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D a t a   F l o w   S y s t e m s ,   I n c .

1. Safety Precautions

Review the following information before installing, servicing, or replacing the TCU or any of its components.  

General Precautions

• 

Carefully read the installation and wiring instructions before connecting the TCU to its power source. 

• 

If the TCU is to be installed into an existing control panel, make sure all sources of power are de-energized (including 
those fed by external sources) before starting the installation. 

• 

Do not work on the TCU or connect/disconnect any of its cables during periods of lightning activity. 

• 

To prevent overheating the TCU, do not operate it in an area that exceeds the recommended temperature range of 
-10°C to 60°C (14°F to 140°F). When using the recommended backup battery, the upper temperature limit is 50°C 
(122°F).

• 

Ensure that the unit is connected to earth ground during normal use. 

• 

Precautionary measures must be observed when installing, operating, and servicing the TCU in order to prevent shock.

• 

All wiring should conform to federal, state, and local electrical codes. 

• 

Read and follow all precautions displayed on the TCU’s side-mounted labels. 

Connecting/Disconnecting the TCU

When connecting the TCU:
 

1. Ensure the cables to be connected to the TCU are routed with sufficient strain relief.

 

2. Integrate all required wires and connect to the TCU.

 

3. Close circuit breakers as required; the TCU will start up as soon as power is applied.

When disconnecting the TCU: 
 

1. Power down the unit. 

 

2. Remove all sources of power, including those fed by external sources.  

 

3. Remove all cables connected to the TCU including the ground cable.

 

4. Move the cables ensuring they will not become entangled in or caught on anything in the surrounding area.

Even if the LCD screen and status LED are not lit, assume the TCU is still powered. The TCU may be in the off 
state, and AC power may still be present. To remove power, the external circuit breaker must be opened. Note 

that TCU power and 3 phase power may be on separate circuit breakers. 

Summary of Contents for TCU800

Page 1: ...Installation and Operation Manual T C U 8 0 0 Data Flow Systems Inc P r e l i m i n a r y ...

Page 2: ...Intentionally left blank ...

Page 3: ...ument at any time without notice This document contains information related to special features and functions that are only available when the TCU is utilized in a DFS TAC II SCADA System These special features and functions may not be available when the TCU800 is utilized in a 3rd party SCADA System If you are unsure about the availability of a feature or function please contact DFS for clarifica...

Page 4: ...D a t a F l o w S y s t e m s I n c Intentionally left blank ...

Page 5: ...ol 13 Analog Input Monitoring 13 Serial Connectivity 14 Phase Voltage Monitoring 14 Internal Monitoring 15 Automatic Manual Control 15 Level Sensing Transducers 16 Internal Phase Monitor 17 Outputs 17 Touchscreen 18 Electrical Protection 18 Battery Backup Optional 18 Principles of Operation 19 Discrete System Contact Closure Devices 19 Analog System Pressure Transducer 21 4 Setup 27 Mounting Instr...

Page 6: ...Screen 75 8 Modbus Support 76 Appendix A Technical Specifications 83 B Checkout Procedure for Pump Controller 84 Step 1 Electrical Termination Review 84 Step 2 Operations Testing 85 C Maintenance and Troubleshooting 87 Blown Fuse 87 TCU Replacement 88 D Parts List 89 E Mounting Instructions 96 F Well Volume Calculations 101 G Adding a RIO to the TCU 102 TCU Replacement 102 Configure RIO for Learn ...

Page 7: ... as Backup Pump Down Mode 119 Discrete System Pump Down Mode 121 J Polling the TCU DFS Point and Modbus Registers 124 Pump Control Application by Module Letter and Point 124 Pump Control Application by Modbus Register 130 K Support Service and Warranty 143 Support and Service 143 Technical Product Assistance 143 Return Authorization RA Procedure 143 Notice 144 Warranty 144 Questions or Comments on...

Page 8: ...ii Intentionally left blank ...

Page 9: ...g systems that use Data Flow Systems TCU For information on customizing the TCU s operations contact DFS Document Conventions The following conventions are used throughout this manual Bulleted lists provide information not procedural steps Numbered lists provide sequential steps or hierarchal information Bold italic type is used for emphasis All CAPITALIZED ITALIC type is used for terminal names A...

Page 10: ...ii Intentionally left blank ...

Page 11: ... observed when installing operating and servicing the TCU in order to prevent shock All wiring should conform to federal state and local electrical codes Read and follow all precautions displayed on the TCU s side mounted labels Connecting Disconnecting the TCU When connecting the TCU 1 Ensure the cables to be connected to the TCU are routed with sufficient strain relief 2 Integrate all required w...

Page 12: ...modules via a radio or network link Can be incorporated into a Remote Terminal Unit RTU by using a Bus Extender Module BEM The default pump control application program enables the TCU to be easily implemented in lift station or storage tank applications The TCU contains all the hardware and software needed to control up to three motor starters Placing custom logic on the TCU enables it to perform ...

Page 13: ...with industry standard devices and VFD motor controllers Network Adapter An integrated 10 100 network adapter allows remote access via SSH client over a local area network USB Service Port Three full speed USB 2 0 ports 2 external 1 internal storing station address config uration profiles and pump statistics Provides Ethernet connectivity with additional USB to ETH adapter Protection Protective fe...

Page 14: ...onnectorized wire terminals allow servicing or replacement of the unit without disconnecting wires Mounting Options Mounting options allow the TCU to be mounted to a front panel as well as mounted flush against or stood off from the back plate of a control panel Legacy TCU001 Operation The TCU800 is backward compatible with the TCU001 Existing TCU001 configurations can be transferred to the TCU800...

Page 15: ...ew digital and analog inputs are disabled so as not to conflict with any pre configured MODBUS devices that may be occupying modules H through O In order to enable the new I O which will be dynamically assigned at the next available module space see procedure on page 82 Added Expansion card slot allows for future expansion of I O using a DFS TCU800 expansion card Ethernet USB internal base 10 100 ...

Page 16: ...0mA input 24V Not Rated I2 P3 11 ANALOG4 return signal for ANALOG4 P3 10 24V Not Rated P1 10 BEMGND Isolated ground wire to BEM001 pin 12 24V Not Rated P1 11 BEM_PWR Isolated power wire to BEM001 pin 10 24V Not Rated P1 12 BEM_CTS Isolated clear to send wire BEM001 pin 6 24V Not Rated P1 13 BEM_RXD Isolated receive data wire to BEM001 pin 4 24V Not Rated P1 14 BEM_TXD Isolated transmit data wire t...

Page 17: ... Common return for input level aux inputs and alarm silence switch 10 30VAC DC 100mA RTN P2 15 ISOGND Internally supplied 24VDC bias source return isolated 24V Not Rated P2 16 ISO 24V Internally supplied 24VDC bias source voltage isolat ed 24V Not Rated B10 P2 17 TXD_232 RS 232 transmit data to external device 24V Not Rated P2 18 RXD_232 RS 232 receive data from external device 24V Not Rated P2 19...

Page 18: ... 24V Not Rated P4 10 CTS_RAD RS 232 clear to send 24V Not Rated P4 11 SDI12_GND SDI 12 return ground 24V Not Rated P4 12 SDI12_DATA SDI 12 data 24V Not Rated P4 13 SDI12_PWR 12VDC power supply for SDI 12 bus devices 24V Not Rated P4 14 Unused Reserved for future use do not connect Not Connected P2 20 SHIELD Internally connected to chassis ground cable shield for analog monitor signals Ground P2 21...

Page 19: ...gital input Motor Status where is the associated pump number 1 2 or 3 Flashing A pump status LED will flash when an associated pump is overridden via telemetry or a motor start or stop fault has occurred Flashing will continue for a fault until the pump has properly run or the HOA switch for that pump is taken out of Auto Alarm On Off The alarm LED is on when any alarming condition is active and a...

Page 20: ... The state of the pump is being controlled by the operating logic program and telemetry override and disabled statuses See the telemetry control section for more information Motor Fault Reset If a motor starter fault occurs it is reset by placing the corresponding HOA switch in Hand or Off Soft Touch Button The TCU800 has a single soft touch button labeled with a home symbol The button is located ...

Page 21: ... logs service port access and updating the TCU800 software Configuration Port A removable USB drive replaces the address strap functionality and adds the ability to alter all TCU800 profile configura tion options A congifuration USB can be placed in either of the two USB ports Boot Up When the TCU800 boots up it checks for a USB with a configuration loads it and saves it internally If no con figur...

Page 22: ...n configured Six discrete inputs are provided as float level inputs with a common ground The digital ground is also common to the auxiliary input and alarm silence inputs Auxiliary Input The auxiliary input provides the ability to monitor an input and control an output aux out based on it s status with several configurable options see the auxiliary control configuration section The digital ground ...

Page 23: ...its operation See chapter 6 Operating Procedures for more information on configuration options P1 16 ALM_HORN Load side of alarm horn relay NO P1 17 ALM_LITE Load side of alarm light relay NC P1 18 ALM_PWR Line side of alarm relays P1 19 AUX_OUT Load side of auxiliary relay P1 20 AUX_PWR Load side of auxiliary relay P1 21 MTR3_STR Load side of motor starter 3 relay P1 22 MTR2_STR Load side of moto...

Page 24: ...h standard RS485 sensors as well as other DFS telemetry equipment Protected from voltage transients Half duplex Supports baud rates 1200 115200 P4 2 RS485_GND RS 485 serial ground reference P4 3 RS485_B RS 485 serial interface B P4 4 RS485_A RS 485 serial interface A P4 5 SHIELD Internally connected to chassis ground Cable shield for RS 485 or RS 232 P4 6 EX_GND_RAD RS 232 signal ground P4 7 RTS_R...

Page 25: ...lt is active when the 24VDC bias power supply drops below 20VDC Process Fault The process fault is active when the control program is detected as no longer operating Automatic Manual Control When the TCU s Hand Off Auto H O A switches are in the Auto position the TCU provides automatic control over a pump system However there are two ways to partially or completely override the TCU and manually co...

Page 26: ...g Devices The TCU provides the option to monitor analog level sensing devices including ultrasonic hydraulic pressure and pneumatic pressure transducers through an industry standard 4 20mA 0 5V interface Any analog level detection transducer self powered or TCU powered that supplies a 0 5V 0 10V or 4 20mA current signal can be used as an analog level input device and can be loop powered using the ...

Page 27: ... and relays rating listed elsewhere in this manual Ifnot used for Alarms either can be configured for manual control via telemetry USB Ports and Configuration The TCU s face plate features two USB type A ports that can be used for diagnostics configuration storage and updating A USB flash drive correctly formatted and loaded with appropriate files will allow easy transfer of pump configuration par...

Page 28: ... provided for connecting a battery to the TCU at connections P1 8 and P1 9 Connecting a battery to the TCU allows it to communicate and operate albeit without the ability to run pumps when primary AC power is lost The alarm horn and light can be powered from the battery to provide alarm functionality during a power outage All digital monitor inputs using ISO 24V P2 16 as a bias voltage source cont...

Page 29: ...de fills a tank by maintaining the tank level between the Off and Lead levels Level Sensing Systems Discrete vs Analog A discrete system uses a device that provides an On Off signal These are typically float balls submerged into a wet well The floats are wired to the appropriate inputs on the TCU The TCU then controls the operation of up to three pumps based on input signals from these floats In a...

Page 30: ...inimum number of levels required depends on the type of station simplex one pump duplex two pumps or triplex three pumps Low Level All pumps are stopped and alarms are activated Low is active when the well s level is below Low level Must be set below all other levels Off Level Minimum operational level of a well All pumps are stopped when the well s level is below the Off level Lead Level Lead fir...

Page 31: ...ied 4 20 mA or 0 5 V input that is wired to the TCU s analog input The operator sets the 4 mA or the 1 V input equal to the transducer s low range in feet and the 20 mA or 5 V input equal to the transducer s high range in feet Low and High levels as well as staging levels for the Lead Lag and Lag2 pumps are also set by the operator The TCU interprets the input signal and starts or stops pumps acco...

Page 32: ...d pump is stopped when the well s level is below the Lead Off level Lag Off Level duplex and triplex stations only Lag second pump is stopped Lag Off is active when the well s level is below Lag Off level Lag2 Off Level triplex stations only Lag2 third pump is stopped Lag2 Off is active when the well s level is below Lag2 Off level Lead Level Lead first pump is started Lead is active when the well...

Page 33: ...triplex stations only Lag2 third pump is started Lag2 is active when the tank s level is below the Lag2 level Low Level All pumps are stagger started and alarms are activated Low is active when the tank s level is below Low level Must be set below all other levels Pump Alternation The TCU includes a pump alternator function that can be used to minimize pump cycle times or equalize pump run times W...

Page 34: ...ommodate the use of an external phase monitor where one is required The external phase monitor must provide a closed set of contacts that open during a phase fault The voltage used to monitor the set of contacts must be the same used to monitor the pump run statuses Phase Monitor Bypass The TCU s phase monitor can be bypassed if the internal phase monitor function is not required and there is no e...

Page 35: ...onally the auxiliary input can operate as a pulse counter and be used with pulse type flow meters and rain gauges To use AUX_IN and AUX_OUT as general monitor and control points or to use AUX_IN as a pulse input the time delay relay function must be disabled This is done by setting the function s delay time to 0 zero Time Delay Relay An example of an auxiliary relay application is switching on a b...

Page 36: ...faulted pump until it is taken out of service via its corresponding H O A switch Phase Fault The TCU s phase monitor is designed to detect phase losses high and low phase faults and phase sequence faults When the TCU detects a phase fault it disables the pump motor outputs and activates the alarm light and horn relays The TCU s H O A switches can be used to override the TCU s phase monitor and con...

Page 37: ...the installation and operating instructions thoroughly before installing or servicing this equipment Precautionary measures must be observed when installing operating and servicing the TCU in order to prevent shock from voltages present If the TCU is to be installed into an existing control panel make sure that all breakers are shut off before starting the installation All wiring must conform to f...

Page 38: ... The Power LED does not indicate that AC power has been removed Even if the TCU s Power LED is not lit you should assume that the TCU is still powered To remove power you must turn off the external circuit breaker AC Power The TCU operates from 120 VAC Verify the input voltage on the TCU s connector label before wiring Three terminals are provided for wiring power P1 5 AC_PWR AC power P1 6 AC_NEUT...

Page 39: ...ects the TCU relays from short circuited coils 3 Connect the other side of the motor starter coil through appropriate disabling contacts to control power neutral Make similar connections for Pump 2 and Pump 3 for duplex and triplex stations When the alternator function is disabled through the TCU s configuration MTR1_STR controls the Lead pump MTR2_ STR controls the Lag pump and MTR3_STR controls ...

Page 40: ...outputs use mechanical relays to drive up to 0 5 A at 120 VAC or 1 A at 0 24 VDC The addition of 1 A slow blow fuses on the TCU outputs is recommended to protect the TCU s alarm relays from short circuits The alarm light output is a set of contacts that are closed when the TCU is powered down The alarm light output is designed to energize an incandescent lamp Any other application requires an inte...

Page 41: ... with the white band on the diode body must be connected to the supply power and the anode connected to the supply power Most DC relays do not have a polarity requirement on their coils so you must trace out the polarity or use a Voltmeter Remember that the inductive transient is a reverse voltage which causes the diode to conduct and short out the voltage Phase Monitor Single Phase Option 240 VAC...

Page 42: ...s phase monitor is labeled for clockwise phase sequence If the three phase power is labeled for counter clockwise rotation and is connected in accordance to the TCU s terminal label the TCU will detect a phase sequence fault To correct this condition reverse any two leads connected to the TCU s phase monitor Single Phase Monitor Wiring Three Phase Monitor Wiring ...

Page 43: ...alarm LVL inputs are used as markers to determine the current level of the well Using information from these inputs pump control logic decides if pumps need to be turned on or off MTR SEAL Motor Seal inputs must be connected to a seal sensor This detects the presence of water inside the pump housing which typically leaks past the shaft seal The sensor will activate if a leak in the seal is detecte...

Page 44: ... power at the output of the motor breaker and through the motor starter auxiliary contact Connect a wire from this point through a voltage dropping resistor to the corresponding motor run input P2 1 for MTR1_RUN P2 2 for MTR2_RUN and P2 3 for MTR3_RUN Connect the IN_COM_1 terminal P2 5 to the neutral The transformer must provide AC neutral When wiring to a typical three phase 4 wire 240 V transfor...

Page 45: ...35 S e t u p Input Bias Voltage Resistor Size BIAS None 10 30 VDC VAC None 31 100 VDC VAC 22K 1 2 W 101 200 VDC VAC 47K 1 2 W 201 300 VDC VAC 100K 1 W Motor Run Monitoring Signal 4 wire transfer ...

Page 46: ...erent types of input supported transducers Digital type devices such as contact closures float switches and pressure switches Analog type devices that are either analog current 4 20 mA or analog voltage 0 5 V Floats The input terminals for the contact closure devices are LOW_LVL P2 6 OFF_LVL P2 7 LEAD_LVL P2 8 LAG1_LVL P2 9 LAG2_LVL P2 10 HIGH_LVL P2 11 ...

Page 47: ... input to be used to detect other signals If a LOW_LVL is not used the LOW_LVL function must be disabled in the TCU s configuration as the TCU will not function and control pumps unless this is done 1 Connect the bias source to one side line side of the floats or pressure switches being monitored and the bias return to the IN_CON_2 P2 14 2 Connect the other side load side of the float or switch to...

Page 48: ...P2 24 SHUNT must be tied to ANALOG for current signals for ANALOG1 Jumping SHUNT to ANALOG places a 250 Ω load across the ANALOG1 and ANALOG terminals which converts the voltage input to a current input 1 Wire the power for the analog transducer according to the transducer manufacturer s instructions 2 Connect the positive current or voltage signal from the transducer to the terminal ANALOG1 P2 22...

Page 49: ...39 S e t u p Externally Powered Non submersible Transducer TCU Powered Non submersible Transducer ...

Page 50: ...Auxiliary Analog Input Optional Configurations and Hookups Backup Battery Two optional backup batteries are available for use with the TCU Although a backup battery is not necessary for operation of the TCU it is recommended to prevent telemetry data loss from a power failure Note that statistical and configuration data is retained even without a backup battery The purpose of the battery is to mai...

Page 51: ...ral with no voltage potential when referenced to earth ground or the negative terminal of a DC power supply connecting the backup battery since this circuit is not diode protected Alarm Silence Switch The alarm horn if installed can be silenced in three ways through the ALM_SIL input by pressing the TCU s Power Home button or by navigating to the TCU s Alarm screen and viewing the alarm The follow...

Page 52: ...r is designed for 200 240 VAC or 480 VAC using external resistors 3 phase only If you are using an external phase monitor and would like to have the voltage values available to HT3 for monitoring and trending purposes you can wire the TCU s three phase inputs For this option to work correctly you must also configure the TCU s phase monitor range and alarm trip points This is necessary because if t...

Page 53: ... either AC neutral with no voltage potential when referenced to earth ground or the negative terminal of a DC power supply Auxiliary Digital Input AUX_IN is an optically isolated digital monitor point and is wired the same as the other monitor points Connect a bias voltage to one side of a contact closure device Connect the other side through a voltage dropping resistor if required to the AUX_IN t...

Page 54: ...n a TCU is included in an RTU via a BEM it is important to remember that the TCU defines its internal modules without exception Any additional modules added to the RTU must be addressed beginning with the module letter after the last dummy module defined in the TCU ...

Page 55: ...45 U s e r I n t e r f a c e 5 User Interface touchscreen soft touch button receive LED HOA switches USB port HOA LEDs transmit LED status LED ethernet pigtail optional radio pigtail optional Trend View ...

Page 56: ...46 C h a p t e r 5 Quick View Analog View Pump Statistics ...

Page 57: ...47 U s e r I n t e r f a c e Alarms Settings Screen 1 Settings Screen 2 ...

Page 58: ...48 C h a p t e r 5 Advanced Settings About ...

Page 59: ... licensed frequency that can be used Even when adding a site to an existing frequency the FCC requires that a complete application be submitted DFS can assist you in obtaining a new licensed frequency or adding a site to an existing frequency Configuration Setup Configuring the TCU800 is done from the Settings screen First ensure the H O A switches are all in the HAND or OFF position Then navigate...

Page 60: ... the new value to be configured is selected the window will disappear Lastly the values can be altered via a digital switch This method is presented when a configuration option only has two options In this editing process no additional window will appear Clicking the configuration option will cause it to toggle between the two options Enabled and Disabled Remote Configuration Changes Changing conf...

Page 61: ...ches and pressure switches Alternator Type None All 1 2 2 3 Minimum Run Time To prevent short cycling of the pumps a minimum run time can be configured When used this option will cause a started pump to run for the specified time before it can be turned off The minimum run time can be set between 0 and 2 hours in one tenth minute increments Setting MinmumRun to zero disables the function which all...

Page 62: ...abled Alarm Output Alarm Horn Disabled Enabled When Alarm Horn is enabled alarms are reported both at the station and through telemetry If there are active alarms when the TCU s alarm horn option is enabled the alarm horn will not sound until the existing alarms have cleared and a new alarm occurs Disabling the alarm horn option does not prevent alarms from being reported via telemetry Alarm Light...

Page 63: ...ndition generates a low well alarm and an optional transducer fault alarm XDCR High Float Fault Disabled Enabled When this option is enabled a high float condition generates a transducer fault and switches control to the configured fault mode Leaving the option disabled leaves pump control on the primary transducer whenever a high float condition occurs or the transducer reaches or exceeds 20 mA X...

Page 64: ...terface requirements of the radio the TCU is connected to A value of 0 indicates it is disabled A value of 1 indicates it is enabled Async Baud The communication baud rate on the radio Current config options are 0 for legacy radio or 9600 for high speed serial radio Dash Number The dash number is assigned to indicate the model and mode of the radio installed in the unit GBL MOD DLY Global Module D...

Page 65: ... and makes them available to telemetry as general monitor and control points Aux Input Turns off on Together the settings AuxOut Turns On Off and AuxIn Turns On Off define how AUX_OUT responds when the state of AUX_IN changes e g AUX_OUT turns OFF whenAUX_IN turns OFF orAUX_OUT turns OFF whenAUX_IN turns ON Aux Input Alarm off on The TCU monitors the AUX_IN terminal p2 12 and it can be configured ...

Page 66: ...tations only Pump Up mode In tank filling operations the TCU turns off the Lag2 or third pump when the tank s level rises above this set point Pump Down mode For well emptying operations the TCU turns off the Lag2 or third pump when the well s level falls below this set point This can be set to the same value as LeadOff Pt for either operation Lag 1 On Level Note This setting is used for duplex tw...

Page 67: ...umps are shut down and alarms are activated when the well s level falls below this set point This level must be set below all other levels XDCR 1 Low Cal Point The value expected when the input is at its lowest signal level 4 mA or 0 V depending on transducer type XDCR 1 High Cal Point The value expected when the input is at its highest signal level 20 mA or 5 V depending on transducer type XDCR 2...

Page 68: ...igital monitoring is enabled set to one of two failure alert options for a seal failure Generic Input passes the value through to telemetry Seal Failure generates an alarm and stop pumps when the input reaches the state indicated by the SEAL ALARM ON option High or Low SEALAlarm on The digital state of the pin High Low which will generate an alarm for the SEAL Function SEAL Failure function only A...

Page 69: ...hose listed here then the TCU will resolve the baud rate to the closest valid value H Address ModX Adr address is the Modbus device ID node and the first register for the range of registers being added to the current module The ID and starting register are separated with a dot For example ModH Adr would be 1 10001 when adding digital inputs to device 1 module H Valid range for Modbus device IDs is...

Page 70: ...ystem Health Display Touch Gestures off on Touch gestures are subtle animations displayed when the TCU800 detects a touch on the interface Use this feature to ensure the unit is properly reading touches Debug Logging off on Debug Logging refers to the internal logging for the unit When Debug Logging is on bug reports will be sent to the manufacturer for review and fixing TCU Settings Well Volume C...

Page 71: ...ation values listed in the Autodialer section of the editor as the TCU800 does not support Autodialer and the settings have been repurposed for other use This workaround is temporary If only changing a few configuration values this step can be bypassed as only the changed values need to be selected and sent For more detail on remote configuration changes see the HT4 User Guide available on dataflo...

Page 72: ...screen with the month day year hour minute and second to which the TCU is currently set Selecting the Edit button at the bottom of this screen presents a screen listing each option for individual editing Scroll to see all five options When the date and time are correct press Save Please note if edits are made the time change takes effect as soon as the Save button is pressed Reset Pump Stats Selec...

Page 73: ...r future use or transfer to another unit a USB drive is needed Insert the USB into the top port on the face of the TCU Then navigate to the Advanced Settings and select the Device Manager icon On the screen that appears select Export Settings If the export to the USB drive was successful a notification reading Export successful will appear If the export failed or no USB was available the notificat...

Page 74: ...in obtaining a new licensed frequency or adding a site to an existing frequency TCU Installed with DFS RTU If the TCU is being interfaced with an RTU station a Bus Extender Module BEM must be installed in the RTU and connected to the TCU If the TCU s pump controller process is being used the TCU must be configured with the number of real modules already on the bus The TCU will then occupy the next...

Page 75: ... GND P1 10 Do not jumper pins 43 41 39 37 and 35 on the BEM Bus Extender Module Wiring Diagram TCU Used with Modbus Compatible Radio The TCU includes an RS 232 Modbus radio interface which acts as an interface to industry standard radios Pins on the TCU s second bottom connector P 4 are provided for connecting the TCU to an external RS 232 Modbus compatible radio For more information on this optio...

Page 76: ...vice P4 9 EX_RXD_RAD RS 232 recieve data from external device P4 10 CTS_RAD RS 232 clear to send TCU as Stand Alone Unit The TCU can be ordered with an integrated 2 W 200 MHz radio or 5 W synthesized 400 MHz radio and operate independently of an RTU The TCU s integrated digital radio enables radio communication between the TCU and the HyperTAC central computer or server Hyper SCADA Server Through ...

Page 77: ...67 O p e r a t i n g P r o c e d u r e s TCU Installed in Existing Control Panel ...

Page 78: ... run time for each configured pump Average amount of flow each configured pump moves per pumping cycle Total cycles for each configured pump The TCU begins logging these running totals and averages when the unit is installed The unit continues accumulating data until the time meters are reset HyperTAC Software Configuration Telemetry components drivers stations modules points etc are configured us...

Page 79: ...he alarm message stops flashing Messages for inactive cleared alarms are static non flashing These messages are stored in the TCU s alarm log until they are viewed Once a message for an inactive alarm condition has been viewed it is cleared from the TCU s display The Alarm LED flashes when there are active alarms and is static on continuously lit until all alarms have cleared and all corresponding...

Page 80: ...urrent load on the ISO 24V source It should be less than 100 mA If the current load is excessive disconnect and isolate ISO 24V and ISOGND terminals to determine if the fault is with the bias source or in the external circuitry If the fault appears to be with the external circuitry try isolating each input connected to the ISO 24V voltage until the problem is found If the problem cannot be isolate...

Page 81: ...ed at the HIGH_LVL input Measure the voltage between the HIGH_LVL and IN_COM_2 terminals Make sure the high float or pressure switch is not fouled or shorted If necessary disconnect the HIGH_LVL input to isolate the problem further Phase Sequence Fault The TCU s phase monitor is designed to detect phase losses high and low phase faults and phase sequence faults When the TCU detects a phase fault i...

Page 82: ...ured from 2 510 seconds Zero disables the starter fault alarm and the output remains on regardless of the run status input To accommodate applications where the run signal may not be immediate such as soft starts or Run signals from check valves you can configure the TCU with a longer start and stop delay A pump that experiences a Motor Start Fault with or without Auto Retry enabled remains faulte...

Page 83: ... the input to follow the output is two seconds To accommodate applications where the stop signal may not be immediate such as occurs with solid state motor controllers you can configure the TCU with a start and stop delay from 2 510 seconds If the Auto Retry function is enabled see Auto Retry page 53 the TCU will attempt to use the faulted pump the next time its turn comes up in the alternation or...

Page 84: ...nd or low float Timer based on the station s pumping history average cycle per each hour of the day Second analog transducer Float system Off float and at a minimum a Lead or High float Combination of a high and or low float and the desired fault mode timer second transducer floats The TCU uses the selected backup scheme until the problem with the transducer has been identified and fixed and the T...

Page 85: ...ppendix H Support Service and Warranty for removal replacement and servicing instructions Leaving the Alarms Screen Use the TCU s navigation keys to exit the Alarms screen All inactive alarms are cleared from the TCU s alarm log when the Alarms screen is exited Additionally if no active alarm conditions exist leaving the Alarms screen clears the Alarm LED ...

Page 86: ...or your installation must be identified in the TCU s configuration TCU as Modbus Slave RS 232 Interface The TCU s RS 232 Modbus interface acts as an interface to industry standard Modbus compatible devices including radios modems and PLCs Connecting a serial Modbus device to the TCU s RS 232 interface connector P4 enables the TCU to operate as a Modbus slave device and respond to queries of its I ...

Page 87: ...77 M o d b u s S u p p o r t Figure 1 Figure 2 Figure 3 ...

Page 88: ...IELD Internally connected to chassis ground Cable shield for RS 485 or RS 232 P4 6 EX_GND_RAD RS 232 signal ground P4 7 RTS_RAD RS 232 request to send P4 8 EX_TXD_RAD RS 232 transmit data to external device P4 9 EX_RXD_RAD RS 232 recieve data from external device P4 10 CTS_RAD RS 232 clear to send In Figure 4 note that the RTS request to send and CTS clear to send connections are optional They are...

Page 89: ...s of your system Figure 5 Querying the TCU When communicating with the TCU via Modbus radio or as a Modbus slave device via the RS 232 port you must query the TCU using the equivalent Modbus register The TCU supports the following Modbus functions on its RS 232 serial slave port 01 Read Coil Status read digital control registers 1 9999 02 Read Input Status read digital status registers 10001 19999...

Page 90: ...CU s P4 connector is its interface to RS 485 devices Refer to the pin definitions for the TCU s Bottom Connector 2 P4 provided on page 8 A wiring diagram is provided below The TCU does not support 15 Force Multiple Coils control multiple control registers 16 Preset Multiple Registers control multiple analog control registers TCU as a Modbus Master Device RS 485 Interface When the TCU is used as a ...

Page 91: ...onfiguring the TCU for Modbus polling The TCU polls Modbus registers as follows Digital Status 10001 19999 and Analog Status 30001 39999 Registers are polled continually Digital Control 0001 9999 andAnalog Control 40001 49999 Registers are updated using the multiple register update command At TCU power up the status of the Control registers is read once After TCU power up Modbus control registers ...

Page 92: ...82 D a t a F l o w S y s t e m s I n c Appendix ...

Page 93: ...synthesized 400 MHz RS 232 Interface 9600 115200 baud serial interface for Modbus ASCII devices RTU protocol option available RS 485 Interface 9600 115200 baud serial interface for Modbus ASCII RTU devices Ethernet Interface 10 100base T USB 2 0 Full Speed 2 ports external 1 port internal Isolated 24VDC Bias 300 mA current limited and regualted Input Protection MOV Metal Oxide Varistor TVS Transie...

Page 94: ... is fused and correctly routed through the TFS supplied by DFS If the TCU shows an active 3 phase error follow the steps provided in Chapter 6 Operation Procedures to adjust the Low Phase and High Phase limits To facilitate a start up the 3 phase limits can initially be adjusted fully open and then later adjusted for less tolerance 8 If the Phase Monitor Bypass is used to monitor third party 3 pha...

Page 95: ...is tipped and the high float is enabled the bell or alarm should go on If the Low float s contact is open the bell or alarm should go on If the TCU is using an analog input for level control refer to Chapter 6 Operation Procedures for information on setting the level set points along with other options for analog and float back up operation Note The alarm light and alarm horn have to be enabled in...

Page 96: ...ay on pump start after the level input is activated 12 After the system is checked out connect the backup battery if used Make sure the battery is properly connected Observe polarity markings 13 If the battery is charged cycle the TCU s AC power off and verify battery backup operation Make sure to turn the TCU on when finished with the checkout procedure ...

Page 97: ...rating AC power voltage greater than 375 A Heat condition that exceeds designed operating temperature of 160 degrees Incorrect control voltage wiring Shorted circuit within the TCU Before replacing the fuse Inspect the TCU site and wiring to see if any of the conditions listed above may have occurred If you received an offline alarm for this station check the battery to verify it is functioning pr...

Page 98: ...cement TCU replace the fasteners and reconnect the terminals 6 Place the replacement TCU s three H O A switches into the Off position and turn the breakers back on 7 Reconfigure the replacement TCU If the faulted TCU s configuration was backed up on a portable computer it can be restored on the replacement TCU 8 After configuring the replacement TCU place the required H O A switches in the Auto po...

Page 99: ...V 7 0Ah Rechargable Battery Part DFS 00363 008 01 12V 2 6Ah Rechargable Battery Part DFS 00363 008 02 DFS 00540 008 01 NO RADIO DFS 00540 008 16 IP DFS 00540 008 21 145 225 MHZ RADIO DFS 00540 008 22 450 470 MHZ RADIO DFS 00540 008 26 LEGACY XT200 RADIO Furnished Parts Optional Parts ...

Page 100: ... d i x D Bus Extender Module Part DFS 00223 008 01 Circuit Breaker Part 014 0010 Rail Pressure Transducer RPT Small Parts Kit Part DFS 00546 008 02 Network Surge protection for 1000 100 10 Base T Part DFS 002 0584 ...

Page 101: ...91 P a r t s L i s t 1A Slow Blow Fuse Part DFS 00271 008 09 TCU Snap in Install Kit Part DFS 00392 008 09 Adjustable Mounting Bracket Short Part DFS 00394 008 01 ...

Page 102: ...92 A p p e n d i x D Adjustable Mounting Bracket Medium Part DFS 00394 008 02 Adjustable Mounting Bracket Long Part DFS 00394 008 03 TCU Front Mount Install Kit Part DFS 00392 008 05 ...

Page 103: ... arres tor three DIN rail mounted terminal blocks with integrated 49 9k resistors and fuse block with three 1 Amp fuses Adjustable Mounting Bracket Long Part DFS 00394 008 03 47K Resistor Part DFS 00271 008 01 49 9K Resistor Part DFS 00271 008 24 100K Resistor Part DFS 00271 008 07 Power Diode Part 006 0019 ...

Page 104: ...94 A p p e n d i x D 120V Surge Protector SPS001 Part DFS 005 0061 240V Surge Protector TPS001 Part DFS 005 0062 RC Snubber Part 007 0084 Service Adapter Part 002 0540 ...

Page 105: ...95 P a r t s L i s t Spring Clamp Connector Tool Part DFS 00389 008 01 USB to RS 232 Adapter Part 002 0351 USB Thumb Drive Part DFS 00540 108 06 ...

Page 106: ...rol panel make sure that all breakers are shut off before starting the installation All wiring should conform to federal state and local electrical codes Attention should be given to the location of the TCU to provide accessibility for wiring and servicing Leave enough space around the TCU to access the TCU s fuse located on the side of the TCU and labled F601 and to remove the connectorized termi...

Page 107: ...g bracket is attached to the back of the control panel and the TCU is snapped into place With this mounting option the TCU can be installed and removed quickly and easily This option uses the Snap In installation kit Basic Install Kit or Full Install Kit See Appendix D Parts List ...

Page 108: ... Mount With this mounting option the TCU is attached to the mounting bracket with screws instead of being snapped into place This option uses the Front Mount installation kit Basic Install Kit or Full Install Kit See Appendix D Parts List ...

Page 109: ...e graphic below depicts how each of the TCU s three optional connector types can be attached to the unit The first option uses the Spring Clamp Connector Tool See Appendix D Parts List for information on ordering connectors and the connector tool ...

Page 110: ...ensional drawing is provided to aid in installation If a panel cutout is required the TCU can be installed with or without edge molding around the front panel opening The panel cutout is different for each mounting configuration ...

Page 111: ...s and multiply by 3 14 3 Multiply height by area to give volume in cubic feet To convert to gallons multiply the volume in cubic feet by 7 48 F Well Volume Calculations IMPORTANT Well volumes less than 500 gallons or 37 ft3 are prone to accuracy errors Example Assume a circular well of 10 feet diameter 5 foot radius with Off Level at 2 feet and Lead Level at 5 feet The display shows VOLUME in the ...

Page 112: ... configured for PCU emulation it must be changed to the TCU module configuration in order to add a RIO or any other Modbus slave device The steps required to add a RIO to a TCU are 1 Set RIO s device station address typically 1 2 Configure RIO for Learn mode 3 Mount RIO and I O as detailed in the RIO032 Installation and Operation Manual 4 Connect RIO to TCU via RS 485 interface 5 Place RIO in Lear...

Page 113: ...6 2 ADDR1 Station address bit 1 value 2 bit P6 3 ADDR2 Station address bit 2 value 4 bit P6 4 ADDR3 Station address bit 3 value 8 bit P6 5 ADDR4 Station address bit 4 value 16 bit P6 6 ADDR5 Station address bit 5 value 32 bit P6 7 ADDR6 Station address bit 6 value 64 bit P6 8 ADDR7 Station address bit 7 value 128 bit To give the RIO032 a device address of one 1 leave the bits for the P6 1 pin bit ...

Page 114: ... RIO to TCU The TCU s RS 485 interface is located on the TCU s P4 connector Pin definitions for the TCU RIO032 and RIO128 RS 485 interfaces appear below followed by a wiring diagram RS 485 Pins Name Description TCU Pin RIO032 Pin RIO128 Pin A RS 485 serial interface A P4 4 P5 1 P17 1 B RS 485 serial interface B P4 3 P5 2 P17 2 Ground RS 485 ground optional as required P4 5 P5 3 P17 3 Wiring ...

Page 115: ...ol This protocol is identical to RTU protocol except that the RIO expects a CTS to occur whenever it asserts an RTS and it will wait for the CTS signal before it transmits any data This protocol allows the RIO032 to be connected to an RDR Rail Data Radio or other manufacturer radio without using special cabling Configuring the TCU to Poll the RIO In order for the TCU to poll the RIO and make the R...

Page 116: ...g outputs M ACM 1 40005 4 15 4 After adding all of the required module and register information navigate through the TCU s configuration screens until you reach the screen that reads Press Enter to Save Esc to Abort Press Enter to replace the TCU s existing configuration with the changes made during the current session After the settings are successfully save you must cycle power to the TCU IMPORT...

Page 117: ...nalog output points If you are using an HMI other than HT3 you will need to configure that software with the correct Modbus register information for the RIO s additional I O Module Letter Module Type Number of I O Points Modbus Registers Used for Polling Module H DMM 8 digital input points 14337 14344 Module I DCM 8 digital output points 2305 2312 Module J AMM 4 analog input points 35505 35508 Mod...

Page 118: ...ent at 333 mVAC so having a CT output its maximum current at 333 mVAC will make configuration easier Installing CTs 1 CTs will be mounted in a separate panel where the 3 phase main breaker is located from the TCU800 2 CTs will be attached to the lines after the main breaker but before the individual pump starters 3 A CT harness kit is available including the CTs and related terminal blocks for eas...

Page 119: ...ule letter Enabled Disabled Disabled CT Function Motor current mode will derive each pump current as the pump is on as long as the CTs are installed per Figure 1 Direct Input will simply measure the average total current being read from the CTs i e to measure station current This setting will change how the display screen looks see Power View Screen section this can be used to determine in which m...

Page 120: ...he average current drawn from pump 2 while running at full capacity This setting is used to determine the thresholds for the undercurrent and overcurrent alarms Alarming can be disabled by setting this to 0 0 100 0 Full Load Current 3 The average current drawn from pump 2 while running at full capacity This setting is used to determine the thresholds for the undercurrent and overcurrent alarms Ala...

Page 121: ...ent 2 minutes of pump runtime The average current is only measured when all other pumps are off The average current will continue to display and be reported to telemetry even when the pump is off The average phase imbalance is calculated using the worst maximum phase to phase current imbalance difference measured during the most recent 2 minute of pump runtime Note This screen may display less dat...

Page 122: ...terrupt the pump control operation they are warnings only sent via telemetrey and notice on GUI Configuration Description Stops Pumps Disable Amp 1 Fault Triggers when the AMPS reading goes above the overcurrent limit of FLC 1 or below the undercurrent limit of FLC 1 Also acts as the singular AMPS fault for Direct Input mode No Set FLC 1 0 Amp 2 Fault Triggers when the AMPS reading goes above the ...

Page 123: ...limit of FLC 3 No Set FLC 2 0 Phase Current Fault Generic fault that indicate other misc issues with the current module i e Phase Imbalance No Set Imbalance Alarm 0 Faults will be indicated on the screen in the same way other alarms are with a notice pop up and will highlight the surrounding screen number in flashing red see above ...

Page 124: ...onds regardless of the frequency of float transitions Minimum run and off timers apply to all pump operations not just fault conditions so these timers should be set considering the pump and well characteristics during normal pump cycles Conversely low float events shut off all pumps Note If a high and low float condition exist simultaneously the low float condition takes precedence and no pumps w...

Page 125: ...ault alarm remains active until the TCU has been reset Transducer high condition High well alarm All pumps on A high well alarm is generated and all pumps are staggered on When the transducer level returns to the normal range the high well alarm clears and normal pump operation resumes Transducer noise condition Transducer fault alarm Normal pump operation A transducer fault alarm is generated Pum...

Page 126: ...sequence faults are disabled in this mode Minimal floats can be used to operate the station until the transducer fault has been resolved but the TCU utilizes all the float inputs the same as if configured for Floats The Off through Lag2 float inputs are ignored when the transducer is not faulted but these inputs can only be used for the specified floats The High Float Override can be enabled to al...

Page 127: ...system is a bubbler system and you want to generate a transducer fault when the TCU doesn t detect air pump induced noise page 54 High Float Override Enabled or Disabled Enable this setting to give the High float precedence in the event of an Off float failure when the TCU is in Floats fault mode page 54 Minimum Run 1 0 Minimum time pumps should run Used to prevent short cycling page 52 Minimum Of...

Page 128: ...dition and Off float is off with high float override option disabled Transducer fault alarm High well alarm All pumps on off Control switches to float inputs High well and transducer fault alarms are generated All pumps are staggered on and then shut off after minimum pump run time even if the High float remains on High float transitions do not restart pumps If Off Lead float activity does not occ...

Page 129: ... well and transducer fault alarms are generated The Low float takes precedence and all pumps are turned off If the low float condition clears but the high float condition remains the pumps are not started If Off Lead float activity does not occur the TCU will not start the pumps until a reset clears the transducer fault 4 20 mA or 0 5 VDC Transducer with Analog Input 2 as Backup Pump Down Mode Thi...

Page 130: ... an Off float failure when the TCU is in Floats fault mode page 54 Minimum Run 1 0 Minimum time pumps should run Used to prevent short cycling page 52 Minimum Off 0 5 Minimum time pumps should remain off Used to prevent short cycling page 52 Response to Fault Conditions Transducer with Floats Backup Fault s Alarms Pump Operation Behavior Transducer Low Condition Normal pump operation Low well alar...

Page 131: ...dition and all pumps are staggered on Minimum pump run and off timers are applied Normal pump operation resumes on the second analog input if both conditions clear The transducer fault alarm remains active and pump control remains with second analog input until the TCU has been reset Low float conditions Low well alarm All pumps off A low well alarm is generated and all pumps are shut off When the...

Page 132: ...r more information see Transducer Type Floats Select floats for a discrete system page 52 Number of Pumps 1 2 or 3 Select the number of pumps at the station page 52 Low Float Enabled or Disabled Enable this setting to use a low level float to override normal pump control if a transducer fault occurs page 54 High Float Enabled or Disabled Enable this setting to use a high level float to override no...

Page 133: ...esumes IMPORTANT A low float condition has precedence over all other faults and alarms including high float and high level If a low float condition exists no pumps will be allowed to start Concurrent high float and low float conditions High well alarm Low well alarm All pumps on High well and low well alarms are generated The high float condition takes precedence and the pumps will continue to run...

Page 134: ...ump 2 Status DI 12546 OFF RUNNING Detects the state of Pump 2 3 Pump 3 Status DI 12547 OFF RUNNING Detects the state of Pump 3 4 Phase Monitor Bypass DI 12548 OFF ON Detects if the phase monitor bypass is OFF or ON 5 Low Float Input DI 12549 OFF ON Detects the state of the Low Float 6 Off Float Input DI 12550 OFF ON Detects the state of the Off float 7 Lead Float Input DI 12551 OFF ON Detects the ...

Page 135: ...12810 NORMAL FAULT Allows telemetry to sense DC bias failure and activate the alarm These points need not be configured when the TCU is running the pump control process because they are being controlled by the TCU s pump control program Points A1 Pump 1 A2 Pump 2 and A3 Pump 3 are used to report pump status Module C AMM002 Point Point Name Point Type Modbus Register Low State Label High State Labe...

Page 136: ...High raw value Module D DCM001 Point Point Name Point Type Modbus Register Low State Label High State Label Alarm State Description 1 Pump 1 Disable DO 1025 OFF ON Allows telemetry to turn off Pump 1 regardless of pump s TCU state 2 Pump 2 Disable DO 1026 OFF ON Allows telemetry to turn off Pump 2 regardless of pump s TCU state 3 Pump 3 Disable DO 1027 OFF ON Allows telemetry to turn off Pump 3 re...

Page 137: ...e Level AO 42273 4 820 20 4095 0 01 mA Calibration point for displaying level for a remote input 2 Unused 3 Unused 4 Well Level AO 42276 0 0 60 600 0 1 FT Calibration point for displaying well level For analog points the Low State Label column gives the point s Low engineering value followed by its Low raw value For analog points the High State Label column gives the point s High engineering value...

Page 138: ...tion of HOA 3 switch and activates alarm for Auto position Module G DCM001 Point Point Name Point Type Modbus Register Low State Label High State Label Alarm State Description 1 Aux Out Override On DO 1793 OFF ON OFF Normal Operation ON Override Aux Output to ON state 2 Alarm Light Override DO 1794 OFF ON OFF Normal Operation ON Override Alarm Light Output to ON state 3 Alarm Horn Override DO 1795...

Page 139: ...to battery power 2 10 Unused 11 DI 12299 OFF ON OFF Detects the presence of isolated DC bias and activates the Alarm when absent 12 DI 12300 OFF ON OFF Detects the presence of AC Power and activates the Alarm when absent 13 AI 32945 0 0 255 100 0 1 Detects the amount of current drawn when the radio is keyed 14 AI 32946 0 0 255 100 0 1 Detects the average receive signal strength 15 AI 32947 0 32 10...

Page 140: ... 1 Pump 1 Speed Feedback AI 35249 0 819 100 4095 0 2 Pump 2 Speed Feedback AI 35240 0 819 100 4095 0 3 Pump 3 Speed Feedback AI 35251 0 819 100 4095 0 Module J DMM002 Point Point Name Point Type Modbus Register Low State Label High State Label Alarm State Description 1 8 Spares DI 14849 14856 OFF ON Spares for connecting any required additional I O Module K DCM003 1 Point Point Name Point Type Mod...

Page 141: ...oint used to turn off the TCU s AC power and go to battery power 520 Station Disable DO OFF ON In the ON state allows telemetry to remove power from all pump motors 1025 Pump 1 Disable DO OFF ON In the ON state allows telemetry to cut power to Pump 1 1026 Pump 2 Disable DO OFF ON In the ON state allows telemetry to cut power to Pump 2 1027 Pump 3 Disable DO OFF ON In the ON state allows telemetry ...

Page 142: ... will have a large impact on the radio polling rate 12299 Bias Voltage DI OFF ON OFF Detects the presence of isolated DC bias and activates the alarm when absent 12300 TCU Power DI OFF ON OFF Detects the presence of AC power and activates the alarm when absent 12545 Pump 1 Status DI OFF RUNNING Detects the state of pump 1 12546 Pump 2 Status DI OFF RUNNING Detects the state of pump 2 12547 Pump 3 ...

Page 143: ... DI OFF ON Detects the state of the alarm light 12806 Alarm Horn Status DI OFF ON Detects the state of the alarm horn 12807 Alarm Silence Input DI OFF ON Indicates the status of the external alarm silence switch 12809 AC Power DI NORMAL FAULT Allows telemetry to sense AC power failure and activate the alarm 12810 DC Bias DI NORMAL FAULT Allows telemetry to sense DC bias failure and activate the al...

Page 144: ... Stop DI NORMAL FAULT FAULT Allows telemetry to sense a Pump 3 stop failure and activate the alarm 13826 Low Well Level DI NORMAL ALARM ALARM Detects the state of the Low level sensor 13827 High Well Level DI NORMAL ALARM ALARM Detects the state of the High level sensor 13828 HOA 1 DI HAND HAND Detects position of HOA 1 switch and activates alarm for Hand position 13829 HOA 1 DI OFF OFF Detects po...

Page 145: ...5 0 01 mA Settings for the auxiliary analog input 33715 Phase AB Voltage 240 VAC AI 0 350 300 3102 1 VAC Settings for Phase AB voltage for 240 VAC 1 or 3 phase monitor 33715 Phase AB Voltage 480 VAC 3 phase AI 0 350 600 3114 1 VAC Settings for Phase AB voltage for 480 VAC 3 phase monitor 33716 Phase AC Voltage 240 VAC AI 0 350 300 3077 1 VAC Settings for phase AC voltage for 240 VAC 1 or 3 phase m...

Page 146: ...4095 0 35251 Pump 3 Speed Feedback I AMM002 AI 0 819 100 4095 0 14849 14856 Spares J DMM002 DO OFF ON Spares for connecting any required additional I O 2817 2824 Spares K DCM003 1 DI OFF ON Spares for connecting any required additional I O Additional Modbus Registers Used in VFD TCU If you are using an HMI other than HT3 you will need to configure that software with the correct Modbus register inf...

Page 147: ...37 14593 14849 15105 15361 15617 15873 16129 2 14338 14594 15850 15106 15362 15618 15874 16130 3 14339 14595 14851 15107 15363 15619 15875 16131 4 14340 14596 14852 15108 15364 15620 15876 16132 5 14341 14597 14853 15109 15365 15621 15877 16133 6 14342 14598 14854 15110 15366 15622 15878 16134 7 14343 14599 14855 15111 15367 15623 15879 16135 8 14344 14600 14856 15112 15368 15624 15880 16136 9 143...

Page 148: ...55 43811 44067 44323 44579 44835 4 43044 43300 43556 43812 44068 44324 44580 44836 Note DFS analog modules have 12 bit resolution 0 4095 If the Modbus slave device being configured has a higher resolution the number of bits typically 15 will need to be configured in the TCU s ModX Lth field where X represents the module letter being configured in order for the value to read correctly Legacy PCU Th...

Page 149: ...2 Level Transducer DI OK FAULT FAULT 23 Backup Memory DI OK FAULT FAULT 24 AC Power DI OK FAULT FAULT 25 DC Bias DI OK FAULT FAULT 26 Low Well Level DI OK ALARM ALARM 27 High Well Level DI OK ALARM ALARM 31 HOA Switch 1 DI HAND HAND 32 HOA Switch 1 DI OFF OFF 33 HOA Switch 1 DI AUTO 34 HOA Switch 2 HAND HAND 35 HOA Switch 2 DI OFF OFF 36 HOA Switch 2 DI AUTO 37 HOA Switch 3 DI HAND HAND 38 HOA Swi...

Page 150: ...sor is in the OFF state or the ON stat 5 Lag 2 Float Input Detects if the Lag2 Level sensor is in the OFF state or the ON state 6 High Float Input Detects if the High Level sensor is in the OFF state or the ON stat 7 Auxiliary Input Detects if the Auxiliary Input is in the OFF state or the ON state 8 Alarm Horn Cond Gives status of external alarm silence switch 9 Pump 1 Status Detects whether pump...

Page 151: ...hether the auxiliary output is in the OFF or ON state 41 Alarm Horn Status Detects whether the alarm horn is in the OFF or RINGING state 42 Alarm Light Status Detects whether the alarm light is in the FLASHING or OFF state 43 Any Pump Indicates the run status of any pump 44 PCU Configuration Detects if the Local Configuration has been updated and activates the alarm for UPDATE 49a Analog Input Set...

Page 152: ...he AUTO or DISABLED state 70 Alarm Light Override Allows telemetry to override the Alarm Light and activate the alarm at the central site 71 RESERVED RESERVED 72 Override Reset When set allows the Off Level input to reset pump overrides 73 Analog Updating Enables Analog readings ...

Page 153: ...d highly reliable We back this performance with a 3 year full warranty see our warranty statement for details In the event that a function module fails during or after the warranty period it may be returned to Data Flow Systems to be repaired or replaced All RA s will be subject to standard shipping and handling charges Minimum handling charge will be assessed in most cases for work such as Radio ...

Page 154: ... employees are not permitted to hand carry an unpacked module Modules are typically repaired and shipped back to the customer within a two week period starting at the time the module reaches the RA department If additional information is required during the repair of the module s the DFS service department will contact you To get information on the progress of your equipment in for repair contact ...

Page 155: ...period when installed per factory approved requirements Questions or Comments on this Manual If you find a problem with any of the information in this manual or have suggestions on how it could be improved please contact us at the following address Data Flow Systems Inc Documentation Department 605 N John Rodes Blvd Melbourne FL 32934 Alternatively e mail us at documentation dataflowsys com ...

Page 156: ...cate an on off condition line Input side of switch or relay contacts load Output side of switch or relay contacts neutral Zero reference point of an AC voltage output Digital control output of the TCU override Control output logic is ignored and the output is set to a specific state pump mode Selected method of pumping for either a well pump down or storage tank pump up return The circuit wire or ...

Page 157: ...147 D a t a F l o w S y s t e m s I n c ...

Page 158: ...148 D a t a F l o w S y s t e m s I n c ...

Page 159: ...149 D a t a F l o w S y s t e m s I n c ...

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Page 161: ...151 D a t a F l o w S y s t e m s I n c ...

Page 162: ...Data Flow Systems Inc 605 N John Rodes Blvd Melbourne Florida 32934 321 259 5009 www dataflowsys com ...

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