent from Gamry Instruments If your input voltage circuit breaker routinely trips it indicates a serious problem Contact Gamry
18. na 3 3 Manually Tuning the TDG215 85 2 041 ii ill 3 3 Appendix A RS232 Connector Pinout 4 1 Chapter 1 Safety Considerations Introduction Your TDC2 Temperature Controller has been supplied in a safe condition This chapter of the TDC2 Operator s Manual contains some information and warnings that you must follow to insure continued safe operation of the TDC2 Inspection When you receive your TDC2 Temperature Controller you should inspect it for evidence 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 TDC2 is damaged in shipment Do not operate damaged apparatus until its safety has been verified by a qualified service technician Tag a damaged TDC2 to indicate that it could be a safety hazard Protective Grounding and Product Safety As defined in IEC Publication 348 Safety Requirements for Electronic Measuring Apparatus the TDC2 is a Class apparatus Class apparatus is only safe from electrical shock hazards if the case of the apparatus is connected to a protective earth ground In the TDC2 this protective ground connection is made via the ground prong in the AC line cord When you use the TDC2 with an approved line cord the connection to the protective earth ground is automatically made prior
19. ort has been wired as an RS232 DCE data communications element similar to a modem Your computer s RS232 port is normally wired as a DTE data terminal element In most cases an RS232 cable that connects a modem to your computer will successfully connect the TDC2 to your computer Appendix A of this manual contains a full description of the TDC2 s RS232 connector Connecting the TDC2 to a Heater and or Cooler There are many ways to heat an electrochemical cell These include an immersable heater in the electrolyte heating tape surrounding the cell or a heating mantle The TDC2 can be used with all these heater types 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 real 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 TDC2 This output is a CEE 22 Standard V female connector Electrical cords with the corresponding male connector are available worldwide Please check that the fuse on the Output 1 is appropriate for use with your heater The TDC2 is shipped with a 5 amp Output 1 fuse In addition to controlling a heater the TDC2 can control a cooling device The AC power for the cooler is drawn from the outlet labeled Output 2 on the rear of the TD
20. ou remove your TDC2 from its shipping carton you should 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 TDC2 is damaged in shipment Do not operate damaged apparatus until its safety has been verified by a qualified service technician Tag a damaged TDC2 to indicate that it could be a safety hazard Physical Location You can locate your TDC2 on a normal workbench surface You will need access to the rear of the instrument because all cable connections are made from the rear The TDC2 is not restricted to operation in a flat position You can operate it on its side or even upside down Power Cord The TDC2 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 TDC2 The line cord must be rated to carry 20A This is well above the maximum current allowed on the line cords supplied with computers and most test equipment Because of this higher rating the TDC1 line cord is thicker heavier and stiffer than these mo
21. pears in the lower window Use the UP DOWN arrow keys to select PidA if it is not shown 4 Press the MODE key once more The lower window will alternate between an Autotune Set Point message At and the set point value 5 Wait for auto tune to complete its cycle This can take up to 80 minutes During auto tune the cell temperature should cross the set point four times The controller halts the auto tune process after four crossings or after 80 minutes whichever comes first If the system response is too slow for four set point crossings the controller will still use the data that it has to calculate the PID values If the resultant values don t work you can wait for the cell to cool down and try again with a smaller temperature excursion If auto tune still fails you need to manually tune the system To cancel auto tune set the Autotune Response AUt parameter to O press the AUT MAN key twice or turn the TDC2 OFF then back ON When you do this the controller retains its previous tuning settings Switched cooling must be auto tuned separately from heating Repeat the above process with a set point 10 to 20 C below the current temperature Manually Tuning the TDC2 The following step by step procedure has been used to successfully tune the TDC2 using real electrochemical cells The TDC2 is manually tuned with assistance from an Explain script provided with the Gamry Instruments CPT110 Critical Pitting Test software You mu
22. ratus Thermal Design of Your Experiment The TDC2 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 TDC2 switches AC power to the heater or cooler to control the direction of any heat transfer The TDC2 is a closed loop system It measures the temperature of the cell and uses feedback to control the heater and or cooler Two major thermal problems are present to some degree in all system designs The first problem is temperature gradients in the cell They are invariably present However they can be minimized by proper cell design Stirring the electrolyte helps a great deal The heater should have a large area of contact with the cell Water jackets are good in this regard Cartridge type heaters are poor 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 heat escape pathway It is not unusual to find the electrolyte temperature near the working electrode is of 5 20 C lower than that of the bulk of the electrolyte If you cannot prevent thermal inhomogenieties you can at least minimize their effects One important design consideration is the placement of the RTD used to sense the cell temperature You should get the RTD as
23. re common cords The TDC2 line cord plugs into a receptacle located on the lower left side of the TDC2 s rear panel Line Voltage Selection The line voltage setting is shown on the rear panel of the unit There are two AC range labels below the line cord receptacle Each label is proceeded by a white circle The circle corresponding to the line voltage wiring has a black dot within the circle Figure 1 1 shows the appearance of the line voltage labels on a unit wired for 120 VAC operation Figure 2 1 Line Voltage Range Label 120 VAC LINE 50 60 Hz O 240 VAC 15A 120 VAC 15A Check that the TDC2 has been wired for the voltage range appropriate for use in your area Warning You can damage an TDC2 by attempting to operate it from an incorrect line voltage It is particularly dangerous to plug a unit set for an AC line voltage of 120 VAC into a outlet supplying a higher voltage such as 240 VAC If the AC line voltage selection is not correct for your power supply voltage it must be changed The AC line voltage cannot be changed in the field Internal rewiring and parts replacement is required Please contact your local Gamry Instruments representative or the factory directly if you have any questions regarding the line voltage configuration Power Up Check Once the TDC2 has been 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 lef
24. rocedure Figure 3 3 Chart of TUNE DTA File in Excel Microsoft Excel Tune dta D ms vate axis y m 499E 01 498E 01 497E 01 496E 01 495E 01 4 94E 01 Series 493E 01 492E 01 491E 01 4 90E 01 dl ae 500 1000 1500 4 Calculation of Tuning Parameters a Usingthe chart from step 3 estimate the dead time L This is the time prior to the start of the linear increase in the temperature If a line approximating the linear increase in temperature has been drawn on the chart the deadtime is the time at which this line intersects the initial temperature The units should be in seconds In Figure 3 3 the dead time is approximately 300 seconds NOTE Only an estimate of the dead time is required An exact answer is not expected or required b Again using the chart estimate the S the slope of the initial linear portion of the temperature rise The answer should have units of C second In Figure 3 3 the slope is about 7 7 x 107 C second 1 C change in 1300 seconds NOTE Again the key word is estimate An exact answer is not expected or required 3 8 Calculate the normalized slope R from the equation R 5 96 change in output power 4 in our example Continuing the analysis of the data in Figure 3 3 this becomes R 7 7 x 10 C sec 4 1 9 x 10 C sec output Calculate the proportional gain K from K 1 RL in our example K 1 1 9x 10 300 17 96 Output C T
25. st install your CPT110 software and verify CPT110 operation prior to using this script 1 Setup the System a Set up the cell and its stirrer The cell must be filled with liquid with roughly the same thermal properties and volume as the solution that will be used in the electrochemical tests In most cases water can be used for tuning if later tests will use aqueous solutions b Hook up the heater to the TDC2 Output 1 and to the cell Hook up the RTD to the TDC2 RTD input Place the RTD in the cell 2 Initialization a Power up the TDC2 and the stirrer if any NOTE Stirring rate is an important tuning parameter If the stirring rate changes drastically you may need to retune the system b Go to the controller s Operator menu OPEr and select control loop PidA tuning c Temporarily change the TDC2 to a simple proportional controller by setting the following control parameters Output 1 Proportional Band Pb1A 14 C Output 1 Reset rE1A 0 min 1 Output 1 Rate A rA1A O min Output 1 Cycle Time Ct1A 1 sec NOTE These are the default parameters for the TDC2 NOTE PID loop B and Output 2 are not used The second output should be turned off if it has been on d Put the controller in the AUTO mode e Set the temperature to 50 C f Wait for the system to settle to a constant temperature In many cases this can take 2 or 3 hours NOTE In most cases the system will not go to exactly 50 C 3 Data Acquisition
26. t side of the front panel This switch is actually a line voltage circuit breaker Note Make sure that a newly installed TDC2 has no connection to its switched outlets when it is first powered We want to verify that the TDC2 powers up correctly before we add the complexity of external devices When the TDC2 is powered up the temperature controller should light up after about 5 seconds If you have an RTD cabled to the unit the upper display should show the current temperature at the probe If you do not have a probe installed the upper display should show a line of dashes After connecting the probe if the unit is already on you will need to shut the unit off to reset the upper display Once the unit has powered up correctly turn it off prior to making the remaining system connections RS232 Cable The TDC2 comes with an RS232 cable suitable for connection of an TDC2 to the 9 pin COM port on an AT compatible PC Connect the 25 pin end of this cable to the RS232 port on the rear panel of the TDC2 Connect the other end to a 9 pin COM port on the computer Note the COM port for example COM2 that is used This information will be required in software configuration If you need to connect the TDC2 to a 25 pin COM port on the computer you can use a 25 to 9 pin adapter These adapters are inexpensive and available at most computer retailers The following information may be helpful if you need a special RS232 cable The TDC2 s RS232 p
27. to Pin 5 Input Peripheral can accept data Jumpered to Pin 4 Input Peripheral has data to send an to Pins 8 and 20 Input ELI NENNEN is powered up and ready Jumpered to Pins 6 and 20 20 DTR Output Computer is powered up and ready Jumpered to Pins 6 and 8 Index A fuse rating 1 3 AC line cord 1 1 AC line voltage 1 2 AC Outlet Fuses 1 3 auto tune 3 3 Cabling 2 2 Cell Cables 2 4 circuit breaker 1 3 cleaning 1 5 Cleaning 1 5 cooler 2 3 electrical transients 1 6 environmental stress 1 5 fuse cooler 2 3 heater 2 3 fuse rating 1 3 fuses 1 4 heater 2 3 modem cable 2 3 operation 1 5 Output 1 2 3 Output 2 2 3 Parameters Operating 3 2 power line transient 1 6 Product Safety 1 1 protective grounding 1 1 RFI 1 6 RS232 cable 2 3 RTD 2 3 safety 1 1 service 1 6 shipping 1 5 shipping damage 1 1 static electricity 1 6 storage 1 5 TDC2 Cabling 2 2 Calibration 2 6 Cell Connections 2 3 Checkout 2 6 Operating Modes 2 4 Tuning 3 2 Thermal Design 3 1 Use TDC2 3 1 ventilation 1 5 Visual Inspection 2 1 Watlow 2 4 Watlow temperature controller 3 1 Watlow Temperature Controller 2 1
28. to making any power connections Do not negate the protection of this earth ground by any means Do not use the TDC2 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 Warning If the protective ground is not properly connected it creates a safety hazard which could result in personnel injury or death The TDC2 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 TDC2 Warning If you replace the line cord you must use a line cord rated to carry 15 amps of AC current An improper line cord can create a safety hazard which could result in personnel injury or death Warning If you replace the line cord you must use a line cord with the same polarity as that supplied with the TDC2 An improper line cord can create a safety hazard which could result in personnel injury or death The wiring polarity of a properly wired connector is shown in the Table 1 1 for both US line cords and European line cords that follow the harmonized wiring convention Table 1 1 Line Cord Polarities and Colors oo Line Neutral
29. umidity Maximum 90 non condensing Shipping Same as storage plus Acceleration Maximum 30 G Operation Ambient Temperature 0 C to 40 C Relative Humidity Maximum 90 non condensing Cleaning Disconnect the TDC2 from all power sources prior to cleaning Clean the outside of the TDC2 enclosure with a rag dampened with either clean water or water containing a mild detergent Do not use a wet rag or allow water to enter the TDC2 enclosure Do not immerse the TDC2 in any type of cleaning fluid including water Do not use any abrasive cleaners Service Your TDC2 Temperature Controller has no user serviceable parts inside You should refer all service to a qualified service technician Warning The TDC2 Temperature Controller must not be operated with any cover or panel on the chassis open Dangerous AC line voltages are present at several points within the TDC2 Always remove the AC power cord before opening the TDC2 case RFI Warning Your TDC2 Temperature Controller generates uses and can radiate radio frequency energy The radiated levels are low enough that the TDC2 should present no interference problem in most industrial laboratory environments The TDC2 may to cause radio frequency interference if operated in a residential environment Electrical Transient Sensitivity Your TDC2 Temperature Controller was designed to offer reasonable immunity from electrical transients However in severe cases the TDC2 could malfunction or e
30. ven 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 TDC2 e Placing your TDC2 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 the static electricity e 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 TDC2 e Try plugging your TDC2 into a different AC power branch circuit e Plug your TDC2 into a power line surge suppresser Inexpensive surge suppressers are now generally available because of their use with computer equipment Contact Gamry Instruments Inc if these measures do not solve the problem Chapter 2 Installation This chapter covers normal installation of the TDC2 Temperature Controller The TDC2 was designed to run the experiments in the Gamry Instruments CPT110 Critical Pitting Test System but it is also useful for other purposes The TDC2 is based on the Watlow Series 989 Temperature Controller Please review the Watlow User s Manual to familiarize yourself with the operation of the temperature controller Initial Visual Inspection After y
31. with your TDC2 for information about the various controller parameters Do not change a parameter without some knowledge of that parameter s effect on the controller The TDC2 was shipped with its default settings In a few cases DIP switches have determined defaults The following tables list the factory TDC2 settings Dashes in a table entry indicates a parameter that is not important or not accessible during CPT110 operation Table 2 1 TDC2 Operation Menus 14 C 0 00 Table 2 2 TDC2 Setup Menus 99 9 C 537 7 C 0 din Calibrating the TDC2 Temperature Controller Unlike the earlier TDC1 the TDC2 does not require system calibration to achieve accurate temperature control The TDC2 does require tuning before it can be used with a new cell This is a complex process described in detail in the next chapter Checking TDC2 Operation To test the operation of the TDC2 you will run a simple checkout script provided with the CPT110 Critical Pitting Test System The name of this script is CHECK110 EXP Use the procedure in the CPT110 Installation Manual to perform this checkout Chapter 3 Use This chapter covers normal use of the TDC2 Temperature Controller The TDC2 is intended for use in the Gamry Instruments CPT110 Critical Pitting Test System The TDC2 is based on the Watlow Series 989 temperature controller Please read the Watlow User s Manual to familiarize yourself with the operation of this appa
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