A-T Controls TRIAO TMC-4 User manual

TMC-4 Control Card
for Electric Actuators
Installation & Operation Manual
1 03/18/21
www.atcontrols.com IOM08139 REVISION 01
Installation and Operation Manual
TMC-4 Control Card (v2.02)
1. Overview
The Triac TMC-4 control card is a motor controller intended to be used in electric actuators rated for running current loads
up to 10 amps. It can drive split phase 120V to 230V AC motors or 12V and 24V DC motors from a single board by simply
selecting the supply voltage type with an on-board switch.
Option slots permit easy expansion on the capabilities of the controller to support various communication busses or other
control options. It is available in two versions to accommodate a variety of actuator sizes. The TMC-4A002-001 controller
can control smaller actuators, and has a single option module slot, while the TMC-4A002-002 is used for controlling larger
actuators and has two option module slots.
When operated as a proportional controller, the TMC-4 compares an external command signal to a position feedback,
typically a potentiometer, that is coupled to the output shaft of the actuator. When the magnitude of the two signals differ
by a given magnitude, the TMC-4 controller will energize the motor to operate either clockwise or counterclockwise to
reduce the difference between the two signals.
When operated as two-position controller, the TMC-4 receives an open or close command, and drives the actuator
clockwise or counterclockwise until closure of a position limit switch is detected.
The TMC-4 must be installed in an appropriate enclosure to avoid electrical shocks. When operating,
high voltages will be present on the controller, requiring caution during the installation process. Power
should be deenergized before making wire connections to the TMC-4. A heater and thermostat
should be used when possible to prevent condensation.

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Layout
1.1.1. TMC-4A002-001
1.1.2. TMC-4A002-002

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Supply Type Switch
Switch to select type of supply voltage. Set to “AC” for
single phase AC supply voltage between 85V and 250V.
Set to “DC” for DC supply voltage between 10V and
30VDC.
Ensure Supply Type Switch is
in the “AC” position when
powering with supply voltage
between 85V and 250V. Failure
to do so may result in damage
to the TMC-4
Fuse
The fuse is a standard 5x20mm time delay fuse rated for
10A, 250V. Replacement fuses shall not exceed this
maximum rating.
Terminals
Terminals are provided for supply power, motor and
control signal connections. The TMC-4A002-001 has a
single row terminal for all connections. The TMC-4A002-
002 has two rows; one for power and motor, the other for
control and feedback signals. Details are outlined in the
section on wiring.
Option Module Slot(s)
mSATA / Mini PCI Express connection point for optional
feature modules such as for serial communication or
other control types. Optional modules can be installed
with (2) 4-40 x 1/4" screws.
(P4) Expansion Header
14 point connection header for optional accessory
interfaces.
(P5) Limit Switch Header
3 point connection header for feedback limit switches
when required for actuator control.
(P7) Feedback Potentiometer Header
3 point connection header for feedback potentiometer
when required for actuator control.
(P8) Temperature Probe Header
2 point connection header for optional motor
temperature monitor probe.
Display
OLED display to display actuator status and menu
options.
Joystick
5-way joystick (up, down, left, right, center) for menu
navigation and adjustment of parameters and settings.
Direction
Function
[ UP ]
Navigate up in menus.
Choose previous setting selection or
increase setting value.
Motor CCW in POSITION CONFIG calibrate
settings.
[ DOWN ]
Navigate down in menus.
Choose next setting selection or decrease
setting value.
Motor CW in POSITION CONFIG calibrate
settings.
[ LEFT ]
Navigate left in menus.
Return to previous menu screen or exit
menu subgroup.
Cancel or exit setting.
[ RIGHT ]
or
[ CENTER ]
Navigate right in menus.
Enter parameter screen to adjust setting.
Confirm or save setting when finished
changing.
NOTE: When incrementing a setting value, the value step
increases by +1 for every 6 presses. Reset the step back to +1
by pressing back in opposite direction.
Insert option module into
connector and rotate flat. Tighten
with #4-40 x 1/4” fasteners.
UP
DOWN
LEFT
RIGHT
CENTER

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2. Wiring and Operation
The supply voltage and motor should be connected as
shown in the wiring section. Set the Supply Type Switch
according to the supply voltage and select AC or DC
motor type in the menu settings based on the type of
motor being controlled. The supply voltage and motor
type will typically always match.
When connecting AC supply power, the
supply type switch must be set to “AC” and
when connecting DC supply power, the
supply type switch must be set to “DC”
accordingly. Failure to do so may result in
damage to the TMC-4 controller.
MOTOR
For split phase AC type motors, the winding that drives
the actuator clockwise should be connected to the
“Motor CW” terminal, and the winding that drives the
actuator counterclockwise should be connected to the
“Motor CCW” terminal. The motor neutral wire should be
connected to the “Motor N” terminal.
For DC type motors, the wires should be connected to
the “Motor CW” and “Motor CCW” terminals only. When
operating DC motors, the “Motor CW” and “Motor CCW”
terminals switch polarity to the motor. A clockwise
operation will apply the positive supply voltage to the
“Motor CW” terminal, and a counterclockwise operation
will apply the positive supply voltage to the “Motor CCW”
terminal. The motor wires should be connected
accordingly.
BRAKE
An external brake connection is provided to operate
spring return type actuators that use a motor brake to
hold the actuator in position. When the motor is set to
“AC” in the menu settings, the external brake output
remains energized until either of the motor outputs is
activated, at which point, the external brake output
deenergizes. This configuration is for brakes that engage
when powered and disengage when unpowered.
When the motor is set to “DC” in the menu settings, the
external brake output remains deenergized until the
motor outputs are activated, at which point the external
brake output energizes. This configuration is for brakes
that engage when unpowered and disengage when
powered.
HEATER
The TMC-4A002-002 also provides terminals dedicated
to a heater output for connecting a heater and
thermostat. This output is protected by the on-board
fuse. The TMC-4A002-001 does not have dedicated
heater output terminals. It is recommended to connect a
heater and thermostat across the supply power, but it
may be powered by the external brake. The maximum
brake output of rating 300mW, 350V, 120mA continuous
load must not be exceeded.
I/O
Standard analog control inputs for 4-20mA, 0-5V, 1-5V,
0-10V and 2-10V should be connected to the I/O 1
terminal. The 4-20mA input can also be set to sourcing
or sinking through the menu settings. Analog outputs of
0-20mA and 0-10V should be connected to the I/O 2
terminal. This feedback signal is self-powered by the
TMC-4 controller, so no loop power is required by the
user.
In addition to typical analog input control signals, a
+24VDC output is available to drive a single device up to
30mA or use with handheld loop calibrator set as 2-wire
transmitter to locally control the actuator while
conserving battery power. Refer to wiring diagrams in
following section.
The internally supplied +24VDC output can also be used
to drive the I/O 1 and I/O 2 terminals to operate as a
two-position actuator when configured for ON-OFF
command. This can be useful if driving AC motor with
isolated low power command signal. If driving the motor
through limit switches, the actuator can be operated like
a standard on/off, but will not display end of position
unless limit switches are wired to the on-board limit
switch connection header.
The TMC-4 can also be configured to operate off a
variable resistor. Two options exist; one for 0-135Ω to
control off a typical slide wire, and the other for 0-1000Ω
for operating off a typical panel dial.

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TMC-4A002-001
(P1)
Terminals
Function
1 Supply L/+ Supply Power.
2 Supply N/- Supply Power.
3 External
Brake
Output that switches supply power when motor outputs are energized. Used for spring return electric actuator
brakes.
AC Operation: Switch off when motor on.
DC Operation: Switch on when motor on.
4 Motor CW AC: Energize clockwise motor winding.
DC: Switch (+) supply voltage for clockwise operation.
5 Motor CCW AC: Energize counterclockwise motor winding.
DC: Switch (+) supply voltage for counterclockwise operation.
6 Motor N AC: Motor neutral, connected to supply N.
DC: not used.
7 +24V Out Auxiliary 24VDC output.
8 I/O 1
Signal In Command signal input.
9 Signal GND Command signal reference.
10 I/O 2
Signal Out Feedback signal output.
11 Signal GND Feedback signal reference.
12 COM1 P Communication non-inverting input.
13 COM1 N Communication inverting input.
14 GND Ground.

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for Electric Actuators
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TMC-4A002-001 AC Proportional Control TMC-4A002-001 AC Two Position Control
TMC-4A002-001 DC Proportional Control TMC-4A002-001 DC Two Position Control

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for Electric Actuators
Installation & Maintenance Manual
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TMC-4A002-002
(P1)
Motor / Supply
Terminals
Function
1 Heater L/+ Fused output for heater.
2 Heater N/- Neutral output for heater, connected to supply N.
3 Supply L/+ Supply Power.
4 Supply N/- Supply Power.
5 External
Brake
Output that switches supply power when motor outputs are energized. Used for spring return electric actuator
brakes.
AC Operation: Switch off when motor on.
DC Operation: Switch on when motor on.
6 Motor CW AC: Energize clockwise motor winding.
DC: Switch (+) supply voltage for clockwise operation.
7 Motor CCW AC: Energize counterclockwise motor winding.
DC: Switch (+) supply voltage for counterclockwise operation.
8 Motor N AC: Motor neutral, connected to supply N.
DC: not used.
(P2)
Signal / Comm
Terminals
Function
1 +24V Out Auxiliary 24VDC output.
2 I/O 1
Signal In Command signal input.
3 Signal GND Command signal reference.
4 I/O 2
Signal Out Feedback signal output.
5 Signal GND Feedback signal reference.
6 COM2 P Communication non-inverting input (Channel 2).
7 COM2 N Communication inverting input (Channel 2).
8 COM1 P Communication non-inverting input (Channel 1).
9 COM1 N Communication inverting input (Channel 1).
10 GND Ground.

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for Electric Actuators
Installation & Maintenance Manual
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TMC-4A002-002 AC Proportional Control TMC-4A002-002 AC Two Position Control
TMC-4A002-002 DC Proportional Control TMC-4A002-002 DC Two Position Control

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for Electric Actuators
Installation & Maintenance Manual
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Input / Output Signal Configurations
Command Type = mA Sinking
Externally Powered Loop Control
Command Type = mA Sinking
2-Wire Transmitter Control
Command Type = mA Sourcing
Externally Powered Loop Control
Command Type = mA Sourcing
2-Wire Transmitter Control
Command Type = 5V and 10V
Command Type = 135Ω Slide Wire or 1kΩ Potentiometer
Command Type = On-Off
Externally Powered Inputs
Command Type = On-Off
Using TMC-4 +24V Output
Feedback = mA or V

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for Electric Actuators
Installation & Maintenance Manual
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3. Menu

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for Electric Actuators
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MAIN submenu
The MAIN menu group contains various status screens displaying functional information such as positioning values, motor
status and control parameters. Pressing [ LEFT ] from any screen will return to the Home screen.
P O S : x x x x
C M D : x x x x
M T R : x x x x
Home
POS:
Current travel position. Percentage with Potentiometer positioning. OPEN, N/A, or CLOSE with
Limit Switch positioning.
CMD:
Setpoint command position. Percentage with Potentiometer positioning. 0.0%, 100.0% or STOP
with Limit Switch positioning.
MTR:
Motor status. OPEN, CLOSE or IDLE
C O N T R O L
C M D : x x x x
F B : x x x x
Control
CMD:
Command signal type set in “Command Type” setting in
COMMAND
CONFIG
submenu
FB:
Feedback signal type set in “Feedback Type” setting in
FEEDBACK CONFIG
submenu.
T E M P E R A T .
M T R : x x x x
A M B : x x x x
Temperature
MTR:
Motor temperature. Only displays with motor temperature monitoring option connected
AMB:
Ambient temperature of TMC-4 installation enclosure.
L I M I T S W T
O P E N : x x x
C L O S : x x x
Limit Switches
OPEN:
State of open limit switch. “ON” if limit switch closed. OFF if limit switch open.
CLOS:
State of close limit switch. “ON” if limit switch closed. OFF if limit switch open.
C O M M S
I D : x x x x
S T A T : x x x x
Communication
ID:
Value set in “Unit ID” setting in
COMMS CONFIG
submenu.
STAT:
Communication status. Indicates if communication is active, idle or lost.
= = = = = = = = = =
C O N F I G U R E
> >
Configure
Enters configuration submenus.

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COMMAND CONFIG submenu
The COMMAND CONFIG menu group contains various parameters that affect the control and response of the actuator.
C O M M A N D
T Y P E :
x x x x
Command
Signal Type
Sets type of command signal used.
10V:
0-10V or 2-10V
5V:
0-5V or 1-5V
mA Sink:
4-20mA sinking
mA Src:
4-20mA sourcing
135 Ohm
1k Ohm
:
2-wire variable resistance input. Selectable between typical 135Ω slide wire,
or 1kΩ potentiometer.
ON
-
OFF:
Independent Open and Close inputs. Feedback is disabled.
Comms: Communication protocol (e.g. Modbus) Specific protocol must be selected in
the
COMMS CONFIG
submenu.
C A L I B R A T E
Z E R O
x x x x
Calibrate
Command
Zero
Sets command signal zero raw count value. Value is scaled between 12 bit count of 0 and 4095 for the selected
command type range. When selected, provide minimum command signal to save.
C A L I B R A T E
S P A N
x x x x
Calibrate
Command
Span
Sets command signal span raw count value. Value is scaled between 12 bit count of 0 and 4095 for the selected
command type range. When selected, provide maximum command signal to save.
D E A D B A N D
x . x %
Deadband
Sets deadband range by percent. Adjust to provide acceptable deviation from command setpoint the controller will
recognize as valid position. When selected, use [UP] or [DOWN] to adjust value.
2.0%
L O S S O F
S I G N A L :
x x x x
Loss of Signal
Sets behavior of actuator when command signal is lost.
In Place:
Remains in current position on loss of command signal.
Open:
Moves to programmed Open position on loss of command signal.
Close:
Moves to programmed Close position on loss of command signal.
Position:
Moves to position defined in “Fail to Position” setting.
F A I L T O
P O S I T I O N :
x x x x
Fail to Position
Sets percent position between 0% and 100% for actuator to control to on loss of command signal. Is only utilized if
“Position” selected in “Loss of Signal” setting.
0.0%

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FEEDBACK CONFIG submenu
F E E D B A C K
T Y P E :
x x x x
Feedback
Signal Type
Sets type of feedback signal.
10V:
0.0 to 10.8 VDC
mA:
0.0 to 21.5 mA
ON
-
OFF:
n/A
C A L I B R A T E
Z E R O
x x x x
Calibrate
Feedback Zero
Sets feedback signal zero raw count value. Value is scaled between 12 bit count of 0 and 4095 for the selected
command type range. When selected, use [UP] or [DOWN] to adjust feedback until desired value is measured.
C A L I B R A T E
S P A N
x x x x
Calibrate
Feedback Span
Sets feedback signal span raw count value. Value is scaled between 12 bit count of 0 and 4095 for the selected
command type range. When selected, use [UP] or [DOWN] to adjust feedback until desired value is measured.
POSITION CONFIG submenu
P O S I T I O N
T Y P E :
x x x x
Position Type
Sets type of feedback for positioning.
Limit SW:
Uses limit switch feedback for 2 position on/off control.
Potent:
Uses potentiometer feedback for modulating and proportional positioning control.
C A L I B R A T E
C L O S E P O S
x x x x
Calibrate Close
Position
Only used with potentiometer feedback to set close position. This position will correspond to a 0% input value.
Value is scaled between 12 bit count of 0 and 4095 based on potentiometer reading. When selected, use [UP] or
[DOWN] to drive motor to desired close position.
C A L I B R A T E
O P E N P O S
x x x x
Calibrate Open
Position
Only used with potentiometer feedback to set open position. This position will correspond to a 100% input value.
Value is scaled between 12 bit count of 0 and 4095 based on potentiometer reading. When selected, use [UP] or
[DOWN] to drive motor to desired open position.
T R A V E L
T I M E O U T
x x S
Travel Timeout
Only used with communication bus options. Value should be greater than the normal actuator travel time. The
TMC-4 begins a counter when the motor outputs are energized to control the actuator to the commanded position.
If the counter exceeds the set value it can indicate a jam or obstruction. The actuator may also be travelling slower
due to loading conditions. When selected, use [UP] or [DOWN] to adjust value. Can also be configured via
communication protocol.
60 sec

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COMMS CONFIG submenu
C O M M S
T Y P E :
xxxx
Communication
Type
Sets type of communication protocol when using one of the communication module options. “Comms” command
type must be selected in the COMMAND CONFIG submenu.
Modbus Modbus RTU
MbusTCP Modbus/TCP
Profibus Profibus DP
U N I T I D :
x x
Unit ID
Actuator ID address. Selectable from 1 to 246
1
B A U D R A T E
x x x x
Baud Rate
Communication channel data rate.
9600, 19200, 57600, 115200 bps
P A R I T Y :
x x x x
Parity
Communication channel parity setting.
None, Odd, Even
T I M E O U T :
x x . x x S
Timeout
Communication timeout. Determines duration of time which the actuator must receive communication before
entering fault condition.
10.00 sec
SYSTEM CONFIG submenu
M O T O R
T Y P E :
x x
Motor Type
Selects type of motor being operated. AC setting is for split-phase AC type motor. DC is for DC motors. This
setting is independent of the AC/DC power supply switch, but should correspond to the switch position.
AC
C Y C L E C N T
O P E N : x x x
C L O S : x x x
Cycle Count
Displays count for open and close position since power supplied to controller.
C L E A R C Y C L
C O U N T S
> >
Clear Count
Clears cycle count. Press [RIGHT] or [CENTER] to select, then press again to confirm and clear counts.
R E S T O R E
D E F A U L T S
> >
Restore Defaults
Restores all settings to their default value. Press [RIGHT] or [CENTER] to select, then press again to confirm and
reset to default values.
S O F T W A R E
V E R S I O N
x x . x x
Software Version
Displays current software revision number.

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4. Setup and Calibration
Feedback Potentiometer Adjustment
A feedback potentiometer is used to detect the position
of the actuator between the 0% to 100% limits for
modulating and proportional control applications. The
feedback potentiometer is coupled to the actuator
output indicator shaft by a set of gears.
The effective electrical angle of the potentiometer,
actuator rotation angle, and ratio of the feedback gears
determine how much of the potentiometer range will be
used for feedback. Typically, the actuator is moved to
the halfway position of the normal travel range, and the
feedback potentiometer is adjusted to the midpoint of its
effective electrical range to ensure operation within the
feedback potentiometer limits.
Analog Control
For when operating as proportional control actuator using some analog input.
1) Set Supply Type Switch for AC or DC.
2) Set “Motor Type” in SYSTEM CONFIG for AC or DC to match Supply Type Switch setting.
3) Select and calibrate input command signal.
a) Enter COMMAND CONFIG submenu.
b) Select command signal type in “Command Type” setting.
c) Connect command signal source to input terminals per appropriate wiring diagram.
d) In “Calibrate Zero” setting, send 0% command signal and confirm.
e) In “Calibrate Span” setting, send 100% command signal and confirm.
4) Select and calibrate output feedback signal.
a) Enter FEEDBACK CONFIG submenu.
b) Select feedback signal type in “Feedback Type” setting.
c) Connect feedback signal monitor to output terminals per appropriate wiring diagram.
d) In “Calibrate Zero” setting, press [UP] or [DOWN] until feedback signal equals desired 0% feedback and confirm.
e) In “Calibrate Span” setting, press [UP] or [DOWN] until feedback signal equals desired 100% feedback and
confirm.
5) Set positioning method.
a) Enter POSITION CONFIG submenu.
b) Set to “Potent” in “Position Type” setting
c) Adjust feedback potentiometer to center at 50% position.
i) In “Calibrate Close Pos” or “Calibrate Open Pos”, press [UP] or [DOWN] to drive actuator to 50% position.
ii) Rotate feedback potentiometer until display reads between 1900-2200, then tighten gears.
d) In “Calibrate Close Pos”, press [UP] or [DOWN] to drive actuator to desired 0% position and confirm.
e) In “Calibrate Open Pos”, press [UP] or [DOWN] to drive actuator to desired 100% position and confirm.

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Two-Position Control
For when operating as two position on/off actuator.
1) Set Supply Type Switch for AC or DC.
2) Set “Motor Type” in SYSTEM CONFIG for AC or DC to match Supply Type Switch setting.
3) Select On-Off input command.
a) Enter COMMAND CONFIG submenu.
b) Select “On-OFF” in “Command Type” setting.
4) Set positioning method.
a) Enter POSITION CONFIG submenu.
b) Set to “Limit SW” in “Position Type” setting
Communication Bus Control
For when using one of the optional communication bus add-on modules.
1) Set Supply Type Switch for AC or DC.
2) Set “Motor Type” in SYSTEM CONFIG for AC or DC to match Supply Type Switch setting.
3) Select communication input command.
a) Enter COMMAND CONFIG submenu.
b) Select “Comms” in “Command Type” setting.
4) Configure communication setting.
a) Enter COMMS CONFIG submenu.
b) Select communication protocol in “Communication Type” setting.
c) Set address and other communication parameters in appropriate setting as needed.
5) Set positioning method.
a) Enter POSITION CONFIG submenu.
b) If operating as 2-position actuator, set to “Limit SW” in “Position Type” setting.
f) If operating as proportional control actuator, set to “Potent” in “Position Type” setting.
i) Adjust feedback potentiometer to center at 50% position.
ii) In “Calibrate Close Pos” or “Calibrate Open Pos”, press [UP] or [DOWN] to drive actuator to 50% position.
iii) Rotate feedback potentiometer until display reads between 1900-2200, then tighten gears.
iv) In “Calibrate Close Pos”, press [UP] or [DOWN] to drive actuator to desired 0% position and confirm.
v) In “Calibrate Open Pos”, press [UP] or [DOWN] to drive actuator to desired 100% position and confirm.

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5. Dimensions
TMC
-
4A002
-
001
TMC
-
4A002
-
002

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6. Specifications
Power
Supply:
Switch AC: 85 – 250 VAC, 50/60Hz, 1 Phase
Switch DC: 10-30 VDC
Fuse
:
10A, 250V, Time Delay, 5 x 20mm
Command Signal In
Voltage
:
-0.8 to 10.8 VDC
Current
:
0 to 23 mA
Resistance:
135Ω Command: 150 Ω maximum (20mA excitation current)
1kΩ Command: 1.1 kΩ maximum (2.7mA excitation current)
On-Off:
24 VDC maximum
< 10V = Off
≥ 10V = On
Resolution
:
12 bit
Feedback Signal Out
Voltage
:
0 to 10.8 VDC
Current
:
0 to 21.5 mA
Load
:
Up to 400Ω@12VDC to 1000Ω@24VDC
Resolution
:
12 bit
Position Feedback
Voltage
:
0 to 3.3 VDC
Potentiometer
:
1kΩ
Limit Switches
:
Normally Open
Outputs
+24V Out
:
24VDC, 30mA maximum
Ext. Brake
:
300mW, 350V, 120mA continuous load
Environmental
Operating
:
0°C to 60°C (32°F to 140°F)
Storage
:
-40°C to 85°C (-40°F to 185°F)
Relative
Humidity
:
0 to 90% non-condensing
Connections
Terminals:
TMC-4A002-001: 0.15” pitch, 16 – 30 AWG (0.05 – 1.3 mm2)
TMC-4A002-002: 5mm pitch, 14 - 26 AWG (0.2 - 2.5 mm2)
Headers
:
0.1” pitch, 2pos and 3pos
Expansion Header:
TMC-4A002-001: 2x7 pos, 2mm pitch
TMC-4A002-002: 2x7 pos, 0.1” pitch

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A-T Controls product, when properly selected, is designed to perform its intended function safely during its useful life. However, the purchaser or user of
A-T Controls products should be aware that A-T Controls products might be used in numerous applications under a wide variety of industrial service
conditions. Although A-T Controls can provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser
/ user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of A-T Controls
products. The user should read and understand the installation operation maintenance (IOM) instructions included with the product and train its employees
and contractors in the safe use of A-T Controls products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only. Because
A-T Controls is continually improving and upgrading its product design, the specifications, dimensions and information contained in this literature are
subject to change without notice. Should any question arise concerning these specifications, the purchaser/user should contact A-T Controls.
For product specifications go to http://download.a-tcontrols.com/
A-T Controls, Inc. • 9955 International Boulevard, Cincinnati, OH 45246 • Phone: (513) 530-5175 • Fax: (513) 247-5462 • www.atcontrols.com
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