TE Technology TC-48-20 Instruction Manual

Thermoelectric cooler temperature controller

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Instruction Manual

Model TC-48-20

Model TC-48-20 OEM

Thermoelectric Cooler

Temperature Controller



15 90 K ean e Dr i ve

Tr a ver se Ci ty , M I 49 6 96 -8 2 57

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April 7, 2020

Drawing #4746 Rev. F

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Page 2 Do not use in an explosive or potentially explosive environment. The TC-48-20 should not be used as a toy, or serious injury could result. The TC-48-20 should only be used for its intended purpose of providing temperature control of TE Technology’s thermoelectric devices only.
Page 3 (including reasonable attorneys’ fees), injuries, liabilities or damages of any kind or nature whatsoever, arising out of the use or inability to use this TE Technology, Inc. product, from the omission or failure to use protection devices, or from failure to comply with this manual. This provision is in addition...
Page 4: Table Of Contents
Optional Multi-Speed Fan Control Setup ..................43 RS232 Communications Connections ................... 44 TC-48-20 Mechanical Package Drawing ..................45 TC-48-20 OEM Mechanical Package Drawing ................46 Standard Thermistors Available for TC-48-20................47 Appendix A Temperature versus Resistance Curves ..............48 Appendix B Serial Communications ....................49...
Page 5: License Agreement
TE TECHNOLOGY, INC. (TE TECH) License Agreement CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS BEFORE OPENING THIS PACKAGE OR SIGNIFYING YOUR ACCEPTANCE BY CLICKING THE APPROPRIATE DIALOG BOX. OPENING THIS PACKAGE, CLICKING THE APPROPRIATE DIALOG BOX OR USING ANY PART OF THE SOFTWARE SIGNIFIES YOUR ACCEPTANCE OF (1) THESE TERMS AND CONDITIONS FOR THE LICENSED SOFTWARE, AND (2) THE TERMS OF ACCEPTANCE OF TE TECH FOR ANY PRODUCTS PURCHASED FROM TE TECH.
Page 6 by others who have not been able to acquire the same through means expressly authorized in this agreement. You agree that, unless you first obtain the prior written consent of TE TECH ,or unless required by law, you shall not communicate or disclose, directly or indirectly, to any person or firm, or use at any time, any of the TE TECH’s proprietary information, except as provided in this Agreement.
Page 7 Michigan, or, alternatively, the U.S. District court for the Western District of Michigan. You hereby waive venue in any other forum. The provisions of the United Nations Convention on the International Sale of Goods shall not apply to this Agreement Should you have any questions concerning this Agreement, contact TE TECH by writing to: TE TECHNOLOGY, INC., 1590 KEANE DRIVE, TRAVERSE CITY, MI 49686.
Page 8: Features
The TC-48-20 can also be configured to control DC heaters. The TC-48-20 controller can be easily configured through its built in keypad. However, it can also interface with a computer through its serial port using the included software. The software provides all of the same configuration options that are available through the keypad plus additional programming features and the ability to log data to a computer.
Page 9 (OEM’s). It is intended to be used in locations where the controller can be protected by a secondary enclosure and where the display, keypad, and box cover are not needed. The TC-48-20 OEM controller is the basic control circuit from the TC-48-20 mounted on an aluminum plate. One MP-3193 thermistor, software and operation manual on CD are included with each controller.
Page 10 Main Features • Single or dual power supply configurations allow a wide range of output voltages: Single power supply configuration: ≥9 VDC, <50 VDC input, powering both controller and TE device Dual power supply configuration: ≥9 VDC, <50 VDC at 150 mA minimum for controller circuitry ≥0 VDC, <50 VDC for TE device •...
Page 11 Pulse-width modulated power output The TC-48-20 controller regulates the output power to the TE device using a method called pulse-width modulation (PWM). With PWM, power to the TE device is switched quickly "ON" and "OFF" at a constant frequency. This creates a square wave “pulse”...
Page 12 If you wish to limit the output voltage of the power supply to less than its full scale voltage you can adjust a controller parameter called the ANALOG OUTPUT MULTIPLIER. For example, assume you have chosen to use a Kepco RKW 24-65K model power supply. This is a 1500 watt power supply with a full-scale output of 24 V and 65 A.
Page 13: Operating Instructions
Set-Temperature will be skewed accordingly. A loss of resolution and control stability may occur as a result. The user assumes all risks associated with making any substitutions, and TE Technology assumes no liability whatsoever for the operation of the controller when a non-standard thermistor is used.
Page 14 The TC-48-20 can be used with either one or two separate DC power supplies, depending primarily on the nominal operating voltage of the TE device. If the maximum TE device input voltage is less than 9 V, then two power supplies must be used with the controller.
Page 15 It is further recommended that such devices require the user to remove and correct the root cause of a fault before allowing the TC-48-20, the load, and related equipment to be re-energized. Protection devices should include, but are not limited to: •...
Page 16 1.4.2 Two Power Supplies Operation: Make sure the power supplies are NOT energized while making electrical connections to the controller. a) Connect the constant DC voltage power supply, ≥9 V and <50 V, 150 mA minimum, to the controller (for powering the controller electronics): Positive (+) power supply terminal to JP5-6 Negative (-) power supply terminal to JP5-5...
Page 17 Turn on power to the power supply (which then powers the controller). When the controller is first turned on, it goes through an initialization sequence which shows the TE Technology website address and that the controller is indeed the TC-48-20. The display then switches to the primary screen.
Page 18 TE Technology’s standard thermoelectric cooling assemblies (TCA) usually have at least one fan on the heat sink. The standard configuration has the thermoelectric modules and fan(s) wired to a terminal block with jumpers across the terminals so that the fans and TE modules are connected electrically in parallel. However, this configuration is applicable only when applying power directly from the power supply.
Page 19 The printed circuit board underneath the JP4 terminal block can reach a normal operating temperature of approximately 90 °C. The controller specifications are based on using wires connecting to JP4 to meet UL 1015 requirements and have a wire size of 2.02 mm effective cross-sectional area, which is comprised of 41 strands of 0.254 mm diameter copper wire.
Page 20 Turn on power supply to the controller and power supply to the TE device if applicable and adjust controller settings as necessary. Controller tuning is discussed in section 3. Remember, the factory default is set to have output power to the TE device enabled when the controller is powered. This can only be turned off by using the software.
Page 21: Display And Menu Options
2.0 Display and Menu Options Note: this section applies only to the TC-48-20. Setup, programming, and communications with the TC-48-20 OEM controller can only be accomplished by using the computer software with the optional MP-3023 RS232 cable. Changes made to the controller using the keypad are always stored in the EEPROM regardless of EEPROM WRITE ENABLE setting.
Page 22 • Press the “MENU” button momentarily to select the parameter to be changed. • Press the Up/Down arrow keys to adjust the parameter value. • If there is more than one value for any given parameter the MENU key will scroll from the first value to the next value and then on to the next parameter.
Page 23 2.3.4 DERIVATIVE GAIN Values: 0.00 to 10.00 (cycles per minute) Default value = 0.00 Description: This senses the rate of change of the temperature and allows the controller to anticipate the power needed to compensate for rapid changes in the system loading. The derivate gain is generally used on very sluggish systems or where very quick response is necessary.
Page 24 2.3.8 TEMP OFFSET Values: -10.0 °C to +10.0 °C Default value = 0.0 °C Description: Offsets the control sensor value for both the display and control algorithm. 2.3.9 ALARM 1 TEMPS Values: -20 to 199 or OFF for HIGH setting; -20 to 199 or OFF for LOW setting Default value for HIGH = 60 Default value for LOW = -20 Description: This sets the high and low temperatures for signaling an alarm based on the control sensor...
Page 25 alarm condition, and the alarm 2 signal on JP5-11 is activated. When TURN OFF OUTPUT is selected, output power to the TE device is turned off, and the alarm 2 signal on JP5-11 is activated. The ALARM 1 and ALARM 2 outputs on JP5-10 AND JP5-11 will momentarily pulse on and off several times in the first second after the controller is turned on.
Page 26: Controller Tuning
3.0 Controller Tuning This tuning method follows the Ziegler-Nichols closed-loop tuning principals. Briefly, the controller will first be set to a high proportional bandwidth setting with no integral or derivative function (integral gain and derivative gain = 0). Then, the bandwidth is gradually decreased until the temperature approaches set point and a small, sustained oscillation in temperature is observed.
Page 27: Controller Software And Rs-232 Communication
MB of RAM). This process will install the National Instruments LabVIEW runtime engine, the TC-48-20.exe file, and various support files to your hard drive. The LabVIEW runtime engine is required since the TC-48-20.exe is actually an executable version of a LabVIEW .vi file. The computer will then ask you to restart. However, you might want to shut down the computer all the way first if you have not connected the controller to the serial port yet.
Page 28 The pop-up screen reminds you that you must first establish communication between the controller and the computer. Click the OK button to clear the pop-up screen. Next, click the COMMUNICATIONS PORT menu key and select the port to which you have the controller connected.
Page 29 The controller software settings are arranged into six sections: CONTROL TEMPERATURE TEMPERATURE SENSOR CONTROLLER OPTIONS CONTROL MODE ALARMS OUTPUT The options for each section box are revealed when you click the corresponding SELECT button. This opens up a menu box next to the left of the graph box. When you make a change to any of the menu options, the controller is updated immediately.
Page 30 CONTROL TEMPERATURE box This shows the set temperature for the controller. The menu options allow for adjustment of the set temperature, whether a temperature from the secondary thermistor is displayed, and for adjusting the high and low limits of the set temperature.
Page 31 TEMPERATURE SENSOR box This shows the present temperature of the control sensor and the secondary sensor. The menu options allow for selecting which temperature-resistance curve the controller is to reference for reporting the present temperatures of the thermistors. The 15K sensor type should be selected if using the MP-3193, MP-2444, or MP-2542 thermistor.
Page 32 This allows the controller to remember its settings even after power to the controller has been turned off. The TC-48-20 and TC-48-20 OEM automatically turn on EEPROM WRITE ENABLE when power is applied to the controller regardless of whether EEPROM WRITE ENABLE was turned off when power to the controller was removed.
Page 33 Alternatively, you can click the GO button next to the “DOWNLOAD CUSTOM DEFAULTS” label to download customized settings from a pre-configured, comma-delimited text file which is saved in the C:\Program Files\TE Technology\TC-48-20\custom settings.csv (unless you changed your default install directory). You can change these settings as needed.
Page 34 ALARMS box The ALARM indicator will be grey if no alarm condition exists. It will flash between yellow and red if an alarm condition exists. The menu provides for adjusting alarm settings. The ALARM STATUS text box will indicate the nature of the alarm if an alarm conditions exists. NO LATCHES: if an alarm condition clears itself, the alarm will automatically reset.
Page 35 The ALARM 2 HIGH SETTING, ALARM 2 LOW SETTING, and ALARM 2 DEADBAND function in the same manner as described above for ALARM 1 settings except that they are referenced to the secondary sensor. OUTPUT SHUTDOWN WITH ALARM1: if this option is turned on and an alarm condition occurs relative to the primary sensor, then the controller will shut power off to the TE device.
Page 36 AUTOSCALE VERTICAL AXIS button Clicking this button automatically scales the graph so that all data plots can be seen. You can also right-click on the axes for further options or enter minimum and maximum Y-axis numbers directly to rescale.
Page 37: Controller Schematic
Controller Schematic TE DEVICE (LOAD) (shown in cooling mode) JP4-3 JP4-4 POWER JP5-10 ALARM 1 OPEN DRAIN; 48 V, 1 A MAXIMUM JP5-1 CONTROL SENSOR JP5-2 CONTROL SENSOR JP5-3 SECONDARY SENSOR JP5-4 SECONDARY SENSOR JP5-11 ALARM 2 OPEN DRAIN; 48 V, 1 A MAXIMUM JP5-12 4000 OHMS 0 TO 5 V OUTPUT DRIVE...
Page 38: Controller Hookup Diagram (One Power Supply Setup)
When one or more external fans are used on the TE device, these should be wired directly to a fixed voltage power supply for constant operation. When connecting the controller to a TE Technology Thermoelectric Cooling Assembly (TCA) verify that the electrical jumpers (shorts) located on the TCA terminal block are installed/removed per the...
Page 39: Controller Hookup Diagram (Two Power Supplies Setup-Option 1)
≥9 V, <50 V, 150 mA minimum FUSE OPTIONAL THERMOSTAT AND SECONDARY OTHER PROTECTIVE THERMISTOR DEVICES CONTROL THERMISTOR TE DEVICE DC POWER SUPPLY ≥0 V, <50 V, 20 A maximum TE DEVICE (COOLING MODE CONNECTION SHOWN) TC-48-20 Thermoelectric Temperature Controller  ...
Page 40: Controller Hookup Diagram (Two Power Supplies Setup-Option 2)
16 V, 150 mA minimum FERRITE BEAD output plug: 5.5 mm OD x 2.1 mm ID x 9.5 mm, female FAIR-RITE PN: 0431173951 suggested power supply: PS-15-0.4 from SUPPLIED WITH PS-15-0.4 TE Technology, Inc. FUSE THERMOSTAT AND OTHER PROTECTIVE DEVICES CONTROL...
Page 41: Linear Control Hookup Diagram
SUPPLIED WITH PS-15-0.4 CONTROLLER DC POWER SUPPLY ≤ ≥9 V, 16 V, 150 mA minimum output plug: 5.5 mm OD x 2.1 mm ID x 9.5 mm, female suggested power supply: PS-15-0.4 from TE Technology, Inc. TC-48-20 Thermoelectric Temperature Controller  ...
Page 42: Optional External Alarms Setup
Other loads, requiring up to 1 amp of current, can also be controlled FUSE THERMOSTAT AND OTHER PROTECTIVE DEVICES ALARM INDICATORS CURRENT LIMITING RESISTORS CONTROL OPTIONAL THERMISTOR SECONDARY THERMISTOR POWER SUPPLY ≥9 V, <50 V, 20 A maximum TE DEVICE (COOLING MODE CONNECTION SHOWN) TC-48-20 Thermoelectric Temperature Controller  ...
Page 43: Optional Multi-Speed Fan Control Setup
OTHER PROTECTIVE CONTROL OPTIONAL DEVICES THERMISTOR SECONDARY THERMISTOR POWER SUPPLY ≥9 V, <50 V, 20 A maximum TE DEVICE (COOLING MODE CONNECTION SHOWN) TC-48-20 Thermoelectric Temperature Controller   NOTE: ADJUST ALARM DEADBAND TO PREVENT FAN SPEED FROM RAPIDLY CYCLING.
Page 44: Rs232 Communications Connections
* CHECK YOUR PC MANUAL TO CONFIRM   Note: the RS232 cable is not included as a standard accessory. However, TE Technology can provide this as optional accessory, part number MP-3023. If using the MP-3023, connect the leads as follows: red lead to JP5-9...
Page 45: Tc-48-20 Mechanical Package Drawing
TC-48-20 Mechanical Package Drawing 34.0 4.24 6.25 TC-48-20 Thermoelectric Temperature Controller 105.7 94.0 60.5   119.5 134.5 148.0 NOTE: ALL DIMENSIONS IN MILLIMETERS...
Page 46: Tc-48-20 Oem Mechanical Package Drawing
TC-48-20 OEM Mechanical Package Drawing 2X 52.4 104.8 106.4 10.3 31.8, MAX NOTE: ALL DIMENSIONS IN MILLIMETERS...
Page 47: Standard Thermistors Available For Tc-48-20
Standard Thermistors Available for TC-48-20 Note: All dimensions in millimeters. Standard 15 k-ohms. Ø3.61 25.4 (2) 26 AWG STRANDED WIRE, THRU UL1430, IRRADIATED CROSS-LINKED EPOXY FILL PVC INSULATION, ORANGE 3.18 3.94 6.35 6.35 SQ. 914.4 ALUMINUM BLOCK MP-3193 MP-3193 MP-2444...
Page 48: Appendix A Temperature Versus Resistance Curves
Appendix A Temperature versus Resistance Curves for MP-3193, MP-2444, and MP-2542 Thermistors (15 k-ohm) 146735 146735 46709 46709 17136 17136 7075 7075 3227 3227 1601 1601 138447 138447 44397 44397 16388 16388 6801 6801 3115 3115 1551 1551 130677 130677 42213 42213 15676...
Page 49: Appendix B Serial Communications
2 ASCII hex characters. The checksum calculation excludes the characters (stx), SS, and (etx). TC-48-20 sums (in an 8-bit register) the ASCII values of the characters sent to/from the controlling computer. Any overflow is truncated, leaving the 8-bit (modulo 256) checksum.
Page 50 II. Examples: A) Send the set temperature of 10.0 to the controller. 1. The control command, CC, for “DESIRED CONTROL TEMPERATURE (SET TEMPERATURE)” is 2. Multiply the desired set-point temperature by 10 (10.0 x 10 = 100 3. Convert 100 decimal to hexadecimal (64 ) and add on leading zeros to make the eight- character send value DDDD (0064).
Page 51 The 8-bit checksum is the 8 least significant binary bits of the sum, represented as 21 in hexadecimal. 4. Combining the characters in one string we send: (stx)0100021(etx). 5. If the temperature controller receives the command and the checksum is correct, it will send back: (stx)0019ca(ack).
Page 52 It is possible for a host computer to send data too quickly for the controller to receive and update. If communications is disrupted are disrupted after repeated queries, TE Technology recommends adding a delay between each command sent to allow the controller sufficient time to process and respond to the query.
Page 53 5. ALARM STATUS Write Command: NA Read Command: 03 Interpret: Convert the hex number to binary and interpret bits as follows: All zeros==means no alarms. Bit 0==1 means HIGH ALARM 1. Bit 1==1 means LOW ALARM 1. Bit 2==1 means HIGH ALARM 2. Bit 3==1 means LOW ALARM 2.
Page 54 10. ALARM1 TYPE Write Command: 27 Read Command: 5b Interpret: 0 no load effect. 1 load off on alarm. 11. ALARM2 TYPE Write Command: 2a Read Command: 5e Interpret: 0 no load effect 1 load off on alarm 12. SENSOR CHOICE Write Command: 20 Read Command: 54 Interpret:...
Page 55 19. ALARM 2 LOW SETTING Write Command: 28 Read Command: 5c Interpret: Temperature reference to compare against secondary sensor for high alarm output. Temperatures are in whole degree increments. To turn the low alarm OFF set the alarm temperature to -21 (ffeb 20.
Page 56 NOTE: this command valid only for firmware versions H and higher. EEPROM WRITE ENABLE is automatically turned “ON” whenever the controller is turned on. Note: for the TC-48-20 only, regardless of the EEPROM WRITE ENABLE setting, changes made to parameters via keypad are automatically stored in the EEPROM.
Page 57 V. ASCII Reference Table Dec Oct Hex Binary Description 000 000 00 00000000 ^@ ^` NULL NUL null c-@ c-` 001 001 01 00000001 ^A ^a SOH GTL c-A c-a start-of-heading 002 002 02 00000010 ^B ^b STX c-B c-b start-of-text 003 003 03 00000011 ^C ^c ETX c-C c-c end-of-text 004 004 04 00000100 ^D ^d EOT SDC end-of-transmission c-D c-d ..._._ 005 005 05 00000101 ^E ^e ENQ PPC c-E c-e enquiry...
Page 58 050 062 32 00110010 2 051 063 33 00110011 3 052 064 34 00110100 4 053 065 35 00110101 5 054 066 36 00110110 6 055 067 37 00110111 7 056 070 38 00111000 8 057 071 39 00111001 9 058 072 3A 00111010 : colon 059 073 3B 00111011 ;...
Page 59 104 150 68 01101000 h 105 151 69 01101001 i 106 152 6A 01101010 j 107 153 6B 01101011 k 108 154 6C 01101100 l 109 155 6D 01101101 m 110 156 6E 01101110 n 111 157 6F 01101111 o 112 160 70 01110000 p 113 161 71 01110001 q 114 162 72 01110010 r...

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