Instrument Controller System for temperature & water based industrial machines
TEC - TPC 4000 - Flexiware Industrial Controller Modules

All the input / output modules, similar to the industrial PLC concept, are explained in detail.

 

These controllers can only be bought from Hydrosaveonline and we suggest that you contact us for our free system design and quotation service to help confirm that you chosen the right product for your application as there are a great deal of factors to consider when designing a control system.

Read about how TEC used these products in industrial control systems.

All the products in this Department are available and made to order only. If you have an industrial control problem that requires a solution, contact Roger Hitch by email or phone.

 

What is a MODULE . . . . . .

These are the electronic device modules that house the input and output hardware drivers that interface with the machines sensors and actuators. They contain, for example, relays and 4-20mA current drivers for outputs and analogue and logic circuitry for inputs.

  • Each intelligent module is controlled by its own on board software controlled PIC microcontroller.
  • These modules are located on DIN T rails or can be flush mounted, inside the interface industrial housing.
  • They can be mounted hundreds of metres away from the controller (or each other) as a serial RS485, 2 wire industrial communications system is used to connect them together.
  • The inputs and outputs (both analogue and on / off with opto coupled options) on the modules are called ports.
  • Each physical port, of the same type, on each module is numbered from No. 1.
  • In the configuration data flexiware file, the user will assign symbols (names) to these ports which should indicate what the port is connected to (i.e. valve name, input sensor type etc.)
  • i.e. for a port having a cold fill valve connected to it, the symbol name could be ‘cold_fill’.
  • i.e. for a port having an expansion tank drain valve connected to it, the symbol name could be ‘exp_tank_drain’.
  • Up to 15 characters can be used for names, including the underscore character which must be used to make the symbol name look like one word.
  • These symbol names are then given virtual port numbers.
  • The controller is then told on which module the real physical port can be found and to which real physical port number each virtual port number refers.
  • Once connected and referenced, in the flexiware file, the commissioning engineer then only has to refer to the name of the virtual port (that he has created) and not have to remember its virtual port or real port number ever again, he just has to remember/look up on which module it is and on which screw terminal.
  • This saves port number referencing mistakes by using understandable machine related names rather than just numbers.

Download an example of a flexiware configuration programme.

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TPC 4000 - Module Specifications

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General Information

Module types should be chosen to make the most efficient use of the mix of input / output types required. Special modules with a specific mix and match of input / outputs can be made on request.

Each module type has its own handbook and these should be referred to when commissioning.

There are currently 16 module types (combinations): 1, 1A, 1AT, 1B, 2, 2A, 2AT, 2B, 3, 3C, 3T, 3CT, 4, 4A, 4AT, 4B.

The specifications (in addition to those below) for intelligent module generic types 1, 2,  4 are:-

  • 1 x MODCOM serial communication port (to talk to the Human Machine Interface - HMI)
  • 1 x Manual override input (to allow selected individual output control)
  • Communications address binary DIP switch (for MODCOM communications)
  • On/off input / output LED indication
  • MODCOM communications active, flashing LED indicator
  • DC power indicator

Modules 3 generic type are not software controlled and therefore do not have a PIC microcontroller.

TPC 4000 Module - Type 1, 1A, 1B Specifications

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Input - Output listings

     Module 1Module Type 1Module Type 1

3     ports   Analogue pt100 temperature probe inputs

4     ports   On/off direct connection inputs

 

 

    

     Module 1A  Module Type AModule Type 1Module Type 1A

3     ports   Analogue pt100 temperature probe inputs

4     ports   On/off direct connection inputs

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15   ports   On/off relay Normally Open outputs

1     port     On/off relay Change Over output

1     port     Expansion o/ps driver

 

Module Type TOption:-     up to 15 semiconductor triac (noise free zero crossing detection) N/O output drivers

                 110/240v ac in place of the mechanical relays using the same footprint

 

 

 

 

 

Module 1BModule Type BModule Type 1Module Type 1B

3     ports   Analogue pt100 temperature probe inputs

4     ports   On/off direct connection inputs

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5     ports   On/off opto-isolated inputs

4     ports   Analogue 4-20mA outputs 

TPC 4000 Module - Type 2, 2A, 2B Specifications

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Input - Output listings

Module 2Module Type 2Module Type 2

4     ports   Analogue 4-20mA transmitter inputs

4     ports   On/off direct connection inputs

 

 

 

 

Module 2AModule Type AModule Type 2Module Type 2A

4     ports   Analogue 4-20mA transmitter inputs

4     ports   On/off direct connection inputs

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15   ports   On/off relay Normally Open outputs

1     port     On/off relay Change Over output

1     port     Expansion o/ps driver

  

Module Type TOption:-     up to 15 semiconductor triac (noise free zero crossing detection) N/O output drivers

                 110/240v ac in place of the mechanical relays using the same footprint

 

 

 

 

 

      Module 2BModule Type BModule Type 2Module Type 2B

4     ports   Analogue 4-20mA transmitter inputs

4     ports   On/off direct connection inputs

----------------------------------------------------------------------

5     ports   On/off opto-isolated inputs

4     ports   Analogue 4-20mA outputs 

TPC 4000 Module - Type 3, 3C Specifications

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Input - Output listings

       Module Type 3Module Type 3Module 3
       7     ports   On/off relay Normally Open outputs (expansion for module types 1A, 2A, 4A only)
     1     port     Expansion o/ps reciever
     1     port     Further expansion o/ps driver
    
Serial communication handshaking LED indicators
     
DC power indicator
    

     Module Type TOption:-     up to 15 semiconductor triac (noise free zero crossing detection) N/O output drivers
                      110/240v ac in place of the mechanical relays using the same footprint 

 

 

 

 

 

 

Module Module Type C3CModule Type 3Module Type 3C

14   ports   On/off relay Normally Open outputs (expansion for module types 1A, 2A, 4A only)

2     ports   Expansion o/ps recievers
2     ports   Further expansion o/ps drivers

Serial communication handshaking LED indicators

DC power indicators

 

     Module Type TOption:-     up to 15 semiconductor triac (noise free zero crossing detection) N/O output drivers
                      110/240v ac in place of the mechanical relays using the same footprint

TPC 4000 Module - Type 4, 4A, 4B Specifications

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Input - Output listings

Module 4Module Type 4Module Type 4

1     port     Analogue pt100 temperature probe input

12   ports   On/off direct connection inputs

 

 

 

 

Module 4AModule Type AModule Type 4Module Type 4A

1     port     Analogue pt100 temperature probe input

12   ports   On/off direct connection inputs

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15   ports   On/off relay Normally Open outputs

1     port     On/off relay Change Over output

1     port     Expansion o/ps driver

 

Module Type TOption:-     up to 15 semiconductor triac (noise free zero crossing detection) N/O output drivers

                 110/240v ac in place of the mechanical relays using the same footprint

 

 

 

 

 

Module 4BModule Type BModule Type 4Module Type 4B

1     port     Analogue pt100 temperature probe input

12   ports   On/off direct connection inputs

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5     ports   On/off opto-isolated inputs

4     ports   Analogue 4-20mA outputs