Full Gauge TC-900 E POWER Digital Controller

1. DESCRIPTION

The TC-900 E POWER is a digital controller designed for refrigeration and defrost applications. It automates defrost processes based on installation needs (smart defrost). The controller features ambient temperature control with a normal setpoint and an economic setpoint, along with fast freezing and alarm functions for open doors. Its 16A relay can directly control compressors up to 1HP, and its defrost output has a 10A capacity. It includes a digital filter to simulate increased thermal inertia for the ambient sensor, preventing unnecessary compressor drives. Additional features include a smart key, lock system, and a control functions shutdown mode. For inductive loads up to 2HP, the TC-900 E 2HP model is recommended.

2. APPLICATION

• Cold Storage Rooms
• Display Freezers

3. TECHNICAL SPECIFICATIONS

• Power supply: TC-900 E POWER: 115 or 230Vac ±10% (50/60Hz); TC-900 EL POWER: 12 or 24Vac/dc ±10%
• Control temperature: -50°C to 105°C (-58°F to 221°F)
• Operating temperature: 0 to 50°C (32 to 122°F)
• Load current (outputs): COMP: 12(8)A/240Vac 1HP; DEFR: 10A/240Vac 1/4HP; FANS: 5(3)A/240Vac
• Operating humidity: 10 to 85%RH (without condensation)
• Dimensions: 76 x 34 x 77 mm (WxHxD)
• Dimensions of clipping for fixing: 71 ±0.5 mm x 29 ±0.5 mm

4. INDICATIONS AND KEYS

The front panel features a digital display showing temperature and status. Indicator LEDs signify: Compressor output (COMP), Fan/Defrost 2 (F/D2), Defrost (DEF), Functions Lock (LOC), Control Functions Shutdown (CTRL), and Temperature Unit (°C/°F). Control buttons include: SET, Quick Access Menu (symbolized by a clock/menu icon), Increase (+), and Decrease (-).

5. INSTALLATION-ASSEMBLING

The diagram shows panel cut-out dimensions of 71 ±0.5 mm width and 29 ±0.5 mm height. A side view illustrates the controller fitting into the panel. For liquid sealing, the cut-out should be a maximum of 70.5x29mm, and side locks must press the rubber sealing to prevent infiltration.

5.1 INSTALLATION - ELECTRICAL CONNECTIONS

Connection 115 Vac / 230 Vac: Terminal blocks are shown for power supply (115/230 Vac), compressor output, fan/defrost 2 output, defrost output, digital inputs 1 (S3) and 2, alarm output, and common. Sensors S1 (ambient, black) and S2 (evaporator, gray) are connected.

Connection 12 Vac/dc / 24 Vac/dc: Terminal blocks are shown for power supply (12/24 Vac/dc), compressor output, fan/defrost 2 output, defrost output, digital inputs 1 (S3) and 2, alarm output, and common. Sensors S1 (ambient, black) and S2 (evaporator, gray) are connected.

Sensor Notes: Sensor S1 (black) must be in the ambient. Sensor S2 (gray) must be placed in the evaporator through a metallic cramp.

6. OPERATIONS

6.1 Quick Access Menu Map

Pressing the Quick Access Menu key (symbolized by a clock/menu icon) allows navigation through functions. Functions include: FAST (Fast Freezing ON/OFF), ECO (Economic Setpoint ON/OFF), DEF (Defrost ON/OFF), FUNC (Function Selection), LOC (Functions Lockdown), ERASE MAX. AND MIN. VALUES, and MAX. AND MIN. TEMPERATURE RECORD.

6.2 QUICK ACCESS KEYS MAP

SET key: Pressed for 2 seconds: Setpoint adjustment. Short press: Displays process status. Pressed for 2 seconds: Inhibits audible alarm.

Quick Access Menu key: Short press: Displays minimum and maximum measurement records. Pressed for 2 seconds: Cleans history when displaying records. Enters the quick access menu.

Increase (+) and Decrease (-) keys: Enter the quick access menu. Enter the functions selection.

6.3 BASIC OPERATIONS

6.3.1 Setting the desired temperature

Press the SET key for 2 seconds to access setpoints. 'SP' appears, followed by the normal setpoint value. Use +/- keys to adjust and press SET to confirm. 'SP-E' appears for the economic setpoint. Adjust using +/- keys and confirm with SET. The display then signals setup completion. Setpoints can also be adjusted via the quick access menu.

6.3.2 Fast Freezing

The fast freezing mode keeps the cooling output permanently activated to accelerate cooling. It can be activated/deactivated via the quick access menu ('FASE') or an external switch. It can also deactivate automatically by time (F15) or low temperature (F14). During fast freezing, the compressor LED flashes quickly, and defrost continues. If a time-based defrost is scheduled, it will occur immediately before entering fast freezing mode.

6.3.3 Economic setpoint (SPE)

The SP-E provides system economy through flexible temperature control parameters (F06, F07). When active, 'ECO' alternates with temperature readings. Economy mode can be activated/deactivated via the quick access menu ('ECO') or an external key. Activation conditions include closed door time, S3-S1 temperature difference, and maximum time in economy mode.

6.3.4 Manual defrost

The defrost process can be manually activated/deactivated via the quick access menu ('DEF') or an external switch. 'DEFr On' or 'dEFr OFF' messages indicate the status.

6.3.5 How to determine the end of defrost by temperature

1. Reconfigure functions: Cooling time (F3) to 999 min, Evaporator temperature to end defrost (F28) to 105°C/221°F, Maximum defrost time (F23) to 0 (OFF).
2. Wait for ice formation in the evaporator.
3. Perform a manual defrost (using DEF option).
4. Observe the melting process.
5. Wait until all ice has melted.
6. Check evaporator temperature (S2) using the key (see section 6.3.9).
7. Set F28 to the measured S2 temperature.
8. Reset maximum defrost time (F23) based on defrost type (e.g., 45 min for electrical, 20 min for hot gas).
9. Set cooling time (F3) to the desired value.

6.3.6 Defrost with two evaporators

With S3 configured for a second evaporator (F49), the Fan output controls the second resistance. Defrost starts with both outputs triggered. Resistors shut down individually as evaporators reach their end-of-defrost temperature. Draining starts when both outputs are off or maximum defrost time elapses. Fan features, including Fan Delay, are disregarded in this mode.

6.3.7 Functions Lockdown

Functions lockdown enhances safety by protecting setpoints and parameters from unauthorized changes. Access the 'LOC' function in the quick access menu. To activate, hold the Quick Access Menu key for the time set in F55 (minimum 15 seconds). 'LOC On' indicates activation. Deactivation requires turning the controller off and on while holding the key for approximately 10 seconds ('LOC OFF').

6.3.8 Control functions shutdown

This feature allows the controller to operate solely as a temperature indicator, disabling control outputs and alarms. It is enabled/disabled via the 'Ctrl' option in the quick access menu. When off ('Ctrl OFF'), the message 'OFF' alternates with temperature. When on ('Ctrl On'), normal operation resumes.

6.3.9 Stage of the process, elapsed time and temperature in sensors S2 and S3

Pressing the Quick Access Menu key displays the controller's operating status. A sequence of messages shows the current process, elapsed time (hh:mm), and temperatures from sensors S2 (evaporator) and S3. If sensors are disabled, their readings are not shown. Stages include: DEL (Initial delay), FRn (Fan-delay), EFr (Cooling), PrE (Pre-Defrost), DEF (Defrost), drA (Drainage), Unlock, OFF (Control functions off). Error indications (Err1, Err2, Err3, ECAL, AlrE) are also displayed.

6.3.10 Minimum and Maximum Temperature Record

Minimum and maximum recorded temperatures for each sensor can be viewed via the quick access menu or by pressing the key. 'E9' precedes ambient sensor (S1) records, '-2' for S2, and '-3' for S3. To clear records, hold the key for 2 seconds while displaying records or use the 'CrE9' option. 'SEE' indicates records have been deleted.

6.3.11 Unit Selection

To select the temperature unit (°C or °F), access the function menu, enter the access code '123' via FOI, then select the unit using +/- keys and confirm with SET. Changing the unit resets function settings to default values.

6.4 ADVANCED OPERATIONS

The function menu is accessed via the quick access menu ('Func') or by pressing SET and Quick Access Menu keys simultaneously. Enter the access code '123' via FOI to modify parameters. Navigate using +/- keys and confirm with SET. To exit, press and hold the SET key until 'End' appears. If Functions Lockdown is active, parameter changes are blocked, displaying 'LOC'.

6.5 TABLE OF PARAMETERS

6.5.1 Description of parameters

F01 - Access code: Used to modify configuration parameters or temperature units. Code 123 allows parameter modification; 231 allows unit selection (°C/°F).

F02 - Delay at start (energization): When energized, the instrument shows temperature only, with outputs off for the set time. Useful for staggered load activation in multi-equipment installations.

F03 - Cooling time (interval between defrosts): Sets the maximum cooling time when defrost starts by time (F25). If defrost starts by temperature, this function is disregarded.

F04 - Normal setpoint: The desired room temperature for cooling; the reference value for temperature control.

F05 - Control differential (normal hysteresis): Temperature difference for turning the cooling output ON/OFF in normal and Fast Freezing modes.

F06 - Economic setpoint (SPE): The desired room temperature when operating in economy mode.

F07 - Control differential (economic hysteresis): Temperature difference for turning the cooling output ON/OFF in economy mode.

F08 - Minimum setpoint allowed to the end user: Electronic stop to prevent excessively low setpoint temperatures.

F09 - Maximum setpoint allowed to the end user: Electronic stop to prevent excessively high setpoint temperatures.

F10 - Time for closed door to enter economy mode: Activates economy mode if the door remains closed for the set time and the normal setpoint is reached. Disabled if set to 0.

F11 - Temperature difference (S3-S1) below which the economic setpoint is activated: Activates economy mode when the temperature difference between sensor 3 and sensor 1 is less than this value.

F12 - Temperature difference (S3-S1) above which the normal setpoint is activated: Activates normal setpoint operation when the temperature difference between sensor 3 and sensor 1 is greater than this value.

F13 - Maximum time in economy mode: Sets the maximum duration for economy mode operation. After this time, it returns to normal mode. If set to tOFF, it is disregarded.

F14 - Temperature limit for Fast Freezing: The minimum temperature the instrument can reach during fast freezing.

F15 - Fast Freezing time: The duration of the fast freezing process.

F16 - Fan operating mode: Sets fan behavior during cooling, considering compressor status and setpoint. Options include cyclic operation (defined by F17/F18), always ON, or OFF.

F17 - Time of fan on: Defines the ON time for the fan in cyclic mode.

F18 - Time of fan off: Defines the OFF time for the fan in cyclic mode.

F19 - Compressor status with ambient sensor (S1) disconnected: Sets compressor status (off, on, or cycling) if sensor S1 fails.

F20 - Compressor on time in case of S1 failure: Defines ON time for the compressor in cyclic mode if S1 fails.

F21 - Compressor off time in case of S1 failure: Defines OFF time for the compressor in cyclic mode if S1 fails.

F22 - Time for gas collection before starting defrost: Time during which only the fan remains on at defrost start, utilizing residual gas energy. Disregarded during defrost at energization.

F23 - Maximum defrost time: Sets the maximum allowed defrost duration. If not finished by temperature, a dot flashes on the display. If sensor 2 is shut down, defrost ends by time. If set to 0, defrost stops.

F24 - Defrost type: 0 for Electrical defrost (resistance), 1 for Hot gas defrost (compressor and defrost outputs triggered).

F25 - Condition for starting defrost: 0 for start by time, 1 for start by temperature. Respects compressor minimum times (F35/F36) and gas collection (F22).

F26 - Maximum open door time for instant defrost: If the door is open longer than this time during cooling, instant defrost occurs. Time restarts if the door is open at the start of cooling. Disabled if set to 0.

F27 - Temperature at evaporator (S2/S3) to start defrost: Defrost starts when evaporator temperature drops below this value. If S3 is a second evaporator, defrost starts if either S2 or S3 meets the condition. Ignored if F25 is time-based.

F28 - Temperature at evaporator (S2/S3) to determine the end of defrost: Defrost ends when evaporator temperature reaches or exceeds this value. For dual evaporators (S3), outputs shut down individually.

F29 - Fan on during defrost: Defines if the fan stays ON or OFF during defrost. Useful for natural defrost or external resistors.

F30 - Defrost at start of instrument: Allows defrost to occur immediately upon instrument energization (e.g., after power failure).

F31 - Temperature indication (S1) locked during defrost: Prevents visualization of ambient temperature rise during defrost by locking the last measured temperature. Released when the next cooling cycle starts or the temperature is reached again. Disabled if set to -1.

F32 - Draining time (dripping of defrost water): Time for water to drip from the evaporator after defrost. All outputs remain off. Set to 0 to skip.

F33 - Maximum time for fan return after drainage (fan-delay): If evaporator temperature doesn't reach F34 or S2/S3 is disconnected, the fan returns after this time elapses.

F34 - Evaporator temperature (S2/S3) for fan return after drainage: After drainage, the compressor starts immediately. The fan activates only after the evaporator temperature drops below this value, to remove residual heat.

F35 - Minimum time for compressor on: Minimum time the compressor stays on to prevent power grid voltage spikes.

F36 - Minimum time for compressor off: Minimum time the compressor stays off to relieve discharge pressure and increase lifespan.

F37 - Fan stop for high temperature in evaporator: Shuts down the evaporator fan if evaporator temperature exceeds this value, to prevent high temperatures and suction pressures damaging the compressor. Fan restarts with 0.1°C/1°F hysteresis.

F38 - Time of open door to shut down fan: Shuts down the fan during cooling if the door remains open for the set time. Disabled if set to -1.

F39 - Time of open door to shut down control outputs: Shuts down compressor, fan, and defrost outputs if the door remains open for the set time. Disabled if set to 0.

F40 - Maximum temperature at condenser (S3) to shut down control outputs: Disconnects loads if condenser temperature (S3) exceeds this value. Alarm is deactivated if S3 is used for another function. Ignored until control temperature is first reached.

F41 - Control differential (hysteresis) for sensor S3 when set as sensor of the condenser: Condenser temperature must drop to F40 minus this value for loads to reconnect.

F42 - Compressor on time without reaching the setpoint to shut down the control outputs: Maximum time compressor can stay on without reaching setpoint during cooling. If elapsed, outputs shut down and an alarm is triggered. Disabled if set to 0.

F43 - Low ambient temperature alarm (S1): Triggers a low temperature alarm (ALO) if ambient temperature (S1) drops below this value. Alarm is ignored until control temperature is first reached. Disabled during Fast Freezing.

F44 - High ambient temperature alarm (S1): Triggers a high temperature alarm (RH.) if ambient temperature (S1) rises above this value. Considers display temperature, influenced by F31. Ignored until control temperature is first reached.

F45 - Alarm inhibition time by temperature: Temperature must remain in alarm condition for this set time for the alarm to be indicated, preventing alerts from temporary variations.

F46 - Temperature of sensor S3 (condenser) to give an alarm: Triggers a high temperature alarm (RC1) if condenser temperature (S3) exceeds this value. Deactivated if S3 is used for another function. Ignored until control temperature is first reached.

F47 - Time of open door to give an alarm: Activates an "open door" alarm if the door remains open for the set time. Alarms suspend upon closing the door. Requires a digital input configured as door contact (F49/F50). Disabled if set to 0.

F48 - Enabling the buzzer: Enables/disables the internal buzzer for alarm signaling.

F49 - Function of digital input 1 / Sensor S3: Configures digital input 1 or sensor S3 for various functions like economic setpoint activation, manual defrost, fast freezing, external alarm, door contact, or condenser/second evaporator temperature control.

F50 - Function of digital input 2: Configures digital input 2 for various functions similar to F49.

F51 - Ambient temperature S1 indication offset: Compensates for deviations in ambient temperature reading (S1) due to sensor or cable changes.

F52 - Evaporator S2 temperature indication offset: Compensates for deviations in evaporator temperature reading (S2). Sensor S2 can be shut down by setting this function to minimum.

F53 - Sensor S3 temperature indication offset: Compensates for deviations in sensor S3 temperature reading.

F54 - Intensity of digital filter applied to sensor 1 (0-deactivated): Simulates increased thermal mass for sensor 1, increasing response time (thermal inertia). Higher values increase response time.

F55 - Time for functions lockdown: Authorizes the locking of control functions. Sets the time in seconds for the command to activate.

F56 - Control functions shutdown: Authorizes the shutdown of control functions. Can enable/disable functions with or without lockdown.

7. SIGNALS

Err1: Ambient sensor disconnected or out of range.

Err2: Evaporator sensor disconnected or out of range.

Err3: Sensor 3 disconnected or out of range.

ECAL: Instrument not calibrated.

AlrE: External alarm (digital input).

ECO: Operating with economic setpoint.

OP: Open door indication.

A0PO: Open door alarm indication.

H: High ambient temperature alarm (sensor 1).

ALO: Low ambient temperature alarm (sensor 1).

AC1: High temperature in condenser alarm (level 1).

AC2: High temperature in condenser alarm (level 2).

AL-C: Compressor reached the maximum time on without reaching the SP.

OFF: Control routines off.

PPPP: Indicates that the temperature for end of defrost has not been reached.

Loss of parameters.

8. OPTIONAL ITEMS - Sold Separately

8.1 Easy Prog ver. 02

An accessory to store controller parameters. Allows loading/unloading parameters to a production line. Connects via Serial RS-485, USB (allows parameter editing and power supply), or Serial TTL (direct connection and power supply).

8.2 Ecase

A protective cover for Evolution line controllers, preventing water and moisture ingress during washing.

8.3 Extension Frame

Allows installation of Evolution/Ri line controllers (76x34x77 mm) into varied situations without precision panel cuts. Accommodates two 10A switches for functions like internal light or air curtain.

ENVIRONMENTAL INFORMATION

Packaging: Materials are 100% recyclable. Dispose through specialized recyclers.

Product: Components can be recycled and reused if disassembled by specialized companies.

Disposal: Do not incinerate or dispose of controllers as household garbage. Observe local electronic waste disposal laws. Contact Full Gauge Controls for guidance.

WARRANTY - FULL GAUGE CONTROLS

Products have a two (02) year warranty from the date of sale against manufacturing defects. Warranty does not cover freight/insurance costs for returns, natural wear and tear, or external damage from falls/inadequate packaging.

LOSS OF WARRANTY: Warranty is void if instructions are not followed, product is submitted to conditions beyond specifications, tampered with, or damaged by fall, impact, water, overload, or atmospheric discharge.

USE OF WARRANTY: Customers must send the product with the invoice/receipt and detailed information about the issue to Full Gauge Controls headquarters for service.