Hi Russ;
Suggestion: You might want to try doing a "Full Build" on your target after adding the new TP ... especially with the heavy PFC framework - to get all the related code generated properly. I have run into this many times, even with my own framework.
FWIW: I don't know of any Control array restrictions in the PFC or PB that should not support up to at least 32K objects per parent.
Regards ... Chris