TC-9102 Manual 42420054Bx
Contents
1.2. SP1 value plus the controller will allow the a 3 differential temperature to rise to 20 and then COOLING APPLICATION turn on the cooling application until the temperature reaches 17 Once the temperature reaches the set point the relay will open again and allow it to rise to 20 before starting the cycle again Cools down to SP1 value With dual stage models each stage is independent so one stage can be set as a cooling stage and the other a heating stage or both can be cooling or heating stages When both stages are set to heating or cooling mode each stage can have any set point or differential value desired If one stage is heat and the other is cool however there is a limitation on how you can set the temperature set points to prevent the controller from having both heating and cooling applications running at the same time When both stages are in COOL or HEAT modes the temperature set points can overlap or be separated by any number of degrees When using both HEAT and COOL applications in a dual stage controller the controller will not let the user set temperature set points that overlap The TC 9102 controller automatically enforces a 2 second delay between one stage turning off and another stage starting The following diagrams show examples of how the Dual Stage TC 9102 controller can be configured in different applications DUAL STAGE MODEL WITH BOTH STAGES IN COOLING MODE SP2 value plus a 6 diff
3. be adjusted 30 from the reading on the display 27 ENTER CAL value is Pressing ENTER saves the value and displays it without flashing displayed ForC This is where you select if the unit should display in Fahrenheit 28 is displayed or Celsius degrees Press MODE to change the selection Flashin 29 For Use the keys to toggle between F and C ForC Pee ENTER 30 isdisplayed Pressing ENTER saves the value and displays it without flashing SCYC represents the Short Cycle Delay Time You select a value 31 SCYC in minutes anywhere from 0 to 15 minutes Press MODE to change the selection Flashing 32 Using the v4 keys set your desired Short Cycle Delay time SCYC value SCYC val 33 ENTER Pere oe Pressing ENTER saves the value and displays it without flashing is displayed SEnS allows you to select from one of two different sensor 34 SEnS k options Press MODE to change the selection Flashin 35 B Use the Y keys to toggle between rtd and Ptc Ptc or rtd Pt td 36 ENTER i he Pressing ENTER saves the value and displays it without flashing is displayed 6 C CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing This is the Lock Out feature that prevents users from changing 37 LOC the temperature alarm set point or the temperature alarm set point Press MODE to turn this ON or OFF ALL or OFF 38 flashes Use the 4 keys t
4. set point is reached 2 Operating Mode COOL HEAT or OFF This setting determines the application the controller is being used for 3 Differential Setting This is the number of degrees above or below the temperature set point the temperature is allowed to rise or fall depending up on the Operating Mode Temperature Set Point Programming Functions Single Stage Applications On single stage models the controller will either turn on or off the heating or cooling application based on the Temperature Set Point set in the Set Point Programming function and the Differential set in Hidden Access Programming Function The diagrams below show how a single stage model operates for either a heating or cooling application CONTROL PRODUCTS C Innovative Technologies in Custom Electronic Design amp Manufacturing In this Heating Application Example the user wants to maintain a 100 temperature With a 2 differential the controller will allow the temperature to drop to 98 and then turn on the heating application until the temperature reaches 100 Once the temperature reaches the set point the relay will open again and allow it to cool down to 98 before starting the cycle again HEATING APPLICATION 100 SP1 value Heats up to SP1 value SP1 value less a 2 differential Dual Stage Applications In this Cooling Application Example the user wants to maintain a 17 temperature With a 3 differential 20
5. 1 will heat up to 32 At 32 Stage 2 the heating application will turn off and allow the application to Cools down to SP2 value rise to 33 at which time the cooling stage will turn on The cooling stage will turn off when the temperature reaches 32 SP1 and SP2 values are the same 32 Although both temperature set points can be set at the same temperature the TC 9102 requires a minimum differential of 1 degree or more In addition the controller enforces a 2 second fie hi delay between one stage turning off and the other stage turning SP1 value on This is designed to reduce the possibility of tripping circuit breakers should both the heating and cooling elements be on at SP1 value less a2 __ 3 the same time Programming Instructions Programming the TC 9102 series temperature controller is completed through two separate programming sequences 1 Temperature Set Point Programming Functions 2 Hidden Access Programming Functions for operation mode differential high amp low set point limits calibration F C selection short cycle delay time temperature sensor selection and lock out functions The programming menus are set up to display a program function first followed by the numeric value or feature value You can change that value and then press the ENTER key to save the value then press the MODE key to move to the next programming function The program functions are displayed with shortened text to rep
6. 2 aval Pressing ENTER saves the value and displays it without flashing is displayed HSL1 will be displayed representing the High Set Point Limit for 13 HSL1 Stage 1 Flashing i Shed A 14 HSL1 s value Using the v4 keys adjust the high set point limit for stage 1 HSL1 s value i eae P ENTER 15 ENTER cae Pressing ENTER saves the value and displays it without flashing LSL1 is displayed representing the Low Set Point Limit 19 ptt programming parameter Flashin 17 e Using the v4 keys adjust the low set point limit for stage 1 LSL1 s value 18 ENTER LL Svan Pressing ENTER saves the value and displays it without flashing is displayed On DUAL STAGE UNITS only the unit displays HSL2 1 HSL2 2 S representing the High Set Point Limit for Stage 2 Flashing x 7 TEE 20 EPS vN Using the v4 keys adjust the high set point limit for stage 2 21 ENTER ee value Pressing ENTER saves the value and displays it without flashing is displayed On DUAL STAGE UNITS only the unit displays LSL2 22 LSL2 ee representing the Low Set Point Limit for Stage 2 Flashing 3 en 23 LSL2 s value Using the v4 keys adjust the low set point limit for stage 2 LSL2 s value z z A F ENTER 24 B cieva Pressing ENTER saves the value and displays it without flashing CAL is displayed representing the temperature sensor CAL calibration adjustment Flashing CAL Using the v4 keys adjust the calibration value of the 26 value temperature sensor This can
7. CONTROL PRODUCTS C Innovative Technologies in Custom Electronic Design amp Manufacturing TC 9102 Series Surface Mount Temperature Controllers General Description amp Applications The TC 9102 Series Temperature Controller offers a versatile solution for a wide variety of applications that may require 30 amp relays short cycle delays and independent dual stages in one convenient easy to use controller The TC 9102 controller can accommodate input voltages from 12VAC to 240VAC The TC 9102 comes with a temperature sensor with a temperature range of 40 to 300F 40 to 148 C An optional RTD sensor is also available Single or Dual stage models with independent relay control Programmable set point differential short cycle delay time and temperature sensor calibration mode Fahrenheit or Celsius Mode Selectable LED relay status indicator NEMA 1 high impact plastic enclosure Specifications Power Requirements e Low Voltage LV models accept 12 to 24VAC amp 24VDC e High Voltage HV models accept 120 to 240VAC Relay s Contact Rating 1 relay on single stage models 2 relays on dual stage models e SPST normally open switch up to 30A at 277 VAC Ambient Operating Temp 20 to 158 F 6 to 70 C Ambient Operating Humidity 90 RH at 95 F 35 C Accuracy 2 F 2 C Wiring Connections Stage 1 rmally Open Stage 2 Normally Open Power Connections No Sensor conne
8. ESS SP2 s JE is HIDDEN MENUS TEMP SET POINT Unit display goes blank for SP2 value is iN o Press Down Arrow MENU 2 seconds and returns to MODE displayed ENTER anaE ONN MODE Press MODE current temperature steady amp saved arrows to adjust MODE Operation Mode for HEAt COOL OFF mode Selected value SP1 OP1is MODE for SP1 flashes Arrows ENTER is steady and displayed toggle selection saved i dee TC 9102 PROGRAMMING MENUS Operation Mode for HEAt COOL OFF mode Selected value SP2 L MODE for SP2 flashes ENTER is steady and eee on OP2 is displayed Arrows toggle selection saved MODE MODE dif1 is displayed for Differential value for Selected value Temp Set point ON or OFF flashes Selected option Differential setting MODE SP1 flashes Arrows to ENTER is steady and menu Lock out Use arrows to select is steady and for SP1 change value saved LOC is displayed option saved A A i MODE MODE ENTER dif2 is displayed for Differential value for Selected value MODE Differential setting MODE SP2 flashes Arrows to ENTER is steady and for SP2 change value saved Temp Sensor Ptc or rtd flashes Use Selected value selection Ptc or rtd arrows to toggle to is steady and MODE is displayed selection saved y E T MODE ENTER High Set Point High set point value for Selected value Limit MODE SP1 flashes Arrows to ENTER is steady and MODE HSL1 is displayed change value saved Short Cycle Delay Short cycl
9. MIT and LOW SET POINT LIMIT This is a tamper proof option that allows a user to set maximum and minimum temperature set point limits to which a user can adjust the temperature set point If a user only wants people to be able to adjust temperature a few degrees they can set very tight High and Low Set Point Limits Both High and Low set point limits can be set to the same temperature to prevent any change in temperature set point Only dual stage units have HSL2 and LSL2 options Factory default value is 100 for the High Set Point Limits and 0 for the Low Set Point Limits CALIBRATION This option allows a user to field calibrate the temperature sensor If the actual temperature is 2 degrees higher than what the TC 9102 is displaying the user can enter a value of 2 in the calibration option to make the TC 9102 controller display the correct temperature You can enter a calibration value anywhere from 30 to 30 Factory set at zero TEMPERATURE SCALE This option allows you to have the TC 9102 display in either Fahrenheit or Celsius degrees Factory default is Fahrenheit SHORT CYCLE DELAY TIME The short cycle protection feature prevents the controller from short cycling a compressor A short cycle condition is when a relay controlling a compressor or other equipment cycles on and off too quickly possibly causing compressor or equipment damage The minimum time between relay state change is determined by the value entered in the Short Cycle Delay Ti
10. Technologies in Custom Electronic Design amp Manufacturing WARNING To avoid the risk of electrical shock disconnect all power sources to the controller and the equipment before wiring any connections More than one disconnect may be required to completely de energize the control and the equipment IMPORTANT All wiring must conform to local national and regional regulations Use copper conductors only for all wire connections Do not exceed the electrical ratings for the TC 9102 series control or the equipment it is wired to Connect the proper power supply to the power connections on the terminal block as shown in the Dimensions amp Wiring section on page one Note your model number indicates what input voltage is acceptable for this unit 1 HV designates the unit can accept input voltage of between 110 and 240 VAC 2 LV designates the unit can accept input voltage of 12 or 24 VAC or 24 VDC On low voltage versions the TC 9102 will have only a 240VAC and Common terminal block There is no polarity on this terminal block for low voltage inputs The input power is independent of the power that can run through the relays On all models regardless of the input voltage the control relays can accept up to 240 VAC power at up to 30 AMPs Connect the heating and cooling equipment to the normally open NO relay terminal block connectors as appropriate The sensor may already be connected but if not or if you ordered the RTD sens
11. ctions are on the smaller circuit board C JIA yA Sensor Connections o TC 9102D Aa hd MODE ENTER e Tamper resistant features to lock out and limit set point adjustment and programming features e 56 high red LED display with three digit display in 1 degree increments e Displays current temperature Durable touch pad programming with LED display prompts Temperature Sensor Range e PTC sensor included 40 to 300 F 40 to 148 C with 36 91M 24AWG 2 conductor wire Nickel plated copper sensor cap 1 75 L 44mm x 251 OD 6 38mm e Optional 1000 Ohm Platinum RTD sensor 0 to 600 F 17 to 316 C Relay Status Indicator LED is on when relay is activated Dimensions L 6 00 15 24cm x W 3 12 7 92cm x D 2 00 5 08cm Agency Approvals UL and CUL recognized RoHS compliant Low Voltage Power On low voltage LV models the input voltage can be 12 to 24 VAC or 24 VDC LV models will only have a two position terminal block marked 240 and COM There is no polarity with any of the low voltage inputs so both power leads can go into either of these terminal positions X 8 m Nopolarity No polarity ear Ka Accepts up Accepts up NS SN S BS _ to240VAC_ to 240VAC O 2 h O Q rfesistive 30 resistive 30 e 3 lt 5 g amps amps a O Sensor Type Ground Signal 5 VDC PTC or RTD sensor Black White NA amp G CONTROL PRODUCTS Innovative
12. e delay time Selected value 4 MODE Time SCYC is begins flashing Arrows is steady and displayed to change saved S IR Low set point value for Selected value A Low Set Point Limit MODE SP1 flashes Arrows to ENTERP is steady and L mor ENTER LSL1 is displayed change value saved MODE i MODE F C selection F or C flashes Use Selected value High Set Point High set point value for Selected value ForCis displayed arrows to toggle for is steady and Limit HSL2 is MODE SP2 flashes Arrows to ENTER is steady and selection saved displayed change value saved A MOD p ENTER t i MODE MODE L ow Set Point Low set point value for Selected value Calibration Calibration value Selected value Limit LSL2 is MODE SP2 flashes Arrows to ENTER is steady and CAL is displa s d flashes Arrows to is steady and displayed change value saved pay change value saved MOD e enren MODE O CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing This page intentionally blank 10 O CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing This page intentionally blank 11 O eS CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing CONTROL oe PRODUCTS 1724 Lake Drive West Chanhassen MN 55317 USA MADE IN USA Printed in the USA DOCUMENT 42420054B REVISION B 0210 12
13. erential 25 Cools down to SP1 value i i sn SP1 value plus a 3 differential SP2 value 19 Cools down to SP2 value 17 SP1 value DUAL STAGE MODEL WITH BOTH STAGES IN HEATING MODE SP1 value 100 Heats up to i SP1 value SP1 value less ve a 6 differential 94 92 SP2 value i Heats up to i SP2 value SP2 value less a 3 differential 89 With both stages in the cooling mode one can stage cooling phases The example on the left shows stage 1 turning on to cool to bring the temperature down to 17 If the temperature continues to rise for some reason stage 2 kicks in at 25 to boost the cooling down Alternately each stage could be separated by any number of degrees In this example both stages are set to HEAT but the stages are separated by 2 degrees When both stages are set to either HEAT or COOL modes the stages can have the same temperature set point be separated by any number of degrees or they can overlap as shown above With dual stages the TC 9102 can be used in a wide variety of applications S E CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing DUAL STAGE MODEL WITH BOTH HEAT AND COOL STAGES It is possible to maintain a very tight temperature range by setting one stage as a cooling stage and one stage as a heating SP2 value plus a 1 differential 2 stage In the example on the left stage
14. ion of the individual programming options go to the end of this programming guide Step PRESS DISPLAYED FUNCTION or INSTRUCTIONS Press and hold the DOWN ARROW key and then press the 1 4 OP1 MODE button OP1 will be displayed representing the Operating Mode for Stage 1 2 Flashing Using the v4 keys select between the HEAT COOL or OFF OPivalue operating mode for stage 1 3 OPES valur Pressing ENTER saves the value and displays it without flashing is displayed On DUAL STAGE UNITS only the unit displays OP2 4 P2 o representing the operating mode for Stage 2 5 Flashing Using the v4 keys select between the HEAT COOL or OFF OP2 value operating mode for stage 2 6 ENTER ake Suave Pressing ENTER saves the value and displays it without flashing is displayed 7 dF1 dF1 will be displayed representing the differential for Stage 1 Flashin 8 8 Using the v4 keys adjust the differential setting for stage 1 dif1 s value dif1 s value ENTER i i it wi i 9 is displayed Pressing ENTER saves the value and displays it without flashing ON DUAL STAGE UNITS only dF2 will be displayed 10 giz representing the differential for Stage 2 Flashin 11 dif2 s ae Using the v4 keys adjust the differential setting for stage 2 C CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing 1
15. me option Enter a value anywhere from 0 to 15 minutes Factory default is 5 minutes SENSOR SELECTION Choose if you have our PTC or RTD sensor connected Factory default is PTC LOCK OUT FEATURE This feature allows the user to prevent anyone from adjusting the temperature set point s If a person attempts to change any value the display will show LOC for a short period of time to show the user these adjustments are off limits Two options are available Factory default is OFF 1 ALL Locks out all functionality of the Temperature Set Point menus No changes can be made 2 OFF This turns off all lock out features and allows a user full access to the Temperature Set Point menu S G CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing Normal Operation During normal operation the current temperature will be displayed Relay indicator lights will be illuminated only if relays are in the closed position Relay Operation 1 Relays will always open when the temperature set point is reached 2 Relays will always close when the temperature set point plus or minus the differential value is reached 3 On a dual stage unit if using one relay for HEAT and the other for COOL the TC 9102 will not allow the relays to be both on at the same time There will a minimum of 2 seconds between turning one stage off and turning another stage on This is designed to eliminate the possibility of a simultaneous switch bet
16. o toggle between ALL or OFF 39 ENTER an Or OEE IS Pressing ENTER saves the value and displays it without flashing displayed Display goes Pressing MODE at the end of this menu results in the display 40 blank going blank for several seconds followed by a display of the current temperature reading from the temperature sensor EXPLANATION OF PROGRAMMING PARAMETER SETTINGS SP1 amp SP2 OP1 and OP2 dF1 and dF2 HSL1 and HSL2 LSL1 and LSL2 CAL Forc SCYC SEnS LOC TEMPERATURE SET POINT This is the temperature you wish to maintain for each stage The TC 9102D model has two independent relay stages The TC 9102S is a single stage model See page 2 for an explanation of how the TC 9102 uses these set points in conjuction with the differential setting OPERATING MODE Select the type of application this controller will be working with Is it a heating application or a cooling application If you don t wish to use this relay at all select the OFF mode Only Dual stage units will haven a OP2 mode Factory default is COOL DIFFERENTIAL This represents the number of degrees from the temperature set point the controller allows the temperature to rise or fall before closing the relay control See diagrams above This is always a positive number from 1 to 30 Zero is not allowed as a differntial value Only Dual Stage units will have a dF2 option The factory default setting is 3 HIGH SET POINT LI
17. ologies in Custom Electronic Design amp Manufacturing PROGRAMMING TEMPERATURE SET POINT e It is assumed the unit is powered up and the current temperature is displayed e Shaded sections are only applicable to Dual Stage Units Step PRESS DISPLAYED FUNCTION or INSTRUCTIONS SP1 represents Set Point 1 for the first stage On single stage 1 SP1 models there will only be one set point value but on dual stage models there will also be a SP2 as shown below 2 Flashing Using the 44 keys adjust the temperature set point value for Temp Value stage 1 3 ENTER P1 valved Pressing ENTER saves the value and displays it without flashing displayed For DUAL STAGE models ONLY SP2 will appear giving you the 4 SP2 ability to program the temperature set point for the second stage Flashing DUAL STAGE MODELS ONLY Using the 4 keys adjust the 2 Tem i p Value temperature set point value for stage 2 6 ENTER SP2 s value DUAL STAGE MODELS ONLY Pressing ENTER saves the value is displayed and displays it without flashing For a few seconds the screen will go blank and then the Exit Blank Screen current temperature will be displayed This signifies the end of this programming menu PROGRAMMING THE HIDDEN ACCESS MENU FUNCTIONS e It is assumed the unit is powered up and the current temperature is displayed e Shaded sections are only applicable to Dual Stage Units e For detailed explanat
18. or option you may need to connect this sensor to the sensor connections If you connected the optional RTD sensor you will need to change the sensor selection menu in the Hidden Access menus to get an accurate temperature sensor reading See sensor connections on previous page Once the unit is powered up and the proper sensor is connected the controller will display the current temperature If the current temperature does not appear to match the actual current temperature you will have an opportunity to calibrate the sensor If the display is showing Shrt or OPEn it means the sensor connection has a problem Shrt indicates there is a short in one of the wires of the sensor or in the sensor itself OPEn indicates a cut wire or open connection on one of the sensor s wires How the Controller Works When programming the TC 9102 temperature controller it is important to determine how the TC 9102 controller should operate for your specific application You will need to know if you are using the controller in a heating application a cooling application or with a dual stage unit it can even be used for both a heating and cooling application There are three different programming parameters that determine how the TC 9102 controller will operate for your specific application Dual stage units have separate programming parameters for each stage 1 Temperature Set Point The relays will always turn OFF or open when the temperature
19. product applications or customer application testing Custom Design amp Modifications Control Products specializes in complete design and manufacture of electronic controls In addition to making any desired modifications to this product we can design a unique control specific to your application Please consult our Customer Service Department for further information on these services CONTROL PRODUCTS Innovative Technologies in Custom Electronic Design amp Manufacturing Menu Flow Charts Powered up unit displays temp of any attached sensors If no sensors attached unit displays sensor p mi ny SP1 value is Program Temp Set message per spec Recommende i _ i ped i Sonne be attached before stage 1 MODE flashes UP DWN NTER gt ee a MOBE TA P proceeding with programming SP1 is displayed arrows to adjust y f MODE A MODE TO ACC
20. resent the function that is to be programmed Fora detailed explanation of all the program functions see page 7 WHAT HAPPENS DURING A POWER FAILURE All settings on the TC 9102 temperature controllers are saved in non volatile memory which means they will stay programmed even if the power is cut to the unit This is crucial during a power failure since the unit will return to normal operating function once the power is restored SAVING YOUR CHANGES To save your changes you MUST press the ENTER value whenever you make a change to any program setting EXITING THE MENUS You can exit the menus in one of several ways If you make changes you will need to press the ENTER button after every change or your values will not be saved 1 Pressing the button will cycle through each programming function and function value At the end of the menu the unit will go blank for several seconds and then return the current temperature to the display 2 Pressing and holding the button for five seconds will allow you to exit the menu without having to cycle through the menus 3 When a programming function is displayed you can press the down and up arrows to move through the various programming options to select the one you wish to change If you get to the last menu and press the down arrow one more time the unit s display will go blank for several seconds and then return with the current temperature displayed C CONTROL PRODUCTS Innovative Techn
21. ween heating and cooling that could cause a circuit breaker to trip FAILED TEMPERATURE SENSOR ALARM The TC 9102 can determine when the temperature sensor is defective or damaged and will alarm when such a condition occurs If the sensor has a cut wire or an open circuit the display will flash OPEn If there is a short in the sensor wire or the sensor element the display will flash Shrt All controller functions will cease to operate until the problem with the sensor is fixed Technical Support amp Contact Info If you have further questions about the operation of your TC 9102 Temperature Controller and Alarm please contact our Customer Service department in one of the following methods Phone 952 448 2217 MODELS AVAILABLE Made in USA Fax 952 361 9420 TC 9102S LV Single stage power 12 or 24 VAC 24 VDC Email customerservice controlproductsinc com TC 9102D LV Dual stage power 12 or 24 VAC 24 VDC Web www controlproductsonline com TC 9102S HV Single stage power 120 or 240 VAC TC 9102D HV Dual stage power 120 or 240 VAC Control Products Inc warrants this product to be free from defects in material and workmanship under normal use for one year and is not responsible for consequential damages or installation costs of any nature Exposure to contaminants and extreme environmental conditions such as moisture temperature chemicals etc may cause the unit to degrade or fail Control Products accepts no liability for
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