TCM120 Operation Manual

TCM120 

Operation Manual 

This manual covers operation of the tcm120, tcm121, tcm122, tcm123, tcm125, and the 

European version tcm121E. The term “tcm120” is used throughout this manual as the 

generic name for this family of temperature controllers. Likewise, the term “itc2200” is 

the generic name for a family of heating system cabinets that includes the itc2208, 

itc2216 and the itc2224. 

Revision Level 3.00 

March, 2000 

VTI, Incorporated 

24 McMillan Way 

Newark, DE 19713 

Phone (302) 738−0500 

FAX (302) 738−6594 

Manual No. 90001853

Table of Contents 

Introduction 1 

Module 1: Understanding the Function of the tcm120 2 

Module 2: Managing the tcm120: Powering Up, Shutting Down, and Moving 8 

Module 3: Reading the LEDs and the Display Screen 13 

Module 4: Using the tcm120 Keys 18 

Module 5: Accessing Parent Menus and Their Submenus 26 

Module 6: Responding to tcm120 Alarms 41 

Module 7: Commencing System Startup 52 

Appendix A: Changing the JP1 Jumper Configuration 60 

Appendix B: Guide to tcm120 Input and Output Options 61 

Appendix C: Guide to Maximum Heater Resistance 

62 

Appendix D: Guide to Self−Limiting Heating Cable Constants 65 

Appendix E: Default tcm120 Configuration Parameters 67 

Appendix F: Revisions 70

Introduction to the Manual 

This manual is divided into seven modules. Each module includes a list of learning 

objectives, and some modules include exercises that provide an opportunity for you to 

practice the operations covered in the module. 

This manual assumes that you have a basic understanding of heating systems and heat 

monitoring terminology, and that you are familiar with the process that the tcm120 

monitors and controls. 

To use this manual, you need a tcm120 in front of you so that you can do the exercises in 

the modules. This tcm120 should be electrically powered, but it should not be attached 

to a heating zone. If you do not have a spare tcm120, disconnect the load from one 

tcm120 within your heating system so that you can complete the exercises in this tutorial. 

Note: The JP1 jumper configuration within the tcm120 hardware is factory−set at VTI 

and determines what functions you can perform on a particular tcm120. If an action is 

not permitted, the tcm120’s display screen shows the code ENBL. If the tcm120 you are 

using does not allow you to do an exercise in this tutorial, the JP1 jumper may need to 

be changed. For instructions on changing the JP1 jumper configuration, See Appendix 

A. 

Before proceeding with this manual, meet with the process engineer overseeing your 

operations to discuss what variables you will be monitoring and what functions you will 

be performing. 

After completing this manual, you will be able to 

> explain the information communicated on the front panel 

> use the keys to access data and set parameters 

> respond to alarms, and 

> commence system startup 

tcm120 Operation Manual/Rev. 3.00 3 

Introduction

Module 1 

Understanding the Function of the tcm120 

In this module, you learn the function of the tcm120 temperature controller and 

your role as an operator. 

Learning Objectives 

After completing this module, you will be able to 

> discuss the function of the tcm120 temperature controller 

> describe the itc2200 cabinet 

> describe the font panel of the tcm120 


Module 1

Introduction to the tcm120 

The tcm120 temperature controller is used to monitor and regulate individual heating 

circuits or zones within a heating system. The tcm120 helps prevent expensive damage 

to heating systems (such as heater damage due to groundfault currents) and freezing of 

process materials in pipes. The tcm120 alarms alert you when the heating zone is not 

operating within the desired parameters. 

For example, a tcm120 may be connected to a heating cable on a long pipeline that is at 

risk of freezing in winter. The tcm120 monitors and controls the temperature of the pipe. 

If the pipe’s temperature falls a pre−set amount below the set point (desired temperature), 

the tcm120 sets off a low temperature alarm to alert you. 

You can adjust the heating zone parameters to meet your particular application 

requirements. To make these adjustments, you use keys on the tcm120’s front panel to 

access one of the menus you will learn about in Modules 5 and 6. Through the menus, 

you can change the operating parameters of the heating zone and the tcm120, and enable 

and disable the alarms. 

As an operator, your primary task is to monitor the tcm120 and to respond to alarms. To 

respond to an alarm, you need to understand how to read the front panel of the tcm120 

and how to use the keys to access menus in the controller. 


Module 1

The tcm120: 

A Communication Center and Controller 

The tcm120 is a small computer that acts as a control and communication center between 

you and a heating zone. Figure 1 shows the communication flow between you and the 

heating zone through the tcm120. 

Data/Info Instructions 

Heating 

Zone Instructions tcm120 Data/Info You 

Figure 1. 

You can give instructions to the tcm120 to obtain information about the heating zone or 

to change the operating conditions of the heating zone. 


Module 1

The itc2200 Cabinet 

As shown in Figure 2, a tcm120 is positioned in an itc2200 cabinet with up to 23 other 

tcm120s. Depending on what model cabinet you are using, you may have one, two, or 

three racks. Each position in the racks is assigned an address (R1−1 through R3−8) that 

corresponds to the individual circuit breaker (CB1−1 through CB3−8) that controls 

power to the zone. Each itc2200 cabinet also has a main circuit breaker. 

Figure 2. 


Module 1

The tcm120’s Front Panel 

You can perform all functions from the front panel of the tcm120. As shown in Figure 3, 

the front panel contains a four digit alphanumeric display screen, 10 circular Light 

Emitting Diodes (LEDs), and six keys. 

Figure 3. 

The tcm120’s screen reveals information that the tcm120 has learned about the heating 

zone and displays new instructions as you enter them into the controller. Module 3 

explains the LEDs and their use. Module 4 explains the keys and their use. 


Module 1


Module 1

Module 2 

Managing the tcm120: 

Powering Up, Shutting Down and Moving 

In this module, you learn how to power up, shut down, and move a tcm120. 



> start up and shut down a tcm120 

> define three precautions necessary in handling a tcm120, and 

> move a tcm120 


Module 2

Powering Up the tcm120 

Because it is designed to run continuously, the tcm120 is powered up only at first use or 

if you need to turn it back on after power or equipment failure. Figure 4 shows the 

location of the main circuit breaker, which supplies power to the entire itc2200 cabinet, 

and the individual circuit breakers that are connected to individual tcm120s. 

Figure 4. 

Although you will learn in this module how to power up the tcm120, you should not 

actually start up your heating system until you have completed Modules 1−7. You will 

then be ready to operate a tcm120 that is connected to an actual heating zone. Module 7 

will walk you through starting up your system and answer common questions. 


Module 2

To power up the tcm120: 

1. Flip on the main circuit breaker, located at the bottom of the distribution section of 

the itc2200 cabinet. 

2. Flip on the individual circuit breakers, located in the distribution section of the 

itc2200 cabinet, for each tcm120 zone. 

The four−digit alphanumeric display lights up on each tcm102 after a few seconds, 

indicating that the tcm120 is powered up. 

(Note: Powering up may falsely trip the watch dog timer alarm or other alarms due to 

turn−on transients. Module 6 discusses how to respond to alarms.) 

Shutting Down the tcm120 

Because the tcm120 runs continuously, you will need to shut it down only for repair 

work. 

If repair work is taking place in a particular zone, always turn off the individual 

breaker for that zone. 

To shut down a single tcm120, flip off the individual circuit breaker, located in the 

distribution section of the itc2200 cabinet, for the zone you want to shut down. 

To shut down all tcm120s in the itc2200 cabinet: 

1. Flip off the individual circuit breakers, located in the distribution section of the 

itc2200 cabinet, for each tcm120 zone (24 breakers). 

2. Flip off the main circuit breaker, located at the bottom of the distribution section of 

the itc2200 cabinet. 


Module 2

Moving the tcm120 

Moving a tcm120 may become necessary 

> if a tcm120 malfunctions, or 

> if repair work is being done in the corresponding zone 

Handling electrical equipment is hazardous, so it is important to follow safety 

instructions carefully. 

Always turn the individual breaker off before removing, replacing, or inserting a 

tcm120. 

The tcm120 is sensitive to static when not enclosed in the itc2200 cabinet. To protect the 

tcm120 from static discharge, keep it wrapped in static free bubble packaging when it is 

not in the itc2200 cabinet. 

To avoid static shock, handle the tcm120 by picking it up with two hands, touching 

only the front panel and rear connector. 

Do not touch the components on the circuit board. 

Removing a tcm120 

To remove a tcm120: 

1. If the master circuit breaker is off, proceed to Step 3. 

2. If the master circuit breaker is on, you must turn off the individual circuit breaker 

corresponding to the particular tcm120. 

3. Remove the screws from the four corners of the front panel 

4. Remove the tcm120 from the rack by pulling on the handle located at the bottom of 

the front panel. 


Module 2

Inserting a tcm120 

To insert a new tcm120 or a tcm120 you have taken from another zone: 

1. If the master circuit breaker is off, proceed to Step 3. 

2. If the master circuit breaker is on, you must turn off the individual circuit breaker 

corresponding to the particular tcm120. 

3. Insert the tcm120 into the rack. 

4. Position the four screws on the corners of the front panel, and tighten them. 

Resetting Parameters 

Each of the tcm120’s operating parameters is preprogrammed by VTI prior to shipment 

for the particular specifications of the heating zone that the tcm120 is intended to control. 

The tcm120 has a small memory capacity that can remember these operating parameters 

even when it is unpowered. When a tcm120 is moved to a new zone, however, you 

consult with the process engineer to set up new parameters for that zone. Module 5 

explains how to change operating parameters. 


Module 2

Module 3 

Reading the LEDs and the Display Screen 

In this module, you learn what information is communicated by the two rows of 

circular Light Emitting Diodes (LEDs) on the tcm120’s front panel. You also learn 

about seven process variables that you can access from the front panel to monitor the 

heating zone. 



> name the LEDs in the top row and describe the function of each 

> name the LEDs in the bottom row and describe the function of each, and 

> explain the seven process variables that you can access from the front panel to 

monitor the heating zone 


Module 3

Reading the LEDs in the Top Row 

The five LEDs in the top row of the front panel correspond to important information 

about the heating zone, such as the present temperature, temperature deviation from the 

set point, and the voltage applied to the heating element. Figure 5 shows the position of 

the five LEDs in the top row. 

Figure 5. 

The display screen between the two rows of LEDs communicates values for the 

following five process variables of the heating zone when the corresponding LED is lit: 

Temp Present temperature of the heating zone in degrees Fahrenheit or degrees 

Celsius. 

T Dev Difference between the temperature of the zone and the desired 

temperature, called the set point (T Dev= Temp − Set Pt). A negative 

T Dev indicates that the zone’s temperature is less than the set point; a 

positive T Dev indicates that the zone’s temperature is greater than the 

set point. 


Module 3

Volt Voltage applied to the heating element. 

Cur Current flowing in the heating element. 

Set Pt Desired temperature or set point 

You will learn in Module 4 how to use the [INDEX] key to access the five LEDs in the 

top row to determine the corresponding value of the process variable for the zone you are 

monitoring. 

Two additional process variables, resistance and ground current, are also accessible from 

the front panel, even though there are no corresponding LEDs. The value shown on the 

screen when you access these process variables indicate the resistance or the ground 

current of the heating element, depending on which process variable you have selected. 

Module 4 explains how to use the [INDEX] key to access the resistance and ground 

current of the heater. 


Module 3

Reading the LEDs in the Bottom Row 

The LEDs in the bottom row also provide important information. Figure 6 shows the 

position of these LEDs. 

Figure 6. 

Man The amber LED in the center, Man, indicates whether the tcm120 is in 

manual or automatic mode. 

When the LED is lit, the controller is in manual. When the LED is not 

lit, the controller is in automatic mode. The controller usually remains 

in automatic mode, but you can use the manual mode to override the 

existing controller output voltage. 


Module 3

° F and ° C The green LEDs on either side of the Man LED indicate whether the 

displayed temperature is in Fahrenheit or in Celsius. Either the °F LED 

or the °C LED is always lit when the tcm120 is powered up. 

Alarm L The red LED at the left end of the row lights if the heating zone falls 

below a specified parameter. 

Alarm H The red LED at the right end of the row lights if the heating zone 

exceeds a specified parameter. 


Module 3

Module 4 

Using the tcm120 Keys 

In this module, you learn the functions of the six tcm120 keys, how to obtain 

information from the heating zone, and how to enter instructions into the tcm120. 



> define the purpose of each key 

> use the keys to monitor the temperature, temperature deviation, voltage, 

current, set point, resistance, and ground current, and 

> use the keys to change the voltage and set point 


Module 4

Using the Keys 

The six black keys positioned on the lower portion of the front panel allow you to 

monitor the heating zone and communicate instructions to it. Figure 7 shows the position 

of the six keys. 

Figure 7. 


Module 4

The keys are used for the following purposes: 

[INDEX] The [INDEX] key is used to move sequentially through the seven 

process variables you learned about in Module 3 and through the 

four parent menus (groups of submenus) that will be explained in 

Module 5. 

[q] and [p] The [q] and [p] keys have a variety of functions. They can 

decrease and or increase the value of the number showing on the 

display screen, or provide access to submenus from the parent 

menus. Module 5 explains submenus and parent menus. 

[ENTER] The [ENTER] key tells the tcm120 that you have finished creating 

a new instruction. Pressing the [ENTER] key prompts the tcm120 

to record the new data. 

[RESET] The [RESET] key has a dual function: it acknowledges alarms 

and also resets enabled alarms that require a manual reset. Module 

6 explains how to respond to alarms. 

[AUTO/MAN] The [AUTO/MAN] key allows you to toggle between auto and 

manual operation. Recall that the manual (or automatic) mode is 

indicated by the amber colored LED on the bottom row. In the 

automatic mode, the tcm120 controls the heater voltage to produce 

the exact amount of heat necessary to hold the zone temperature 

equal to the set point temperature. The manual mode allows you 

to change the heater voltage to whatever value you choose. 


Module 4

Exercise: 

In this exercise you will use the [INDEX] key to access the seven variables 

you learned about in Module 3. 

Press the [INDEX] key successively until the Temp LED lights up, as shown 

in Figure 8. You are now at the beginning of the process variable sequence. 

If your tcm120 is connected to a heating zone, the actual temperature of the 

heating zone is indicated on the display. 

Figure 8. 

Press the [INDEX] key again, and the T Dev LED lights up. Notice the 

temperature deviation indicted on the screen. The temperature deviation is 

the difference between the actual temperature of the heating zone (shown 

when the Temp LED is lit) and the set point (shown when the Set Pt LED is 

lit). 


Module 4

If your tcm120 is connected to a heating zone, the actual temperature deviation is 

indicated on the display. 

Press the [INDEX] key again, and the Volt LED lights up. Notice the 

voltage indicated on the screen in volts. The numbers on the screen may be 

changing constantly if the voltage being applied to the heating element is 

changing. 

Press the [INDEX] key again, and the Cur LED lights up. Notice the actual 

heating element current indicated in amps on the screen. 

Press the [INDEX] key again, and the Set Pt LED lights up. Notice the set 

point temperature indicated on the screen. 

Press the [INDEX] key again and notice that no LED lights up, as shown in 

Figure 9. Notice the resistance indicated in ohms on the screen: three 

numbers followed by an R. 

Figure 9. 


Module 4

Press the [INDEX] key again and notice that no LED lights up, as shown in 

Figure 10. Notice the ground current display in milliamps on the screen: 

three numbers followed by a G. 

Figure 10. 

Press the [INDEX] key four times until you see the Temp LED light up 

again. The three selections that follow the ground current process variable 

do not have LEDs. These selections are parent menus that you will learn 

about in Module 5. 


Module 4

Changing Voltage and Set Point 

All the process variables read information from the electrical heating zone and 

communicate it to you. You can also enter information into the electrical heating zone 

through the third and fifth process variables, Volt and Set Pt by using the keys on the 

front panel. 

To change the voltage, use the [INDEX] key to select the Volt process variable; then, 

press the [AUTO/MAN] key to access the manual mode. To decrease or increase the 

voltage, use the [q] and [p] keys. The voltage changes as the display changes; you do 

not need to press the [ENTER] key. To restore the automatic mode, press the 

[AUTO/MAN] key. 

To change the set point, use the [INDEX] key to select the Set Pt process variable. To 

decrease or increase the set point, use the [q] and [p] keys to change the displayed 

value. Then press the [ENTER] key to record the data. The tcm120 blinks to indicate it 

has accepted the data as the new set point. 

Exercise: 

In this exercise you will increase the heater voltage to full scale for maximum 

heat. 

Use the [INDEX] key to select Volt. 

Press the [AUTO/MAN] key to access the manual mode. 

Press the [p] key and hold it depressed until the voltage reaches full scale. 

When maximum heat is no longer needed, press the [AUTO/MAN] key to 

restore automatic mode. The tcm120 will resume controlling according to the 

set point temperature. 


Module 4

Exercise: 

In this exercise you will increase the set point by five degrees.. 

Use the [INDEX] key to select Set Pt. 

Press the [p] key to increase the displayed value by five degrees. 

After obtaining the desired temperature in the display, press the [ENTER] 

key to enter the data. 

The tcm120 indicates it has accepted the data as the new set point by 

blinking. 


Module 4

Module 5 

Accessing Parent Menus and Their Submenus 

In this module, you learn the functions of the parent menus and how to access 

their submenus. You also learn the difference between numeric and discrete menus, and 

how to change operating parameters. 



> explain the functions of the three parent menus accessible to the operator 

> access these parent menus and their submenus, 

> define the difference between numeric and discrete menus, and 

> change operating parameters 


Module 5

Accessing the Parent Menus 

Three parent menus follow the ground current process variable. The parent menus do not 

have corresponding LEDs. 

(Note: a fourth parent menu, CALB, is not visible or accessible to the operator from the 

front panel. Access to the CALB parent menu, which allows calibration of internal 

tcm120 operating constants, is blocked by the JP1 jumper configuration. The tcm120 is 

factory−calibrated prior to shipment and does not normally require field calibration of 

operating constants in this parent menu. Only factory representatives or other qualified 

persons should alter the calibration settings in the CALB parent menu.) 

The parent menus can be accessed in sequence by pressing the [INDEX] key. When you 

access a parent menu, a four−letter abbreviation appears on the display screen. 

CNFG allows you to configure operating parameters 

CONT allows you to adjust control loop parameters 

ALRM allows you to select alarm actions and enter the alarm set points 

Each parent menus has a number of submenus. This module covers the submenus for the 

configuration (CNFG) and control (CONT) parent menus, with which you should be 

familiar. However, you will rarely use these menus, except as directed by the process 

engineer. The alarm (ALRM) parent menu and its submenus will be covered in Module 

6. 


Module 5

Submenus: 

Discrete versus Numeric 

Submenus—either discrete or numeric—define a particular parameter or command that you 

can change. A discrete submenu requires you to choose from a limited number of 

possible selections. A numeric submenu allows you to choose a value by decreasing or 

increasing the number on the display screen. 

In discrete submenus, press the [q] or [p] key to select the desired option. In numeric 

submenus, press the [q] or [p] key to decrease or increase the value. For both kinds of 

submenus, press [ENTER] to record the data. The tcm120 signals it has recorded the 

data by blinking. 

Accessing the Submenus 

The [INDEX] key allows you to move through the seven process variables and three 

parent menus to survey the information available to you about the heating zone or to 

access a parameter you want to change. To access the submenu list within a parent 

menu, press the [q] key. The first submenu will be displayed. 

To go to the next submenu, press the [INDEX] key. To enter any submenu, press the [q] 

key. Within a submenu, the [q] and [p] keys allow you to select either discrete or 

numeric options as previously discussed. To return to the parent menu after accessing 

the submenu options, press the [INDEX] key to return to the submenu loop; then press 

[p] to return to the parent menu. 

The charts on the following three pages show the location of the submenus within the 

CNFG, CONT, and ALRM parent menus. 

The exercises in Modules 5 and 6 offer an opportunity to practice using the [q] and [p] 

keys and the [INDEX] key to access the submenus. 


Module 5

MENU CHART 1 CNFG 


Module 5

MENU CHART 2 CONT 


Module 5

MENU CHART 3 ALRM 


Module 5

The CNFG Menu 

The configuration parent menu allows you or the process engineer to manipulate 

operating parameters. The menu contains 17 submenus. 

The following chart lists the submenus in the order they appear on the display screen 

when you access them. The second column explains the function of each submenu. The 

third column lists the options for discrete submenus and ranges for numeric submenus 

and ranges for numeric submenus. 

Submenu 

Submenu 

Function 

Function 

CNFG Parent Menu 


Discrete Submenu Options Or 

Numeric Submenu Ranges 

TEMP 

Sets temperature unit display. F – Fahrenheit 

C– Celsius 

TFB Sets source for temperature RTD – Resistance Temperature 

measurement. 

Device 

T/C – Thermocouple 

RES – Resistance Inference 

XMIT – Remote 4−20 mA 

Transmitter (see X4 and X20 

submenus for range selection) 

T/C Sets thermocouple type. 

J – Type J Thermocouple 

K – Type K Thermocouple 

X4 Sets temperature in degrees 

corresponding to the 4 mA signal 

from an external transmitter (cannot 

exceed limits set by RMIN and 

RMAX values.) X4< X20. 

Range : 0( C to 1300( C 

X20 Range : 0( C to 1300( C 

Sets temperature in degrees 

corresponding to the 20 mA signal 

from an external transmitter (cannot 

exceed limits set by RMIN and 

RMAX values.) X20 > X4. 




Module 5

RMIN Sets minimum temperature to be 

measured by the controller in 

Range : 0( C to 1300( C 

degrees. It is used internally to scale 

all temperature values. RMIN < 

RMAX 

RMAX 

Sets maximum temperature to be 

measured by the controller in 

Range : 0( C to 1300( C 

degrees. It is used internally to scale 

all temperature values. RMAX > 

RMIN. 

OUT Sets output selection. PHAS – Phase Controlled Output 

PRO – Time Proportioned Output 

REMI – Isolated 4−20 mA Output 

(Requires 4−20 mA output option 

to be installed. See X4 and X20 

submenus for range selection.) 

SP Sets source for process set point. LOC – Local Source, i.e., Front 

Panel 

COMP – Remote Source via 

Serial Interface; LOC locked out 

REMI – Remote 4−20 mA 

Transmitter (See X4 and X20 

submenus for range selection.) 

BAUD Sets baud rate for serial interface. 150 baud 

300 baud 

600 baud 

1200 baud 

1800 baud 

2400 baud 

4800 baud 

9600 baud 


Module 5

Submenu 

ILIM 

RNOM * 


Function 

Sets output current limit in amps 

(only effective if phase fired SCRs 

are used as output mode.) 

DEF Sets default display (activated 

when front panel operations not 

conducted for 15 minutes). 

REV Shows current software revision 

(cannot be changed from front 

panel). 



Range: 

0 to 20 amps for tcm120 series 

0 to 5 amps for tcm125, and 

0 to 25 amps for tcm121E. 

Sets default heater resistance in Normally set at 10 or at the 

ohms. Used by tcm120 in resistance approximate nominal resistance of 

inference mode whenever controller the heater when the heater is 50( 

output is


Submenu 

Function 

W0 Modeling constant for particular 

self−regulating heating cable being 

used (used in resistance inference 

mode only). 

W1 Modeling constant for particular 

self−regulating heating cable being 

used (used in resistance inference 

mode only). 

VMAX** Input power voltage to controller, 

usually 120, 208 or 240 volts 



As required. See Appendix D for 

details. 

As required. See Appendix D for 

details. 

Range 0 to 250 volts 

** The tcm120 cannot achieve full output because there will always be some voltage 

loss due to the tcm120’s solid state power switching device, the circuit breakers in 

the itc2200 cabinet, and the typical voltage loss through wiring that always occurs in 

an electrical system. Consequently, the maximum output voltage is 112 − 115 volts 

on a 120−volt system, 200 − 203 on a 208−volt system and 232−235 volts on a 240− 

volt system. 


Module 5

Exercise: 

In this exercise you will change the temperature scale from Fahrenheit to 

Celsius or vice versa. 

Access the CNFG parent menu. 

Press the [q] key to move to the submenu, TEMP. 

Press the [q] key again to enter the submenu, TEMP. You will see either F 

or C on your screen. The letter indicates the temperature scale that is 

presently used (Fahrenheit or Celsius, respectively). 

You can change F to C or C to F by pressing the [q] or [p] key. When you 

have selected the desired temperature scale, press [ENTER] to register it as 

the new temperature scale. 

The tcm120 indicates it has accepted the data by blinking. Note that the 

corresponding °F or °C LED on the front panel is now lit to indicate the new 

temperature scale. 

Press the [INDEX] key to exit the Temp submenu and go to the next 

submenu, TFB, within the CNFG parent menu.. 

Press the [p] key to return to the CNFG parent menu. 


Module 5

Exercise: 

In this exercise, you will set the baud rate to 1200. 

Access the CNFG parent menu 

Press the [q] key to access the first submenu in the CNFG parent menu; then 

press the [INDEX] key to move to the submenu, BAUD. 

Press the [q] key to enter the BAUD submenu. 

Press the [q] or [p] key to move to 1200. 

Press [ENTER] to register 1200 as the new value. 

The tcm120 indicates it has accepted the data by blinking. 

Press the [INDEX] key to exit the BAUD submenu and to go the next 

submenu, ILIM, within the CNFG parent menu. 

Press the [p] key to return to the CNFG parent menu. 

The CONT Menu 

The control parent menu permits you or the process engineer to change control loop 

parameters. The tcm120 uses PID control when utilizing thermocouple, RTD, or remote 

transmitter temperature sensing. A proprietary algorithm is used for control when 

resistance inference temperature sensing is operating. 

There are actually two CONT parent menus within the tcm120 controller, one menu for 

the PID control algorithm and one menu for the proprietary algorithm. The menu is 

selected automatically by the tcm120. The selection is based on whether the controller is 

operating in resistance inference mode. 

Each 


Module 5

CONT parent menu contains six submenus. When resistance inference mode is 

operating, the submenus consist of a resistance calibration mode and five parameters. 

When resistance inference mode is not operating, the submenus consist of five 

parameters and an auto−tuning option. The parameters have numeric submenus. By 

pressing the [q] or [p] key, you can decrease or increase the value of the selected 

parameter. Pressing [ENTER] records the new value. Without direct instructions from 

the process engineer, the resistance calibration mode and the auto−tuning option are 

probably the only submenus you will use. However, you will use them infrequently, if at 

all. 

The following charts show the two CONT parent menus and their submenus in the order 

they appear on the display screen when you access them. The second column explains 

the function of each submenu. The third column lists the units in which the value is 

measured. The fourth column lists the options for discrete submenus and ranges for 

numeric submenus. 

Submenu 

CNFG Parent Menu #1 

Resistance Inference Mode 

Function Measured In 

RCAL Activates resistance calibration 

cycle 

YES * 

NO 

MOFF Adds manual offset to the set point Degrees Normally set to 0. 

Range: −199 to +199 

R0 Wire model constant. Should be set 

to 0.0 for current software revision. 

Used only in resistance inference 

mode. 

Discrete Submenu 

Options Or Numeric 

Submenu Ranges 

R1 Sets controller dead band. (Used in (C 

Normally set at 10. 

software revisions 0.20 and higher.) 

Used only in resistance inference 

Range: 3 to 50 

mode. 

R2 Not used with software revision 

0.03 and subsequent revisions. 

SLEW Sets output slew rate. Percent Per Normally set at 2. 

Second Range: 0 to 100 

* Used only to reactivate the resistance calibration mode for self−limiting cable if 

changes to heating circuit have been made since last calibration. 


Module 5

CNFG Parent Menu #2 

Not Resistance Inference Mode 

Submenu 

Function 

Measured In 

Discrete Submenu 

Options Or Numeric 

Submenu Ranges 

RATE Sets PID RATE (derivative) action. Seconds Normally set at 0. 


RST Sets PID reset (integral) action. Seconds Normally set at 600. 


PRO Sets PID gain (proportional) action. Degrees Normally set at 40. 


MOFF Adds manual offset to the set point Degrees Normally set at 0. 

Range: −199 to +199 

SLEW Sets output slew rate. Percent Per Normally set at 2. 

Second Range: 0 to 100 

TUNE Activates auto−tuning feature. YES 

NO 

PID loop parameters are sometimes sensitive to specific thermal characteristics of your 

heating zone. Auto turning a tcm120 in the field may polish its performance. To check 

whether the control loop parameters can be better tuned, use the auto−tuning feature. 

(The auto−tuning feature is not available when using resistance inference mode.) 

The auto−tuning feature is a discrete submenu with two options: YES and NO. To 

auto−tune the tcm120, press the [q] or [p] key to select YES. Press [ENTER] to record 

the information. Once set to YES the tcm120 switches immediately to the manual mode 

(the yellow Man LED lights up) and waits. You initiate an auto−tune cycle by pushing 

the [AUTO/MAN] button; the tcm120 enters an auto−tune sequence to adjust the 

RATE, RST, and PRO parameters for best possible control loop dynamics. The yellow 

Man LED on the front panel of the tcm120 blinks while the auto−tune cycle is in 

progress. The cycle can take several hours, depending on the thermal dynamics of your 

heating zone. When the cycle is complete, the controller switches to automatic mode. 


Module 5

Exercise: 

In this exercise, you will activate the auto−tuning mode to refine the 

parameters. (Remember: The auto tune option is available only in the 

second CONT menu. You will not be able to access it when the tcm120 is 

operating in resistance inference mode.) 

Access the CONT parent menu. 

Press the [q] key to access the first submenu in the CONT parent menu; then 

press the [INDEX] key to move to the submenu, TUNE. 

Press the [q] key to enter the TUNE submenu.. 

Press the [q] or [p] key to select YES. 

Press [ENTER] to record the information. 

Once set to YES, the controller switches automatically to the manual mode 

(the yellow Man LED lights up). Start the auto−tuning sequence by pushing 

the [AUTO/MAN] button; the tcm120 initiates an auto−tune cycle to adjust 

the RATE, RST, and PRO parameters. The yellow Man LED on the front 

panel of the tcm120 blinks while the auto−tune cycle is in progress. 

Press the [INDEX] key to exit the TUNE submenu and go to the next 

submenu. (Because TUNE is the last submenu in the list, you return to the 

first submenu, RATE.) 

Press the [p] key to return to the CONT parent menu. 

The ALRM Menu 

The alarm parent menu allows you to select alarm actions and enter the alarm set points. 

Module 6 discusses the alarm parent menu in detail. 


Module 5

Module 6 

Responding to tcm120 Alarms 

In this module, you learn how to recognize and identify an alarm, and how to use 

your knowledge of the menus and keys to respond to an alarm. 



> respond to alarms 

> access the alarm menu and submenus 

> set parameters for alarms, and 

> enable and disable alarms 


Module 6

Responding to Alarms 

How often do alarms go off? If all equipment operates properly, the alarms should never 

go off. When alarms do go off, however, it is important to respond quickly. More than 

one alarm can go off at once. It does not matter to the tcm120 in what order you respond 

to alarms. However, some alarms could indicate more harm to your heating zone than 

other alarms; therefore, the more urgent fault conditions should be addressed first. 

When a tcm120 enters an alarm condition, the front panel LEDs for the high and/or low 

alarms light up and flash. To identify which of the 16 possible alarms are activated, 

select the Temp process variable on the front panel. The names of the activated alarms 

flash on the display screen, identifying the alarms so that you can take appropriate action. 

Whenever the Temp process variable is displayed, the alarm names will continue to 

flash until you clear the fault condition in the field and reset the alarms. 

To respond to an alarm, press the [RESET] key once to acknowledge the alarm. The 

alarm LED stops flashing, but remains lit until you correct the fault condition. If you do 

not correct the fault condition within four hours, the alarm reactivates and the alarm LED 

starts flashing again. If a new alarm occurs after you have acknowledged an activated 

alarm, the LED starts flashing again. 

If the alarm is configured for automatic reset, the alarm clears automatically and the LED 

turns off after you correct the fault condition. If the alarm is configured for manual reset, 

you must press the [RESET] key again to clear the alarm and return the LED to normal. 

In review, if an alarm goes off, follow these steps: 

1. Press the [RESET] key to acknowledge the alarm. 

2. Clear the fault condition. 

3. Press the [RESET] key to clear the alarm if it is configured for manual reset. 

Example: The T Dev LED of a tcm120 is lit, and the display screen shows a 

temperature deviation of −0.03. Suddenly, because the ground current 

exceeds its alarm set point, the Alarm H LED starts flashing. 


Module 6

Respond to the alarm as follows: 

Use the [INDEX] key to step to the Temp process variable display. 

(On the display, the alarm GFI alternates with the temperature.) Press 

the [RESET] key to acknowedge the alarm (the Alarm H LED will 

stop flashing). Correct the fault condition that created the alarm. 

When the condition has been corrected, the alarm will clear 

automatically if it is configured for automatic reset. If the alarm is 

configured for manual reset, you must press the [RESET] key again 

to clear the alarm. 

It is possible to completely disable alarms, but, in general, you should only disable 

alarms under unusual or extenuating circumstances. After all, the 

purpose of an alarm is to notify you of a condition that requires 

correction. 

System Alarms 

Each tcm120 has two separate alarm relays. In the itc2200 cabinet, each alarm relay 

output is wired in parallel with the corresponding relay outputs from all other tcm120s. 

These outputs activate two system alarm relays to generate two overall heating system 

alarms. A third system alarm relay detects loss of power to the cabinet to ensure fail− 

safe system alarm operation. The outputs of these system alarm relays are available to 

you to activate an annunciator or to serve as an input to a DCS computer. 

Accessing the ALRM Submenus 

The alarm parent menu allows you to enable individual alarms (or, when appropriate, 

disable alarms), to select manual or automatic reset of specific alarms, to enter alarm set 

points, and to select the operation for the two alarm relays (see submenus K1 or K2 in 

the chart on the following pages). The alarm parent menu contains 27 submenus. 

Submenus for specifying alarm set points are numeric. Use the [q] and [p] keys to 

decrease or increase the set point; then press the [ENTER] key. The tcm120 signals it 

has recorded the data by blinking. 

Submenus for disabling or enabling alarms are discrete. Use the [q] and [p] keys to 

select the desired alarm mode; then press the [ENTER] key. The tcm120 signals it has 

recorded the data by blinking. 

The following chart lists the submenus, their functions, and the options for discrete 

submenus. 


Module 6

Submenu 

ALRM Parent Menu 

Function Comments 

AH Sets the alarm point in degrees for 

high temperature 

AHD Sets the alarm point in degrees for 

high temperature deviation. 

AL Sets the alarm point in degrees for 

low temperature. 

ALD Sets the alarm point in degrees for 

low temperature deviation. 

RHI Sets the alarm point in ohms for 

high heater resistance; detects an 

open heater or a high resistance 

connection in the heater circuit. 

Set as an absolute temperature that is 

independent of set point temperature. 

Set as a positive delta above the set point 

temperature: Dev = Temp − Set Pt 

Set as an absolute temperature 

independent of set point temperature. 

Set as a negative delta above the set point 

temperature: Dev = Temp − Set Pt 

Alarm also activated when heater 

resistance changes more than +20% in 2.5 

seconds. 

RLOW Sets the alarm point in ohms for low activated when heater resistance changes 

heater resistance; detects a shorted more than +20% in 2.5 seconds. 

heater or low selflimiting heater 

resistance. 

GFIS Sets the alarm point for ground fault Adjustable from 10ma to 100ma. Normally 

current, measured in milliamps. set at 30ma. 

TAMB Sets the alarm point in degrees for 

high ambient temperature (if air 

around tcm120 >85(C, damage to 

circuitry could result. 

OCS Sets alarm point in amps for the 

output overcurrent (amount of 

current flowing into zone.) 

Factory set at 85(C. 

Tcm120 series: 

Adjustable from 0 to 25 amps. Normally set 

at 22 amps. 

Tcm125: 

Adjustable from 0.5 to 6 amps. Normally set 

at 6 amps. 

Tcm121E: 

Adjustable from 0 to 28 amps. Normally set 

at 27.5 amps. 


Module 6

Submenu 

* Silicon Controlled Rectifier 


Function Discrete Submenu Options 

K1 Selects alarms assigned to the K1 

alarm relay. 

K2 Selects alarms assigned to the K2 

alarm relay. 

ALL – Activated by all enabled alarm 

conditions. 

HI – Activated by high temp alarms and 

ground fault alarm (HT, HTD, GFI). 

HI+ – Activated by high temp alarms, 

ground fault alarm, and any nontemperature 

related 

ALL – 

alarm. 

Activated by all enabled alarm 

conditions. 

LOW – Activated by low temp alarms (LT, 

LTD). 

LOW+ – Activated by low temp alarms, 

and any non−temperature related alarm. 

FUSE Disables or enables alarm for blown DIS – Disables alarm. 

fuse. 

A/DF – SCRs* will be disabled if alarm 

occurs; automatic reset 

A/EF – SCRs will not be disabled if alarm 


M/DF – SCRs will be disabled if alarm 

occurs; manual reset required 

M/EF – SCRs will not be disabled if alarm 


HAMB Disables or enables alarm for high 

ambient temperature 

DIS – Disables alarm. 

A/DF – SCRs will be disabled if alarm 









Module 6


Submenu 


Submenu Function 

HT Disables or enables alarm for high 

process temperature. 

HTD Disables or enables alarm for high 

process temperature deviation. 

LT Disables or enables alarm for low 

process temperature. 

LTD Disables or enables alarm for low 

process temperature deviation 

Function 


Discrete Submenu Options 







































Module 6

RESH Disables or enables alarm for high 

heater resistance. 

RESL Disables or enables alarm for low 

heater resistance. 

GFI Disables or enables alarm for 

ground fault 

OC Disables or enables alarm for 

overcurrent condition 







































Module 6

Submenu 

Function 


** Resistance Thermonic Device 


OT/C Disables or enables alarm for open 

thermocouple. 

SRTD Disables or enables alarm for 

shorted RTD.** 

ORTD Disables or enables alarm for open 

RTD. 

DATA Disables or enables alarm for data 

loss. (Data loss occurs when data 



Module 6 

Function 































stored in the configuration parameter occurs; automatic reset 

EEPROM is corrupted.) 






occurs; manual reset required

Submenu Discrete Submenu Options 

MAN Disables or enables alarm for 

manual mode. 

WDT Disables or enables the watch dog 

timer. (If program execution is 

interrupted for any reason, a watch 

dog timer will reboot the system.) 


Exercise: 




















Module 6

Exercise: 

In this exercise, you will increase the low temperature set point by five 

degrees. 

Select ALRM. 

Press the [q] key to access the first submenu in the ALRM parent menu; then 

press the [INDEX] key to move to the submenu, AL. 

Press the [q] key to enter the AL submenu. 

Use the [p] key to raise the set point by five degrees. 

Press the [ENTER] key to enter the data. 


Press the [INDEX] key to exit the AL submenu and go to the next submenu, 

ALD. 

Press the [p] key to return the ALRM parent menu. 


Module 6

In this exercise, you will disable the GFI alarm. 

Select ALRM. 

Press the [q] key to access the first submenu in the ALRM parent menu; then 

press the [INDEX] key to move to the submenu, GFI. 

Press the [q] key to enter the GFI submenu. 

Press the [q] or [p] key to select DIS. 

Press the [ENTER] key to enter the data. 


Press the [INDEX] key to exit the GFI submenu and move to the next 

submenu, OC. 

Press the [p] key to return the ALRM parent menu. 


Module 6

Module 7 

Commencing System Startup 

In the previous six modules, you have learned how to operate a tcm120. You are 

now ready to work with the process engineer to commence system startup. Module 7 

takes you through actual system startup, step−by−step. 



> start up the system 

> check the thermal system 

> check the field wiring 

> energize the transformer, and 

> energize the heating zones 


Module 7

Starting Up the System 

The startup procedure for the itc2200 heating system involves the following important 

steps: 

> checking the thermal system 

> checking and verifying field wiring 

> energizing the transformer 

> energizing each heating zone 

Checking the Thermal System 

The thermal characteristics of your heating system are just as important as the electrical 

controls in achieving overall system performance objectives. After installing the heating 

elements but before connecting them to an itc2200 system and before applying thermal 

insulation, complete the following steps: 

> Carefully inspect each heating element to make sure no physical damage has 

occurred during installation 

> Verify that good thermal contact has been achieved between each heating 

element and pipe or vessel. 

> Megger−test each lead of every heating element to exceed 20 Mohms to 

ground. 

> Energize each heating element to full rated voltage and measure the current. 

> Check the measured current against calculated design specifications. 

After thermal insulation is installed and carefully inspected for weatherproofing, each 

heating element should be energized again to full rated voltage. The measured current 

should be rechecked to design specification. Each lead of every heating element should 

also be megger−tested again to exceed 20 Mohms to ground. 


Module 7

Checking the Field Wiring 

Before any power is applied to the individual tcm120 controllers within the system, you 

should check and verify all field wiring by ensuring that the following steps have been 

completed: 

> The main power service to the transformer has been properly connected. 

> The itc2200 cabinet has been adequately grounded. 

> Each heating element has been correctly connected to the proper zone on the 

load terminal blocks (located in the distribution compartment). 

> The system alarm relay outputs, located at the bottom end of the load terminal 

blocks, have been wired to a DCS or annunciator panel. 

If the system is utilizing thermocouple or RTD temperature sensors, 4−20 mA remote 

inputs for set point or temperature feedback, or 4−20 mA outputs, you must verify the 

field wiring connections to the signal terminal blocks (located in the top compartment of 

the cabinet). 

Energizing the Transformer 

To ensure that adequate voltage is available to meet the heating system design 

requirements, energize the transformer and measure the secondary voltage following 

these steps: 

1. With the main circuit breaker and all zone circuit breakers within the itc2200 

cabinet turned off, energize the transformer. 

2. Measure the no−load secondary voltage to neutral (ground) on all three 

phases. (If the voltage is between +2.5% and +7.5% of the nominal system 

design value – 120 or 138 volts ac – then the proper secondary output tapes 

are being used.) 

3. If the measured secondary voltage of any phase does not fall between +2.5% 

and +7.5% of the nominal system design value, de−energize the transformer 

and use alternate secondary output taps, repeating steps 1−3 until the voltage 

is within these limits. 


Module 7

Energizing the Heating Zones 

To ensure proper operation, use the following steps to energize each heating zone 

individually and determine that each tcm120 operating correctly. 

1. With all zone circuit breakers in the itc2200 cabinet off, energize the 

transformer, and then turn on the main circuit breaker (the cooling fans will 

start). 

2. Turn on zone breaker CB1−1. This action energizes the tcm120 labeled R1−1 

and lights up its display screen and LEDs. 

3. If the tcm120 is configured for resistance inference mode temperature 

sensing, it starts up in the calibration cycle automatically, with the Temp LED 

flashing and the Man LED lit. The controller will not allow you to switch to 

automatic mode until you complete the temperature calibration sequence 

described in the next section. The completion of this procedure allows the 

tcm120 to properly measure or display process temperature and monitor or 

activate alarms related to process temperature. Therefore, while in the 

calibration sequence, the tcm120 temporarily disables HT, HTD, LT, LTD, 

and MAN alarms. 

(Note: all the menus and all other displayed values, such as voltage, current, 

set point, heater resistance, and ground current, are fully operational at all 

times. In addition, all alarms not related to temperature are operational, and 

therefore the tcm120 can indicate that alarms not related to temperature have 

tripped.) 

4. If the tcm120 is using thermocouple, RTD, or 4−20 mA remote inputs, no 

calibration is required. When the tcm120 is powered up, the front panel 

display immediately indicates the present state of the heating zone. 

Generally, one or both of the front panel alarm LEDs light up, and the display 

flashes the names of tripped alarms sequentially. Press the front panel reset 

key several times to clear any alarms falsely triggered due to turn−on 

transients. Any alarm that remains tripped is valid, and the fault causing the 

alarm must be addressed. Remember that at power up, the heating zone is 

still cold, so the LT and LTD alarms will trip, and the tcm120 will ramp the 

output up to full voltage until the heating element can bring the zone up to the 

temperature. 

5. When tcm120 R1−1 is running properly and heating the zone to temperature, 

turn on circuit breaker CB1−2 and repeat the full procedure. When you 

complete the procedure for tcm120 R1−2, repeat the procedure for tcm120 

R1−3 and so on, until all the zones are operating. 


Module 7

Your system is now on−line, maintaining and monitoring the temperature of the heating 

zones. 


Module 7

Calibrating Resistance Inference 

The tcm120 is factory−calibrated for all operating modes except resistance inference 

temperature sensing. When operating a tcm120 (with self−limiting heating cable) in the 

resistance inference mode, you must calibrate the tcm120 to the heating zone it controls 

once at initial start−up. If the controller has not been previously calibrated, the tcm120 

initiates a special resistance calibration cycle, requiring you to perform this calibration 

before the controller can be switched into automatic mode. 

This calibration process uses a simple, single−point procedure that is performed only at 

system startup. During this process, the tcm120 operates in manual mode; therefore, the 

[AUTO/MAN] key does not function until the sequence is completed. Note that the 

Temp LED flashes steadily during this process, and the display screen shows 000.0. 

Until the calibration sequence is completed, the tcm120 ignores HT, HTD, LT, LTD and 

MAN alarms. 

Follow these steps to complete the calibration procedure: 

1. Press the [INDEX] key to select the Volt parameter on the font panel display. 

2. Press the [p] key to increase the voltage to the approximate value expected on 

the heating cable to achieve the set point temperature at the present ambient 

conditions. (You can obtain this value from the electrical designer.) 

3. Let the heating zone come to equilibrium, a process which, due to thermal 

mass, may take as long as eight hours or more. (Note: The zone is at 

equilibrium when the Cur process variable display has stabilized.) 

4. Measure the actual pipe temperature with a portable temperature measuring 

instrument. If the measured temperature is not within +10 °F of the desired 

operating set point, adjust the heating zone voltage up or down, allow the 

zone to come to equilibrium, and take another temperature measurement, 

repeating this cycle until the actual measured temperature is within +10 °F of 

the desired operating set point. 

5. When the pipe is at the desired temperature range, use the [INDEX] key to 

select the Temp parameter; use the [q] and [p] keys to set the actual 

measured pipe temperature in the display. 

6. Press the 


Module 7

7. [ENTER] key to complete the calibration sequence. After the tcm120 

display blinks (indicating it has accepted the data), the Temp LED stops 

flashing, indicating that the calibration sequence has been completed. The 

HT, HTD, LT, LTD and MAN alarms are now re−enabled to operate as 

specified by customer selections and the tcm120 switches to auto mode. 

8. When the heating circuit is too short as described in Appendix C (on page 65) 

the controller will display P.LOW. 


Module 7

Resistance Inference Mode Operating Concept 


Module 7

Appendix A 

Changing the JP1 Jumper Configuration 

The JP1 configuration located on the control circuit board (P/N 90001225) controls write 

permission for either the configuration parameters or set point or both. The 

configuration also disables or enables the CALB menu. 

Function 

Disables set point changes 

and manual mode operation 

Permits set point changes 

and manual mode operation 

Disables configuration 

changes 

Permits configuration 

changes 

Disables CALB menu 

Enables CALB menu 

tcm120 Jumper Location 

A1 − B1 

( 

B1 − C1 

( 

A2 − B2 

B2 − C2 

A3 − B3 B3 − C3 


Appendix A 

( 

( 

( 

(

Appendix B 

Guide to tcm120 Input and Output Options 

The tcm120 series controller can be purchased in four models that provide the 

input/ouput options shown in the following table. 

Controller Models 

Options tcm120 tcm121 tcm122 tcm123 

Option 1: Resistance 

Inferred Temperature 

Feedback; 4−20 mA Inputs 

from Remote Transmitters or 

DCS for both Temperature 

Feedback and Remote Set 

Point 

Option 2: RTD and 

Thermocouple (J or K) 

Temperature Feedback 

Option 3: Isolated 4−20 

mA Output Signal 

( ( ( ( 

( ( 

( ( 


Appendix B

Appendix C 

Guide Maximum Heater Resistance 

The tcm120 contains back−to−back silicon controlled rectifiers (SCRs) for the power 

switch. These SCRs are fired by a single pulse, lasting approximately 20 microseconds, 

at the proper time during the 60 Hertz sine wave to produce the required amount of 

power to the load. The SCRs require that the load current increase to a value greater than 

the specified holding current by the end of the trigger pulse so that the SCRs will latch on 

and remain conducting once triggered. If the load resistance is too high or the firing 

pulse is too early, the SCRs may not latch on once triggered. 

The maximum resistances for a heating element connected to a tcm120 are listed below 

for three different power voltages: (See Note) 

120 volts ac: 98.4 Ω 

208 volts ac: 170.6 Ω 

240 volts ac: 196.8 Ω 

When constant wattage, parallel−type heating cable is used as the heating element, these 

maximum values of resistance translate to minimum cable lengths, based on the 

manufacturer’s specification to ohms per foot of cable. Because ohms per foot is 

essentially constant for constant wattage cable, the calculation is independent of cable 

operating temperature. 

Note: (When maximum resistance for the circuit exceeds these values, the controller will 

show P.LOW on the display. When self−limiting heating cable is used as the 

heating element, these values translate to the following minimum heating cable 

troubleshoot lengths for some commonly used cable types at 50° F operating 

temperature. Although the resistance of self−limiting cable changes with 

temperature, the manufacturer’s specifications can be readily used to compute 

minimum cable lengths for any other operating temperature.) 


Appendix C

Cable 

Type 

Rated 

Voltage 

Operating 

Voltage 

Res/Ft @ 50ºF 

(/Ft 

Min. Length 

Ft @ 50(F 

3 BTV 240 volts ac 208 volts ac 19,200 112.5 








5 XTV 240 volts ac 208 volts ac 11,520 67.5 





15 XTV 120 volts ac 120 volts ac 960 9.8 


20 XTV 120 volts ac 120 volts ac 720 7.3 

PSX3 240 volts ac 208 volts ac 19,200 112.5 








TSX3 240 volts ac 208 volts ac 19,200 112.5 



Appendix C

Cable 

Type 

Rated 

Voltage 

Operating 

Voltage 

Res/Ft @ 50ºF 

(/Ft 

Min. Length 

Ft @ 50(F 







2703 240 volts ac 208 volts ac 19,200 112.5 













2315 120 volts ac 120 volts ac 960 9.8 


Appendix C

Appendix D 

Guide to Self−Limiting Heating Cable Constants 

When used in resistance inference mode with self−limiting heating cable, the tcm120 

must be programmed with two constants that describe the operating characteristics of the 

particular cable being used. Normally, these constants are programmed by VTI at the 

factory before shipment; however, they can be reprogrammed from the front panel of the 

controller at any time. The table below lists the constants for a variety of cable types. If 

your cable is not listed, contact VTI and state your cable type. VTI will calculate the 

proper constants for you. 

Cable Type W0 W1 

3BTV 3.90 −0.695 

5BTV 6.34 −1.210 

8BTV 9.44 −1.420 

10BTV 11.70 −1.760 

5XTV 6.42 −0.365 

10XTV 10.60 −0.516 

15XTV 15.80 −0.727 

20XTV 21.00 −0.957 

PSX3 3.57 −0.571 

PSX5 5.78 −0.774 

PSX8 9.17 −1.170 

PSX10 11.45 −1.440 

TSX3−1 3.08 −0.081 

TSX3−2 3.17 −0.171 

TSX6−1 6.17 −0.171 

TSX6−2 6.29 −0.288 

TSX9−1 9.24 −0.243 

TSX9−2 9.41 −0.405 


Appendix D

Cable Type W0 W1 

TSX12−1 12.36 −0.360 

TSX12−2 12.54 −0.540 

2703 3.50 −0.488 

2705 6.00 −0.788 

2708 9.20 −1.156 

2710 11.50 −1.426 

2305 6.00 −0.405 

2310 11.20 −0.718 

2315 17.00 −1.070 


Appendix D

Appendix E 

Default tcm120 Configuration Parameters 

The tcm120 is normally shipped from the factory with configuration parameters 

programmed to match the customer’s requirements as defined in the itc2200 Series 

Configuration Guide. If the customer does not supply the proper configuration 

parameters prior to shipment, VTI will program each tcm120 with default parameters. 

The default parameters are shown in the following table. The customer can reprogram 

all parameters from the front panel. 

Submenu Default Minimum Maximum 

TEMP (C ___ ___ 

TFB RES ___ ___ 

T/C J ___ ___ 

X4 0.000 0.000 1300 

X20 100.0 0.000 1300 

RMIN 0.000 0.000 1300 

RMAX 100.0 0.000 1300 

OUT PHAS ___ ___ 

SP LOC ___ ___ 

BAUD 9600 ___ ___ 

ILIM * 20.00 0.000 20.00 

RNOM 10.00 1.000 2000 

DEF T ___ ___ 

REV ___ ___ ___ 

W0 0.000 −100.0 100.0 

W1 1.00 −10.0 10.0 

VMAX 240.0 0.000 250.0 

RATE 0.000 0.000 9999 

* tcm125 : default = 5.00, min = 0.50, max = 5.00 

tcm121E : default = 25.00, min = 0.0, max = 25.00 


Appendix E

RST 

HT 

HTD 

LT 

Submenu 

* tcm125 : default = 6.00, min = 0.50, max = 6.00 

tcm121E : default = 27.50, min = 0.0, max = 28.00 

Submenu 

Default 

600.0 

DIS 

DIS 

DIS 

Default 

Minimum 

0.000 

Minimum 

Maximum 

Maximum 


Appendix E 

___ 

___ 

___ 

9999 

PRO 40.0 0.000 9999 

MOFF 0.000 −199.0 +199.0 

SLEW 2.000 0.000 100.0 

TUNE YES ___ ___ 

AH 100.0 0.000 600.0 

AHD 10.00 0.000 +100.0 

AL 0.000 0.000 600.0 

ALD −10.0 −100.0 0.000 

RHI 1000 1.000 2000 

RLOW 1.000 1.000 2000 

GFIS 30.00 10.00 100.0 

TAMB 85.00 0.000 100.0 

OCS * 22.00 0.000 25.00 

K1 HI ___ ___ 

K2 LOW+ ___ ___ 

FUSE M/DF ___ ___ 

HAMB M/DF ___ ___ 

LTD DIS ___ ___ 

RESH M/DF ___ ___ 

RESL M/DF ___ ___ 

GFI M/DF ___ ___ 

OC M/DF ___ ___ 

___ 

___ 

___

OTC DIS ___ ___ 

SRTD DIS ___ ___ 

ORTD DIS ___ ___ 

DATA M/DF ___ ___ 

MAN A/EF ___ ___ 

WDT M/EF ___ ___ 

R0 0.000 ___ ___ 

R1 10.00 3.000 50.00 

R2 0.000 ___ ___ 

RCAL NO ___ ___ 


Appendix E

Appendix F 

Revisions 

These pages are reserved for updated information about equipment and procedures. 


Appendix F

TCM120 Operation Manual

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