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TCUManual
TCUManual
Data Flow Systems, Inc. assumes no responsibility for any errors that
may appear in this document, nor does it make any commitment to
update the information contained herein. However, questions regarding
the information contained in this document are welcomed.
Data Flow Systems also reserves the right to make changes to the
specifications of TAC Pack TCU and to the information contained in
this document at any time without notice.
D F S - 00 3 6 7 -0 1 1 - 0 2
This document last revised: September 28, 2010
T ABLE OF C ONTENTS
PREFACE .................................................................................................................................. 1
Purpose of this Manual ..................................................................................................................... 1
Document Conventions..................................................................................................................... 1
Abbreviations Used in this Manual................................................................................................... 1
CHAPTER 1: PRODUCT OVERVIEW .......................................................................................... 3
Description ........................................................................................................................................ 3
Features ............................................................................................................................................. 4
Compatibility Issues.......................................................................................................................... 6
PCU and PCU TAC Pack ............................................................................................................ 6
Analog Level Transducer ....................................................................................................... 6
Alarm Output Relays .............................................................................................................. 6
SCU and SCU TAC Pack ............................................................................................................ 7
Technical Specifications ................................................................................................................... 8
Pin Name / Wiring Definitions for Pump Control Application ........................................................ 9
Top Connector 1: P1 .................................................................................................................... 9
Top Connector 2: P3 .................................................................................................................... 9
Bottom Connector 1: P2 ............................................................................................................ 10
Bottom Connector 2: P4 ............................................................................................................ 11
Pin Name / Wiring Definitions for Customized Application.......................................................... 11
Top Connector 1: P1 .................................................................................................................. 11
Top Connector 2: P3 .................................................................................................................. 12
Bottom Connector 1: P2 ............................................................................................................ 13
Bottom Connector 2: P4 ............................................................................................................ 13
CHAPTER 2: PRINCIPLES OF OPERATION .............................................................................. 15
Modes of Operation ........................................................................................................................ 15
General RTU.............................................................................................................................. 15
Pump Controller......................................................................................................................... 15
Custom Application ................................................................................................................... 15
Automatic/Manual Control ............................................................................................................. 15
H-O-A Switches......................................................................................................................... 16
Telemetry Interface.................................................................................................................... 16
Level Sensing Transducers ............................................................................................................. 16
Digital-type Devices .................................................................................................................. 16
Analog-type Devices.................................................................................................................. 16
Variable Impedance Transducers............................................................................................... 17
Internal Phase Monitor.................................................................................................................... 17
Solid State Control Outputs ............................................................................................................ 18
Mechanical Relay Outputs .............................................................................................................. 18
Status via LED Indicators ............................................................................................................... 18
AC Power Status........................................................................................................................ 18
CPU Fault Status........................................................................................................................ 18
RX DATA & TX DATA Status ................................................................................................ 18
Digital Output and Input Status ................................................................................................. 19
Programmable LEDs.................................................................................................................. 19
LCD Screen..................................................................................................................................... 20
Keypad and Soft Power On/Off Key .............................................................................................. 20
i
Communications Service Port..........................................................................................................20
Self-Monitoring Capabilities ...........................................................................................................22
Last State Recall ..............................................................................................................................22
Integrated Telemetry Interface (Optional) .......................................................................................22
Controlling and Monitoring via Telemetry.................................................................................22
Monitored Inputs ...................................................................................................................22
Controlled Outputs ................................................................................................................22
Battery Backup (Optional) ...............................................................................................................23
Power and Voltage Monitoring........................................................................................................23
Functions Specific to the Pump Control Process .............................................................................24
Types of Stations ........................................................................................................................24
Pumping Modes and Staging Levels ..........................................................................................24
Discrete System .....................................................................................................................24
Analog System.......................................................................................................................25
Staging Levels in Pump Down Mode....................................................................................25
Staging Levels in Pump Up Mode.........................................................................................26
Pump Alternation........................................................................................................................27
Use of Unused Pump Outputs.....................................................................................................27
Phase Monitor Options ...............................................................................................................27
External Phase Monitor .........................................................................................................27
Phase Monitor Bypass ...........................................................................................................28
Motor Run-Time Monitor...........................................................................................................28
Solid State Motor Starter Control Relays ...................................................................................28
Auxiliary Input and Output.........................................................................................................29
Time Delay Relay..................................................................................................................29
Pulse Input .............................................................................................................................29
Alarm Light & Horn/Bell Outputs (Optional) ............................................................................29
LED Indicators............................................................................................................................30
Information Screens....................................................................................................................30
Status Information .................................................................................................................31
Alarm Messages ....................................................................................................................31
Configuration Options ...........................................................................................................32
Failure Modes .............................................................................................................................33
CHAPTER 3: BEFORE YOU BEGIN .......................................................................................... 35
Safety Precautions............................................................................................................................35
General Precautions .........................................................................................................................35
Working with the TCU ....................................................................................................................35
Protecting Against Electrostatic Discharge......................................................................................36
Using the TCU .................................................................................................................................36
Site Selection ...................................................................................................................................36
Receipt of Equipment ......................................................................................................................36
CHAPTER 4: MOUNTING INSTRUCTIONS ................................................................................ 37
CHAPTER 5: MODBUS SUPPORT ............................................................................................. 43
TCU as Modbus Slave (RS-232 Interface) ......................................................................................43
Wiring an External Modbus-Compatible RS-232 Device ..........................................................45
Configure Modbus Device ID.....................................................................................................47
TCU Radio System Setup ...........................................................................................................48
Querying the TCU ......................................................................................................................49
ii
TCU as Modbus Master Device (RS-485 Interface)....................................................................... 53
RS-485 Serial Settings ............................................................................................................... 53
Wiring an RS-485 Slave Device ................................................................................................ 54
Configuring the TCU to Poll Modbus Slave Devices................................................................ 54
Pump Control Process .......................................................................................................... 54
TCU in Custom Application................................................................................................. 55
CHAPTER 6: ELECTRICAL INSTALLATION ............................................................................. 59
AC Power........................................................................................................................................ 60
Motor Starter Outputs ..................................................................................................................... 61
Alarm Light and Horn Outputs ....................................................................................................... 62
Using Snubbers When Connecting Alarm Outputs ................................................................... 63
AC Applications ................................................................................................................... 63
DC Applications ................................................................................................................... 64
Phase Monitor ................................................................................................................................. 65
Three-Phase Option ................................................................................................................... 65
Single-Phase Option (240 VAC Only) ...................................................................................... 66
Digital Monitor Point Inputs ........................................................................................................... 67
Bias Voltage Source Options ..................................................................................................... 69
Internally Supplied Bias Voltage Source.............................................................................. 69
Externally Supplied Bias Voltage Source............................................................................. 69
Motor Run Monitoring Signal......................................................................................................... 70
Resistor Sizing Chart ................................................................................................................. 70
Level Sensing Transducers ............................................................................................................. 73
Contact Closure Devices............................................................................................................ 73
Analog Level Transducer........................................................................................................... 75
Auxiliary Analog Input ................................................................................................................... 78
Optional Configurations and Hookups............................................................................................ 79
Backup Battery .......................................................................................................................... 79
Alarm Silence Switch ................................................................................................................ 79
External Phase Monitor ............................................................................................................. 80
Phase Monitor Bypass ............................................................................................................... 81
Auxiliary Input and Output Connections................................................................................... 82
Auxiliary Digital Input ......................................................................................................... 82
Auxiliary Digital Output....................................................................................................... 83
Comprehensive Wiring Diagram for Typical TCU Installation...................................................... 84
CHAPTER 7: TELEMETRY CONFIGURATION .......................................................................... 87
Hardware Configuration ................................................................................................................. 87
TCU Installed in DFS RTU ....................................................................................................... 87
Installing the BEM................................................................................................................ 88
TCU Used with Modbus Compatible Radio.............................................................................. 89
TCU as Stand Alone Unit .......................................................................................................... 89
Connecting the TCU to the antenna...................................................................................... 89
Addressing and configuring the radio................................................................................... 89
Configuring the TCU in HT3 ............................................................................................... 91
Typical Setups ...................................................................................................................... 92
TCU Used without Telemetry.................................................................................................... 93
HT3 Software Configuration .......................................................................................................... 94
TCU Pump Control Application ................................................................................................ 94
iii
Legacy PCU..............................................................................................................................103
Point Values for Legacy PCU .............................................................................................103
Point Descriptions for Legacy PCU ....................................................................................105
CHAPTER 8: PROGRAMMING THE TCU ............................................................................... 109
Introduction....................................................................................................................................109
Applications ...................................................................................................................................109
SIMPLE (DFS BASIC) CENTRAL .........................................................................................109
Central Polling Backup Device.................................................................................................110
Installed in RTU .......................................................................................................................110
DFS BASIC-52 ..............................................................................................................................111
Internally Defined Modules ...........................................................................................................111
Sample TCU-HT3 Configuration...................................................................................................111
Using TCU Control Points with a PLC..........................................................................................113
TCU Analog Output Option...........................................................................................................115
Polling............................................................................................................................................115
Fast Control Point Updating .....................................................................................................115
H-O-A Switches.............................................................................................................................115
LCD Menus....................................................................................................................................115
Keypad ...........................................................................................................................................116
LEDs ..............................................................................................................................................117
Hardware Interface.........................................................................................................................117
Software Interface..........................................................................................................................117
Debug (Program) Mode .................................................................................................................118
Downloading..................................................................................................................................119
Editing............................................................................................................................................120
Debugging/Testing.........................................................................................................................120
Connection/Downloading Debug Table.........................................................................................121
CHAPTER 9: PUMP CONTROLLER USER INTERFACE ........................................................... 123
Keypad and LCD Screen ...............................................................................................................123
Navigation Keys .......................................................................................................................123
Enter Key ..................................................................................................................................123
Esc Key.....................................................................................................................................124
Numbers 0 – 9...........................................................................................................................124
Silence Key...............................................................................................................................124
On/Off Key ...............................................................................................................................124
LED Indicators...............................................................................................................................124
Output 1-6 and Input 1-12 Status..............................................................................................124
Pump Run Status.......................................................................................................................125
TCU Power Status ....................................................................................................................125
CPU Fault Status.......................................................................................................................125
RX DATA & TX DATA Status ...............................................................................................126
Alarm Status .............................................................................................................................126
Well Level Status......................................................................................................................126
Communications Service Port........................................................................................................126
CHAPTER 10: CONFIGURING THE PUMP CONTROL PROCESS .............................................. 127
Placing the TCU in Configure Mode .............................................................................................127
Changing Configuration Options ...................................................................................................127
Exiting Configure Mode and Saving Configurations.....................................................................127
iv
Configuration Screen 1 ................................................................................................................. 128
Number of Pumps .................................................................................................................... 128
Transducer Type ...................................................................................................................... 129
Low Float................................................................................................................................. 129
High Float ................................................................................................................................ 129
Configuration Screen 2 ................................................................................................................. 130
Transducer Fault Mode............................................................................................................ 130
Alarm Horn .............................................................................................................................. 131
Alarm Light ............................................................................................................................. 131
Auto Retry ............................................................................................................................... 131
Motor Start Fault ................................................................................................................ 132
Motor Stop Fault................................................................................................................. 132
Clearing a Motor Start or Stop Fault .................................................................................. 132
Configuration Screen 3 ................................................................................................................. 132
Pump Alternation..................................................................................................................... 133
Motor Start Fault Delay ........................................................................................................... 133
Motor Stop Fault Delay ........................................................................................................... 134
Configuration Screen 4: Time Delay Relay .................................................................................. 134
Define Relationship between AUX_IN and AUX_OUT ........................................................... 134
Define Delay Time................................................................................................................... 135
Configuration Screen 5: Configuring Analog Transducers........................................................... 135
Configuration Screens 6 and 7: Set Point Levels.......................................................................... 136
Configuration Screen 8 ................................................................................................................. 138
Minimum Pump Run Time ...................................................................................................... 138
Minimum Pump Off Time ....................................................................................................... 138
Low- and High-Limit Phase Voltage....................................................................................... 138
Configuration Screen 9 ................................................................................................................. 139
Flow Volume Configuration .................................................................................................... 139
Flow Units Configuration ........................................................................................................ 139
Set Clock.................................................................................................................................. 139
Reset Timers ............................................................................................................................ 139
Configuration Screen 10 ............................................................................................................... 140
Pumping Mode......................................................................................................................... 140
Phase Monitor Range............................................................................................................... 140
Auxiliary Input Alarm Option ................................................................................................. 141
Configuration Screen 11 ............................................................................................................... 141
Number of BEM-connected Modules...................................................................................... 141
Trend Rate ............................................................................................................................... 141
Poll Modbus Slave Devices ..................................................................................................... 142
ModX Adr .......................................................................................................................... 142
ModX Lth ........................................................................................................................... 142
Modbus Master Baud Rate and Protocol ................................................................................. 144
Baud Rate ........................................................................................................................... 144
Protocol............................................................................................................................... 144
TCU Configuration Options Table................................................................................................ 145
CHAPTER 11: VIEWING STATUS ........................................................................................... 147
Version and Radio Configuration Information ............................................................................. 147
Default Screen............................................................................................................................... 148
v
Station Screen ................................................................................................................................148
Total Flow Meter: TFlow .........................................................................................................148
Phase Voltage: Pwr @ AB, Pwr @ AC ....................................................................................149
Cumulative Pump Run Time Meter ...............................................................................................149
Average Pump Run Time Meter ....................................................................................................149
Avg Pump Flow Rate Screen .........................................................................................................150
Pump Starts Screen ........................................................................................................................150
Analogs Screen ..............................................................................................................................150
CHAPTER 12: VIEWING AND TROUBLESHOOTING ALARMS ................................................. 151
AC Power Fault..............................................................................................................................152
Auxiliary Input Alarm....................................................................................................................152
DC Bias Fault.................................................................................................................................153
Float Sequence Fault......................................................................................................................153
High Well Alarm............................................................................................................................154
Low Well Alarm ............................................................................................................................154
Phase Sequence Fault.....................................................................................................................154
Phase Voltage Fault .......................................................................................................................155
Motor Starter Fault.........................................................................................................................155
Motor Stop Fault ............................................................................................................................156
Transducer Fault ............................................................................................................................157
Leaving the Alarms Screen ............................................................................................................158
APPENDIX A: CHECKOUT PROCEDURE FOR PUMP CONTROLLER ....................................... 159
Step 1: Electrical Termination Review ..........................................................................................159
Step 2: Operations Testing.............................................................................................................160
APPENDIX B: MAINTENANCE AND TROUBLESHOOTING ...................................................... 163
Maintenance...................................................................................................................................163
Restoring Factory Default Configurations.....................................................................................163
Troubleshooting .............................................................................................................................163
Radio Test Mode.......................................................................................................................164
Alarm Messages and the Alarm LED (Pump Control Process only)........................................164
CPU Fault .................................................................................................................................165
TCU Replacement..........................................................................................................................166
APPENDIX C: PARTS LIST .................................................................................................... 167
Furnished Parts...............................................................................................................................167
TAC Pack Telemetry Control Unit (TCU) ...............................................................................167
Optional Parts.................................................................................................................................167
Batteries ....................................................................................................................................167
Bus Extender Module ...............................................................................................................168
Circuit Breaker (10A) ...............................................................................................................168
Enclosures.................................................................................................................................168
Fuse...........................................................................................................................................169
Harness .....................................................................................................................................169
Installation Kits.........................................................................................................................169
Mounting Bracket Kits .............................................................................................................170
480VAC Phase Monitor Kit .....................................................................................................171
Polyphaser Kit ..........................................................................................................................171
Power Diode .............................................................................................................................171
Resistors....................................................................................................................................172
vi
Snubber .................................................................................................................................... 172
Spring-Clamp Connector Tool................................................................................................. 172
Submersible Level Sensor ....................................................................................................... 173
Surge Protection....................................................................................................................... 173
Surge Suppressors.................................................................................................................... 174
Test Kit .................................................................................................................................... 174
USB to Serial Adapter ............................................................................................................. 174
APPENDIX D: KEY-INVOKED FUNCTIONS ............................................................................ 175
View Process ID and Version Level ............................................................................................. 175
View Serial Number, Station Address, Radio Configuration, and Firmware Versions................ 175
Place TCU in Radio Test Mode .................................................................................................... 175
Key Radio and Measure Antenna Reflective Power..................................................................... 176
Restore Factory Default Configurations ....................................................................................... 176
Place TCU in Debug Mode........................................................................................................... 176
Adjust the LCD Screen’s Contrast................................................................................................ 176
Auto Download TCU Configuration............................................................................................. 176
APPENDIX E: CONFIGURING LEVEL INPUT DEVICES........................................................... 177
Configuring a Station with Analog Input Devices ........................................................................ 177
Configuring a Station with Float Ball Inputs ................................................................................ 178
APPENDIX F: WELL VOLUME CALCULATIONS .................................................................... 179
APPENDIX G: INVERTED FLOAT INTERFACE ....................................................................... 181
APPENDIX H: TCU001-AD AUTODIALER ............................................................................ 183
Overview....................................................................................................................................... 183
Product Overview .................................................................................................................... 183
Principles of Operation ............................................................................................................ 183
Available alarm conditions ...................................................................................................... 184
Alarm Process .......................................................................................................................... 187
Pre-programmed digital synthesized voice messages.............................................................. 188
Power and backup battery........................................................................................................ 188
Autodialer status LED ............................................................................................................. 188
Connecting the TCU001-AD to a Phone Line .............................................................................. 189
Compatible phone systems ...................................................................................................... 189
Phone line connection.............................................................................................................. 189
Configuring the Autodialer ........................................................................................................... 190
TCU001-AD user interface...................................................................................................... 190
Addressing the station number ................................................................................................ 191
Placing the TCU001-AD in Configure Mode.......................................................................... 192
Changing Configuration Options............................................................................................. 192
Exiting Configure Mode and Saving Configurations .............................................................. 192
Configuration overview ........................................................................................................... 193
Selecting alarms....................................................................................................................... 194
Entering phone numbers .......................................................................................................... 197
Configuring acknowledgement code ....................................................................................... 200
Configuring dial-out retry time................................................................................................ 202
Factory settings ........................................................................................................................ 204
Return to default values...................................................................................................... 204
Receiving and Acknowledging an Alarm Call.............................................................................. 205
Maintenance Mode........................................................................................................................ 205
vii
Place the TCU001-AD in maintenance mode...........................................................................205
Cancel maintenance mode ........................................................................................................206
Configuration Log Sheet................................................................................................................206
Station ID List...........................................................................................................................207
FCC Notice to Users ......................................................................................................................208
FCC Requirements....................................................................................................................208
Service Requirements ...............................................................................................................208
APPENDIX I: TCU001-IP ..................................................................................................... 209
TCU001-IP User Interface .............................................................................................................209
Before You Begin ..........................................................................................................................210
Unique IP Address .........................................................................................................................210
Configuring Subnet Portion of IP Address ....................................................................................210
Configuring Gateway (Optional) & Network Portion of IP Address.............................................211
Placing the TCU001-IP in Configure Mode .............................................................................212
Changing Configuration Options..............................................................................................212
Exiting Configure Mode and Saving Configurations ...............................................................212
Entering gateway (optional) and network portion of IP address ..............................................213
Connect TCU001-IP To Network ..................................................................................................215
Test Network Connection ..............................................................................................................215
APPENDIX J: ADDING A RIO TO THE TCU .......................................................................... 217
Set RIO’s Device Address .............................................................................................................217
Configure RIO for Learn Mode .....................................................................................................218
Mount RIO and Wire AC Power and I/O ......................................................................................218
Connect RIO to TCU .....................................................................................................................219
RS-485 Pins ..............................................................................................................................219
Wiring .......................................................................................................................................219
Place RIO in Learn Mode ..............................................................................................................219
Configuring the TCU to Poll the RIO............................................................................................220
Verify communication between TCU and RIO. ............................................................................221
Add and configure the RIO’s I/O in HT3 ......................................................................................221
APPENDIX K: DFS TO MODBUS REGISTER MAP .................................................................. 223
DMM Module Type.......................................................................................................................223
DCM Module Type........................................................................................................................223
AMM Module Type*.....................................................................................................................224
ACM Module Type*......................................................................................................................224
APPENDIX L: SUPPORT, SERVICE, AND WARRANTY ............................................................ 225
Support and Service .......................................................................................................................225
Technical Product Assistance ........................................................................................................225
Return Authorization (RA) Procedure ...........................................................................................225
Notice.............................................................................................................................................227
Warranty ........................................................................................................................................227
Questions or Comments on This Manual.......................................................................................227
GLOSSARY ............................................................................................................................ 229
INDEX ................................................................................................................................... 231
viii
PREFACE
D OCUMENT C ONVENTIONS
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
Italic type is used to indicate text displayed on the LCD screen.
ALL CAPITALIZED ITALIC type is used for terminal names.
1
Preface
Notes
D ESCRIPTION
The TAC Pack Telemetry Control Unit (TCU) is a microprocessor-controlled device.
There are several options for using the TCU’s multiple input and output points.
They can be used as non-intelligent I/O by setting the number of pumps to 0 (zero).
They can be used in a pump control application.
They can be manipulated logically with a DFS BASIC-52 program (much like a PLC).
Additionally, the TCU:
Can communicate with and manipulate the I/O of up to 15 remote modules via a radio or network
link.
Can be incorporated into a Remote Terminal Unit (RTU) by using a Bus Extender Module (BEM).
[Note that with this configuration, the TCU cannot be used as a simple central site (that is, it cannot
poll remote modules).]
3
Chapter 1: Product Overview
The installed pump control application program enables the TCU to be easily implemented in lift station
or storage tank applications. For a pump control application, the TCU contains all the hardware and
software needed to control up to three motor starters.
Placing a custom BASIC program on the TCU enables it to perform a variety of automated tasks when
interfaced with other telemetry equipment (DFS equipment, or RS-485 or RS-232 compatible devices).
When used as a programmable device, the TCU can control up to six digital output devices, and monitor
up to 12 digital and two analog input devices.
The TCU’s dual functionality (its ability to use the built-in pump control process or a custom program)
helps reduce overhead by enabling one unit to be used in either a pump control or programmable
application.
F EATURES
Legacy PCU operation
The TCU is backward compatible with DFS’ Pump Control Unit (PCU). Very few wiring changes are
required. Existing PCU configurations can be easily transferred to the TCU.
Autodialer (optional)
The TCU001 can be ordered with an autodialer or can be retrofitted at the factory if you want to add
this feature to your existing TCU001. The TCU001-AD (TCU001 with optional autodialer) enables
utilities to be alerted of active alarm conditions at remote well/storage tank stations that aren’t part of a
SCADA telemetry system. For more information on this feature, see Appendix H: TCU001-AD
Autodialer.
Network Adapter (optional)
The TCU001 can be ordered with an optional integrated 10/100 network adapter or can be retrofitted at
the factory if you want to add this feature to your existing TCU001. The TCU001-IP presents an ideal
solution where radio may not be preferred, but where networking is available. For more information on
this feature, see Appendix I: TCU001-IP.
Twelve digital inputs
Twelve digital inputs for monitoring level, contact closure, or pulse counter. *
Two 12-bit analog inputs
Two 12-bit analog inputs offer enhanced accuracy and increased resolution. *
Six digital outputs
Six digital outputs – four solid state and two contact closure (1 normally closed).
Integrated digital radio
Integrated digital radio (2 watts; 200 Mhz) is on-site programmable.
RS-485 Modbus fieldbus half-duplex serial interface
RS-485 Modbus fieldbus half-duplex serial interface enables communication with industry standard
devices and VFD motor controllers. *
Dual double-speed microcontrollers
Dual double-speed microcontrollers (one for controlling functions; one for communication).
C OMPATIBILITY I SSUES
When developing the TAC Pack TCU, DFS made every effort to make the TCU downward compatible
with the Pump Control Unit (PCU), PCU TAC Pack, Supervisory & Control Unit (SCU), and SCU TAC
Pack. There are a few important differences, however, that must be addressed when replacing one unit
type with another.
Please note that the PCU, PCU TAC Pack, SCU, and SCU TAC Pack are not "upward" compatible with
the TCU. DFS' Sales Department can provide assistance with ensuring that your system has appropriate
replacement units on hand. Contact DFS' Sales Department (321-259-5009; sales@dataflowsys.com)
for more information.
T ECHNICAL S PECIFICATIONS
Top Connector 1: P1
PIN# Name Description Electrical Rating
P1-1 PHASE_C Phase C of the three-phase power 120-240VAC, 60HZ, 100mA, 3-phase
monitor
P1-2 PHASE_B Phase B of the three-phase power 120-240VAC, 60HZ, 100mA, 3-phase
monitor
P1-3 PHASE_A Phase A of the three-phase power 120-240VAC, 60HZ, 100mA, 3-phase
monitor
P1-4 UNUSED DO NOT CONNECT
P1-5 AC_PWR TCU's AC power 120VAC, 60HZ, 0.5A
P1-6 AC_NEUT TCU’s AC power neutral 120VAC, 60HZ, 0.5A
P1-7 TGND Safety ground Ground
P1-8 BAT+ Backup battery positive terminal <24V / Not Rated
P1-9 BAT- Backup battery negative terminal <24V / Not Rated
P1-10 BEMGND Isolated ground (wire to BEM001, pin <24V / Not Rated
12)
P1-11 BEM_PWR Isolated power (wire to BEM001, pin 10) <24V / Not Rated
P1-12 BEM_CTS Isolated clear to send (wire to BEM001, <24V / Not Rated
pin 6)
P1-13 BEM_RXD Isolated receive data (wire to BEM001, <24V / Not Rated
pin 4)
P1-14 BEM_TXD Isolated transmit data (wire to BEM001, <24V / Not Rated
pin 2)
P1-15 BEM_RTS Isolated request to send (wire to <24V / Not Rated
BEM001, pin 8)
P1-16 ALM_HOR Load side of alarm horn relay (NO) 120VAC, 60HZ, 0.5A, Tungsten, 0-
N 24VDC, 1A
P1-17 ALM_LITE Load side of alarm light relay (NC) 120VAC, 60HZ, 0.5A, Tungsten, 0-
24VDC, 1A
P1-18 ALM_PWR Line side of alarm relays 120VAC, 60HZ, 1A, 0-24VDC, 2A,
Source
P1-19 AUX_OUT Load side of auxiliary relay 120-240VAC, 60HZ, 1A, Pilot Duty
P1-20 AUX_PWR Line side of auxiliary relay 120-240VAC, 60HZ, 1A, Source
P1-21 MTR3_STR Load side of motor starter 3 relay 120-240VAC, 60HZ, 1A, Pilot Duty
P1-22 MTR2_STR Load side of motor starter 2 relay 120-240VAC, 60HZ, 1A, Pilot Duty
P1-23 MTR1_STR Load side of motor starter 1 relay 120-240VAC, 60HZ, 1A, Pilot Duty
P1-24 STRT_PWR Line side of motor starter relays 120-240VAC, 60HZ, 3A, Source
Top Connector 2: P3
PIN# Name Description Electrical Rating
P3-1 ST_ADDR0 Station address bit 0 (value 1) <24V / Not Rated
P3-2 ST_ADDR1 Station address bit 1 (value 2) <24V / Not Rated
P3-3 ST_ADDR2 Station address bit 2 (value 4) <24V / Not Rated
P3-4 ST_ADDR3 Station address bit 3 (value 8) <24V / Not Rated
P3-5 ST_ADDR4 Station address bit 4 (value 16) <24V / Not Rated
P3-6 ST_ADDR5 Station address bit 5 (value 32) <24V / Not Rated
P3-7 ST_ADDR6 Station address bit 6 (value 64) <24V / Not Rated
P3-8 ST_ADDR7 Station address bit 7 (value 128) <24V / Not Rated
P3-9 ST_ADDR8 Station address bit 8 (value 256) <24V / Not Rated
P3-10 GND Station address ground <24V / Not Rated
P3-11 INV’ Invert data <24V / Not Rated
Bottom Connector 1: P2
PIN# Name Description Electrical Rating
P2-1 MTR1_RUN Motor 1 run digital monitor input 10-30VAC/DC@10mA
P2-2 MTR2_RUN Motor 2 run digital monitor input 10-30VAC/DC@10mA
P2-3 MTR3_RUN Motor 3 run digital monitor input 10-30VAC/DC@10mA
P2-4 EXT_PM External phase monitor digital monitor 10-30VAC/DC@10mA
input
P2-5 IN_COM_1 Common return for motor run and 10-30VAC/DC@40mA RTN
external phase monitor input
P2-6 LOW_LVL Low Level digital monitor input 10-30VAC/DC@10mA
P2-7 OFF_LVL Off Level digital monitor input 10-30VAC/DC@10mA
P2-8 LEAD_LVL Lead Level digital monitor input 10-30VAC/DC@10mA
P2-9 LAG1_LVL Lag1 Level digital monitor input 10-30VAC/DC@10mA
P2-10 LAG2_LVL Lag2 Level digital monitor input 10-30VAC/DC@10mA
P2-11 HIGH_LVL High Level digital monitor input 10-30VAC/DC@10mA
P2-12 AUX_IN Auxiliary digital monitor input 10-30VAC/DC@10mA
P2-13 ALM_SIL Alarm Silence Switch digital monitor 10-30VAC/DC@10mA
input
P2-14 IN_COM_2 Common return for input level, aux 10-30VAC/DC@80mA RTN
inputs, and alarm silence switch
P2-15 ISOGND Internally supplied 24 VDC bias source <24V / Not Rated
return
P2-16 ISO+24V Internally supplied 24 VDC bias source <24V / Not Rated
voltage
P2-17 TXD_232 RS-232 transmit data to external device <24V / Not Rated
P2-18 RXD_232 RS-232 receive data from external <24V / Not Rated
device
P2-19 GND RS-232 ground <24V / Not Rated
P2-20 TGND Shield for analog monitor signals Ground
P2-21 ANALOG2+ 4-20mA+ signal from transducer; - <24V / Not Rated
(C2) signal at pin P2-23
P2-22 ANALOG1+ 0-5VDC or 4-20mA+ signal from <24V / Not Rated
(C1) transducer; - signal at pin P2-23; jump
pin P2-24 to P2-23 for a 4-20mA C1
signal
P2-23 ANALOG- - signal return for both analog inputs C1 <24V / Not Rated
and C2 at P2-22 and P2-21
P2-24 SHUNT 250 ohm shunt resistor; jump to P2-23 <24V / Not Rated
with 4-20mA signal for C1 at P2-22 only
Bottom Connector 2: P4
PIN# Name Description Electrical Rating
P4-1 Unused Reserved for future use; do not <24V / Not Rated
connect
P4-2 Unused Reserved for future use; do not <24V / Not Rated
connect
P4-3 RS485_B RS-485 serial interface B <24V / Not Rated
P4-4 RS485_A RS-485 serial interface A <24V / Not Rated
P4-5 EX_SHIELD Cable shield for RS-485 or RS-232 Ground
cable
P4-6 EX_GND_RAD RS-232 ground <24V / Not Rated
P4-7 RTS_RAD RS-232 Request to send <24V / Not Rated
P4-8 EX_TXD_RAD RS-232 transmit data to external <24V / Not Rated
device
P4-9 EX_RXD_RAD RS-232 receive data from external <24V / Not Rated
device
P4-10 CTS_RAD RS-232 clear to send <24V / Not Rated
P4-11 Unused Not Connected
P4-12 Unused Not Connected
P4-13 Unused Not Connected
P4-14 Unused Not Connected
Top Connector 1: P1
PIN# Name Description HT3 Address
P1-1 PHASE_C Phase C of the three-phase power monitor (120-240VAC, C4
60HZ, 100mA, 3-phase)
P1-2 PHASE_B Phase B of the three-phase power monitor (120-240VAC, C3
60HZ, 100mA, 3-phase)
P1-3 PHASE_A Phase A of the three-phase power monitor (120-240VAC, B11
60HZ, 100mA, 3-phase)
P1-4 UNUSED DO NOT CONNECT --
P1-5 AC_PWR TCU's AC power (120VAC, 60HZ, 0.5A) B9
P1-6 AC_NEUT TCU’s AC power neutral (120VAC, 60HZ, 0.5A) --
P1-7 TGND Safety ground --
P1-8 BAT+ Backup battery positive terminal (<24V/not rated) --
P1-9 BAT- Backup battery negative terminal (<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 to 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 to BEM001, pin 2) (<24V/not --
rated)
P1-15 BEM_RTS Isolated request to send (wire to BEM001, pin 8) (<24V/not --
rated)
P1-16 DIGITAL 120VAC, 60HZ, 0.5A, Tungsten, 0-24VDC, 1A output; B5
OUTPUT normally open contact; source from pin P1-18
POINT
Top Connector 2: P3
PIN# Name Description HT3 Address
P3-1 ST_ADDR0 Station address bit 0 (value 1) (<24V/not rated) --
P3-2 ST_ADDR1 Station address bit 1 (value 2) (<24V/not rated) --
P3-3 ST_ADDR2 Station address bit 2 (value 4) (<24V/not rated) --
P3-4 ST_ADDR3 Station address bit 3 (value 8) (<24V/not rated) --
P3-5 ST_ADDR4 Station address bit 4 (value 16) (<24V/not rated) --
P3-6 ST_ADDR5 Station address bit 5 (value 32) (<24V/not rated) --
P3-7 ST_ADDR6 Station address bit 6 (value 64) (<24V/not rated) --
P3-8 ST_ADDR7 Station address bit 7 (value 128) (<24V/not rated) --
P3-9 ST_ADDR8 Station address bit 8 (value 256) (<24V/not rated) --
P3-10 GND Station address ground (<24V/not rated) --
P3-11 INV’ Invert data (<24V/not rated) --
P3-12 SWAP’ Swap data (<24V/not rated) --
P3-13 CFG_BIT2 Unused – do not connect --
P3-14 CFG_BIT3 Unused – do not connect --
P3-15 GND Configuration ground --
P3-16 EARTH_GND Earth ground/lanyard --
P3-17 --
P3-18 --
Bottom Connector 1: P2
PIN# Name Description HT3 Address
P2-1 DIGITAL INPUT 10-30VAC/DC@10mA Digital monitor point (>30V A1
POINT requires resistor); common at pin P2-5
P2-2 DIGITAL INPUT 10-30VAC/DC@10mA Digital monitor point (>30V A2
POINT requires resistor); common at pin P2-5
P2-3 DIGITAL INPUT 10-30VAC/DC@10mA Digital monitor point (>30V A3
POINT requires resistor); common at pin P2-5
P2-4 DIGITAL INPUT 10-30VAC/DC@10mA Digital monitor point (>30V A4
POINT requires resistor); common at pin P2-5
P2-5 DIGITAL INPUT 10-30VAC/DC@40mA RTN Input Common 1 for digital --
COMMON inputs P2-1 through P2-4 (>30V require dropping
resistors)
P2-6 DIGITAL INPUT 10-30VAC/DC@10mA Low Level digital monitor input A5
POINT
P2-7 DIGITAL INPUT 10-30VAC/DC@10mA Off Level digital monitor input A6
POINT
P2-8 DIGITAL INPUT 10-30VAC/DC@10mA Lead Level digital monitor input A7
POINT
P2-9 DIGITAL INPUT 10-30VAC/DC@10mA Lag1 Level digital monitor input A8
POINT
P2-10 DIGITAL INPUT 10-30VAC/DC@10mA Lag2 Level digital monitor input A9
POINT
P2-11 DIGITAL INPUT 10-30VAC/DC@10mA High Level digital monitor input A10
POINT
P2-12 DIGITAL INPUT 10-30VAC/DC@10mA Auxiliary digital monitor input A12
POINT
P2-13 DIGITAL INPUT 10-30VAC/DC@10mA Alarm Silence Switch digital B7
POINT monitor input
P2-14 DIGITAL INPUT 10-30VAC/DC@80mA RTN Input Common 2 for digital --
COMMON inputs P2-6 through P2-13 (>30V require dropping
resistors)
P2-15 ISOGND Internally supplied 24 VDC bias source return (<24V/not --
rated)
P2-16 ISO+24V Internally supplied 24 VDC bias source voltage (<24V/not B10
rated)
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 GND RS-232 ground (<24V/not rated) --
P2-20 TGND Shield for analog monitor signals --
P2-21 ANALOG2+ (C2) 4-20mA+ signal from transducer; - signal at pin P2-23 C2
(<24V/not rated)
P2-22 ANALOG1+ (C1) 0-5VDC or 4-20mA+ signal from transducer; - signal at C1
pin P2-23; jump pin P2-24 to P2-23 for a 4-20mA C1
signal (<24V/not rated)
P2-23 ANALOG- - signal return for both analog inputs C1 and C2 at P2-22 --
and P2-21 (<24V/not rated)
P2-24 SHUNT 250 ohm shunt resistor; jump to P2-23 with 4-20mA signal --
for C1 at P2-22 only (<24V/not rated)
Bottom Connector 2: P4
PIN# Name Description HT3 Address
P4-1 Unused Reserved for future use; do not connect --
P4-2 Unused Reserved for future use; do not connect --
In the water and wastewater industry, pumps are used to fill tanks and empty wells, in addition to other
methods of moving liquid from place to place. In the following discussion and description of pump
control systems, pumps and their associated motors are considered inseparable, because they are
physically connected and operate as a unit. Whenever the word "pump" is used, it refers to the pump unit,
including its associated motor.
M ODES OF O PERATION
General RTU
The TCU’s points can be used as non-intelligent I/O by setting the number of pumps to 0 (zero). See
“Number of Pumps” on page 128 in Chapter 10: Configuring the Pump Control Process.
Pump Controller
The TCU can be used to control up to three pumps using its built-in pump control process. Information
on configuring and using this process is provided in Chapter 9: Pump Controller User Interface, Chapter
10: Configuring the Pump Control Process, and Chapter 11: Viewing Status.
Custom Application
For applications that don’t fit the built-in pump control process, the TCU’s I/O can be manipulated
logically with a DFS BASIC-52 program (much like a PLC). Information on programming the TCU for a
custom application can be found in Chapter 8: Programming the TCU and in the TAC Pack TCU
Programming Reference.
15
Chapter 2: Principles of Operation
H-O-A Switches
Three H-O-A switches on the TCU’s front panel are provided to manually override the TCU's automated
control. That is, they can be used to manually control the pumps connected to the unit.
The H-O-A switch for a pump motor must be in the “Auto” position for the TCU to provide
automatic control of that motor.
Placing a switch in the “Hand” position overrides the TCU's control and forces the corresponding
pump motor on.
Placing a switch in the “Off” position overrides the TCU's control and forces the corresponding
pump motor off.
Unused switches should be left in the “Off” position.
The H-O-A switches are fail-safe; they remain operational even if the TCU fails or loses power. They
will continue to function in the “Hand” and “Off” positions with the TCU in a faulted state or powered
down. Motor Starter faults are reset when the corresponding H-O-A switch is moved from the “Auto”
position.
The TCU can also function while partially overridden; that is, it can operate when as few as one of the
H-O-A switches is in the “Auto” position. Automated control continues while outputs are in the
automatic state.
All three H-O-A switches must be in the “Hand” or “Off” position before any changes can be made to
the TCU’s configurations.
Telemetry Interface
Connecting to a telemetry system provides a remote H-O-A system that can be used to override the TCU.
Through telemetry, all outputs of the TCU can be individually overridden (forced on) or disabled (forced
off). Note that local H-O-A control will always override any telemetry control.
Digital-type Devices
The TCU can accommodate digital-type devices such as contact closures (for example, floats), float
switches, and pressure switches. Several digital-type devices can be connected to up to six discrete
digital monitoring points to control the operation of pumps.
The TCU is designed to handle simplex, duplex, and triplex configurations. Other devices such as
pressure switches and bubbler mercury switches are adaptable to this design.
Analog-type Devices
Optionally, analog level-sensing devices, including ultrasonic, hydraulic pressure, and pneumatic
pressure transducers, can be monitored through an industry standard 4-20mA / 0-5 volt interface. Any
analog level-detection transducer (self powered or TCU powered) that supplies a 4-20 mA current signal
or a 0-5 volt signal can be used as an analog-level input device.
AC Power Status
The TCU’s Power LED illuminates when the TCU is in the on state and AC voltage is applied. If a
backup battery is connected to the TCU and primary AC power is interrupted, the ACPwr alarm is
activated and the TCU’s Alarm LED flashes.
IMPORTANT: If the TCU’s Power LED is not lit, you should assume that the TCU is still powered.
The Power LED indicates only that the TCU is in the off state, not that AC power has been removed.
To remove power, you must turn off the external circuit breaker.
The twelve LEDs (Inputs 1-12) located along the bottom edge of the TCU provide field status of the
following 12 digital inputs:
Input 1: P2-1 Input 7: P2-8
Input 2: P2-2 Input 8: P2-9
Input 3: P2-3 Input 9: P2-10
Input 4: P2-4 Input 10: P2-11
Input 5: P2-6 Input 11: P2-12
Input 6: P2-7 Input 12: P2-13
Programmable LEDs
Thirteen of the TCU’s LEDs are programmable when not using the built-in pump control process.
The LEDs below each of the three H-O-A switches
The LEDs that are located on either side of the LCD
The Alarm LED
The LCD backlight
The LEDs that appear on either side of the LCD screen can be used in conjunction with information on
the LCD to provide status at a glance. The TCU’s pump control process is designed this way. When you
are viewing the default status screen, each of the LEDs corresponds to a condition (for example, HiWell)
that is listed on the screen. A lit LED indicates that the station is currently in that state. You can create
custom status screens using the DGOUT and MENU statements.
More information on programming these LEDs can be found in the section titled “LEDs” beginning on
page 117 in Chapter 8: Programming the TCU.
These LEDs serve specific functions when using the TCU’s pump control process. For more information,
see the section titled “LED Indicators” beginning on page 124 in Chapter 9: Pump Controller User
Interface.
LCD S CREEN
The TCU’s large 4-line x 20-character LCD, in conjunction with the 12-key keypad, provides an
interface for configuring the TCU, viewing and resetting alarms, and analyzing status information. The
contrast of the LCD is controlled by an onboard temperature sensor, which helps to ensure that the LCD
screen is easy to read in both high- and low-temperature conditions.
The TCU’s LCD may be used to display program variables, status conditions, or lists of items. Although
the number of displayable menu items is limited to 16 (1-16) at any one time, the use of sub menus
allows the total number of menu items to be virtually unlimited. By programming the Enter key to switch
to a sub menu, each of the primary 16 menu items can have up to 16 sub menu items, and so on. For
more information, see “LCD Menus” on page 115.
When the pump control process is being used, five types of information are available to the operator from
the TCU’s LCD: Current status, historical status, alarm messages, configuration options, and version
information. For more information, see “Information Screens” on page 30.
IMPORTANT: If the TCU is connected to telemetry, telemetry functions will be interrupted when the
service port is used.
The interface cable can be purchased from Data Flow Systems or can be built from parts purchased
locally. Figure 2-1, "Service Port Interface Cable" (next page) provides details for building a cable. The
cable may be purchased as part of the TCU, PCU & SCU Test Kit (see Appendix C: Parts List for
ordering information.
All telemetry functions for monitoring and controlling are available via the service port. Additionally, the
TCU can be configured and configurations can be saved and restored by connecting a portable computer
that is running WinRTU Test to the TCU’s service port. The WinRTU Test software is included in the
TCU, PCU & SCU Test Kit. See Appendix C: Parts List for ordering information.
9 8 CTS
5 GND
1 6 4 DTR
3 TXD 5 GND
9
2 RXD
1 4 DTR
RJ11 TO 9-PIN "D" 8 CTS
ADAPTER 3 TXD
1 2 RXD
6
1 9-PIN RS-232
9 COMMUNICATIONS
1 PORT
2 RXD
3 TXD
1 6 4 CTS
1
5 RTS
25 8 CTS 2 TXD
6 WIRE MODULAR
CABLE ASSEMBLY 3 RXD
(COILED OR STRAIGHT
RJ11 TO 25-PIN "D" 5 CTS
UP TO 25 FEET LONG)
ADAPTER 7 GND
20 DTR
25
25-PIN RS-232
COMMUNICATIONS
PORT
6 1 2 3 4 5 6
1
SERVICE
TCU RS-232
SERVICE PORT
Monitored Inputs
The telemetry system can monitor all 12 of the TCU’s digital monitor inputs. Some of the digital
monitor inputs can be used for special monitoring functions when not needed to control the station.
For example, unused motor run and level inputs can be used to monitor generator status and intrusion
switches.
All alarm conditions are monitored by the telemetry system. The operator can be aware of alarm
conditions before the situation becomes critical.
Controlled Outputs
All six of the TCU’s outputs can be controlled by telemetry. The remote control allows individual
pumps to be overridden to the ON or OFF state. Additionally, the entire station can be disabled
(overridden OFF) remotely. Unused outputs (those not needed for other station control functions) can
be used for special functions. For example, unused starter outputs can be used to turn on auxiliary
equipment.
Types of Stations
The station type – simplex, duplex, or triplex – is determined by the number of pumps at the station.
Simplex – A simplex station consists of one pump. The simplex station uses as a minimum the Lead
and Lead Off staging levels.
Duplex – A duplex station consists of two pumps. The duplex station uses as a minimum the Lead,
Lead Off, and Lag staging levels.
Triplex Station – A triplex station consists of three pumps. The triplex station uses as a minimum the
Lead, Lead Off, Lag, and Lag2 staging levels.
Discrete System
In a discrete system, the TCU controls the pumps based on up to six discrete input signals, typically float
balls submersed into a wet well. The floats are positioned at designated levels in the well to enable the
pumps to be started and stopped based on the detected contact closure. The float contact closures can be
monitored with various voltage levels (see Chapter 6: Electrical Installation). Both the Low and High
floats are optional as alarms.
In a Discrete Pump Down Mode (Lift Station) system, all pumps are stagger-started on a high-level float
condition. The pumps will remain on until the high float condition clears. (NOTE: to prevent the pumps
from short cycling on a high float, configure minimum run and off times for the pumps. See Minimum
Pump Run and Off times in Chapter 10: Configuring the Pump Control Process beginning on page 138.)
All pumps will be stopped on a low-level float condition, and the same pump timer rules apply. In the
event of a High and Low float condition at the same time, the high float condition takes precedence and
pumps will continue to run until the high float condition clears.
In a Discrete Pump Up Mode (Storage Tank) system, all pumps are stagger-started on a low level float
condition. The pumps will remain on until the low float condition clears. (NOTE: to prevent the pumps
from short cycling on a low float, configure minimum run and off times for the pumps. See Minimum
Pump Run and Off times in Chapter 10: Configuring the Pump Control Process beginning on page 138.)
All pumps will be stopped on a high level float condition, and the same pump timer rules apply. In the
event of a Low and High float condition at the same time, the Low float condition takes precedence and
pumps will continue to run until the Low float condition clears.
Note: If the Low float is not going to be used, it must be disabled in the TCU’s local configuration in
order for the TCU’s pump control operations to function normally in automatic. Failing to disable the
Low float configuration in this situation, results in a false alarm condition. This condition, which occurs
because the Low float input’s normal state is ON, prevents all of the pumps in automatic from running.
LAG Starts LAG pump LAG OFF Turns off LAG pump
LEAD Starts LEAD pump LAG2 OFF Turns off LAG2 pump
LEAD OFF Turns off LEAD pump LEAD Starts LEAD pump
LAG OFF Turns off LAG pump LAG Starts LAG pump
LAG2 OFF Turns off LAG2 pump LAG2 Starts LAG2 pump
Figure 2-2, "Lift Station (Pump Down) and Storage Tank (Pump Up) Staging Levels"
Analog System
In an analog system, pumps are controlled by a variable, transducer-supplied 4-20mA or 0-5-volt input
that is wired to the TCU’s analog input. The operator sets the 4mA or the 1-volt input equal to the
transducer’s low range (in feet) and the 20mA or 5-volt 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 according to the configured
staging levels. When the analog level reaches the set point value, the corresponding Well Level LED
illuminates and the TCU starts the appropriate pump(s).
The TCU pump control operation functions with eight possible staging levels: Low, Lead Off, Lead, Lag
Off, Lag, Lag2 Off, Lag2, and High. The legacy PCU operation functions with six possible staging
levels: Low, Off, Lead, Lag, Lag2, and High. When operating the TCU in legacy PCU mode, the Lag
Off and Lag2 Off set points are set to the same level as the Lead Off set point.
In this situation, a Low and/or a High float can be used as a backup system and can also operate as
optional alarms.
Note: If the Low float is not going to be used, it must be disabled in the TCU’s local configuration in
order for the TCU’s pump control operations to function normally in automatic. Failing to disable the
Low float configuration in this situation, results in a false alarm condition, which fails the transducer.
This condition, which occurs because the Low float input’s normal state is ON, prevents all of the pumps
in automatic from running.
configured for a lift station. The minimum number of levels required depends on the type of station –
simplex, duplex, or triplex. See Types of Stations, p. 24 for more information on station types.
All pumps are stagger-started on a High-Level float condition, and stopped on a Low-Level
float condition.
Low Level – Low shuts down pumps and activates alarms. Low is considered active when the
well’s level is below Low. Low must be set below all other levels.
Lead Off Level – Lead Off is the minimum operational level of a well. The TCU shuts down the
Lead pump when the well’s level drops below Lead Off. See Figure 2-2, "Lift Station (Pump
Down) and Storage Tank (Pump Up) Staging Levels", page 25. When configuring the TCU for
legacy PCU operation, set the LagOff Pt and Lag2Off Pt to the same level as the LeadOff Pt.
Lag Off Level – Lag Off is the well level at which the TCU shuts down the Lag pump. Note that
this setting can only be used when an analog input is used to control the pumps. Lag Off is not
used in legacy PCU operations or when discrete inputs are being used to control the pumps.
Lag2 Off Level – Lag2 Off is the well level at which the TCU shuts down the Lag2 pump. Note
that this setting can only be used when an analog input is used to control the pumps. Lag2 Off is
not used in legacy PCU operations or when discrete inputs are being used to control the pumps.
Lead Level – Lead starts the Lead (first) pump. Lead is active when the well’s level is above
Lead. When Lead is active, one pump is started.
Lag Level – Lag starts the Lag (second) pump. Lag is active when the well’s level is above Lag.
When Lag is active, the second pump is started.
Lag2 Level – Lag2 starts the Lag2 (third) pump. Lag2 is active when the well’s level is above
Lag2. When Lag2 is active, the third pump is started.
High Level – High starts all three pumps and activates alarms. High is active when the well’s
level reaches High. High must be set above the other levels.
Lead Level – Lead starts the Lead (first) pump. Lead is active when the tank’s level is below
Lead. When Lead is active, one pump is started.
Lag Level – Lag starts the Lag (second) pump. Lag is active when the tank’s level is below Lag.
When Lag is active, two pumps are started.
Lag2 Level – Lag2 starts the Lag2 (third) pump. Lag2 is active when the tank’s level is below
Lag2. When Lag2 is active, all three pumps are started.
Low Level – Low starts all pumps and activates alarms. Low is considered active when the
tank’s level is below Low. Low 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. When enabled, the alternator updates each time it starts a pump. If a pump fails to start,
the alternator advances to the next available pump. Pumps can be taken out of service with the H-O-A
switches, and the TCU will continue to alternate the remaining pumps.
The following alternation options are available:
Alternate among all available pumps.
Alternate between pumps 1 and 2 (High Service Pump option).
Alternate between pumps 2 and 3 (Jockey Pump option).
Disable pump alternation
The TCU uses a numeric alternation scheme. With numeric alternation, the pump assigned as the new
Lead pump is always the next pump in the numeric order. For example, in a triplex lift station, if pump 2
(current Lead pump) and pump 3 (current Lag pump) are running when the Lead Off level is reached,
pump 3 would become the new Lead pump regardless of the number of pumps running.
If the Jockey Pump or High Service Pump options are enabled, the remaining pumps will alternate per
the selected scheme. When the alternator is disabled, Pump 1 is used as the Lead pump, Pump 2 as the
Lag pump, and Pump 3 as the Lag2 pump.
For more information on configuring the TCU for pump alternation, see Configuration Screen 3: Pump
Alternation, p. 132, in Chapter 10: Configuring the Pump Control Process.
phase fault. The voltage used to monitor the set of contacts must be the same used to monitor the
pump run statuses.
Pulse Input
In order for the auxiliary input to be used as a pulse input, its corresponding HT3 point (point 12 of
Module A, a DMM002) must be configured as a digital pulse point (select DP for the Point Type).
Additionally, the time delay relay function must be disabled in the TCU. See “Configuration Screen 4:
Time Delay Relay” beginning on page 134 for more information.
The specifications for the pulse input are as follows:
Supply voltage: 8 to 14 VDC
Minimum pulse width: 25 mS
Maximum burst frequency: 40 PPS
Maximum count frequency: 8 PPS
Alarm outputs are activated only when the TCU detects an alarm condition, such as phase faults, high-
and low-well conditions, and internal TCU faults. The alarm horn can be silenced by pressing the TCU’s
Silence switch, by viewing the TCU’s alarm screen, from a telemetry-provided alarm silence control
point, or from a momentary switch connected to the TCU’s Alarm Silence input. Any new alarm
condition reactivates the alarm horn.
The ALM_HORN output relay closes to power a horn or bell when critical alarm conditions occur. The
relay opens when all critical alarm conditions clear or when the ALM_HORN relay is overridden. All
alarm conditions activate the ALM_LITE output relay. This is a normally closed set of contacts that opens
when no alarms are active. The ALM_LITE relay closes when the TCU is faulted or powered down.
A fail-safe feature is incorporated into the TCU. In normal operation, contacts for the alarm light output
are open. When power to the TCU is interrupted, the contacts of the alarm light output are closed. If the
power source controlling the light is still operating, the alarm light is lit. The alarm horn contacts are not
affected on loss of power to the TCU, and the alarm horn is not activated.
Both the alarm light (ALM_LITE) and alarm horn (ALM_HORN) become inactive when all alarm
conditions clear. However, the Alarm LED on the TCU’s front panel continues to flash and the alarm
message continues to be displayed until the alarm message is viewed. This is not the case if the TCU is
used in a telemetry configuration and the alarm has been acknowledged. See Chapter 12: Viewing and
Troubleshooting Alarms for details on alarm messages.
The alarm light and alarm horn inputs are powered from ALM_PWR, P1-18. Contacts for ALM_HORN,
terminal P1-16, and ALM_LITE, terminal P1-17, are rated for 120VAC, 60HZ, 0.5 A, Tungsten, 0-24VDC,
1A. A battery connection and charging circuitry for battery backed up operation are provided at P1-8
(BAT+) and P1-9 (BAT-).
LED Indicators
The TCU provides 34 ultra-bright LEDs to provide system status at a glance.
Pump Run Indicators (3)
TCU Power Indicator
CPU Fault Indicator
TX Data Indicator
RX Data Indicator
Alarm Indicator
Well Level / Status Indicators (8)
Digital Output Status (6)
Digital Input Status (12)
For more information on these LEDs, see “LED Indicators” (starting on p. 124) in Chapter 9: Pump
Controller User Interface.
Information Screens
Five types of information are available to the operator from the TCU’s LCD: Current status (such as
TCU or system time), historical status (such as pump or level history, or run times), alarm messages,
configuration options, and version information (obtained by pressing specific key combinations). When
the TCU is cycled on, it is initialized and then displays the first status screen. During initialization, the
TCU’s software revision date and serial number are briefly displayed. Status information, alarm
messages, and configuration options can be accessed by using the TCU’s navigation keys to cycle
through the available screens.
Status Information
The TCU collects statistical data and maintains a historical log of pump operations. This information
can be analyzed by viewing each of the TCU’s seven status screens. During initialization, the TCU
displays information including firmware level, process ID, and radio configuration. After initialization,
the LCD displays the default status screen and will return to the default screen after 5 (five) minutes of
button inactivity. For detailed information on the TCU’s status screens, see Chapter 11: Viewing Status.
The display for the default status screen differs depending on the type of level-sensing device being
used.
Analog level-sensing transducer: Current well or tank level, along with a graph showing the
well’s level over the last 5 ½ minutes, is displayed.
Floats: Current time, along with a graph showing the maximum number of pumps running over
the last 5 ½ minutes, is displayed.
The current staging level is indicated by a lit LED next to the corresponding staging level label.
Subsequent status screens, which can be accessed using the TCU’s navigation keys, provide the
following information:
Total station flow – (Used in well applications only) Flow totalization, also referred to as
derived flow, is calculated based on accurate well volume and a full pump cycle (from Lead Off
to Lead and back to Lead Off again).
Phase voltage – Phase voltage between legs A and B and between legs A and C.
Total elapsed pump run time – Cumulative run time for a pump. Readouts are provided for
each pump.
Average pump run time – Average time the pump is on. This is calculated each time the pump
shuts down. Readouts are provided for each pump.
Average pump flow rate – (Used in well applications only) Calculated as an average based on
the station flow volume, the individual pump run time, and the station fill rate. Flow Rate is only
displayed if the well volume is configured.
Pump starts counter – The total number of times each configured pump has started since the
TCU was installed or the time meter was reset.
Analog input status – Current values for the TCU’s two 12-bit analog inputs displayed as mA
or V depending on the TCU’s setup and configuration.
Remote monitor point status – A value for a remote monitor point is displayed if one is in use.
The TCU can accept data via telemetry from a monitor point and use this data to control pump
operations remotely instead of locally. This feature is referred to as remote level auto control.
Alarm Messages
Alarm messages that may be displayed on the LCD screen include those for:
Floats out of sequence (FltSeq)
Pump did not start (Strt)
Pump did not stop (Stop)
Configuration Options
The number of pumps, level-sensor type, pumping method, control levels, etc., are entered into the
unit to customize its operation. A keypad is provided as the main method of configuration input.
Additionally, information can be transferred to the unit through an RS-232 service port or over a radio
link using HT3 telemetry equipment. Configurations are stored in non-volatile memory allowing the
unit to retain configuration information even during extended power outages and servicing.
The TCU’s configuration options are accessed by:
1. Placing all three of the H-O-A switches in the “Hand” or “Off” position.
2. Navigating to the Change Configurations screen.
3. Pressing the Enter key.
The following are used for entering the TCU’s configuration data:
Keypad and LCD – A 4x20-character LCD is provided to view status, alarms, and configuration
data. The TCU’s 12-key keypad enables you to navigate through displays and change the
configuration. The keypad includes the numbers 0-9, navigation keys (up ▲, down ▼, left ◄, and
right ►), an ENTER key, and an ESC (escape) key. Some keys have two functions. For example,
the number 2 key is also the “up” scrolling key. The function of the key is dependent on the
screen currently being displayed.
Communications Service Port – The TCU’s front panel features an RS-232 interface that can
be used for diagnostics and configuration storage and updating. Configuration data can be
uploaded from the TCU to a portable computer and saved. If the TCU is replaced, the
configuration can be downloaded from a laptop computer to another TCU. When the TCU
configuration is modified using this method, the TCU will reset itself causing any pumps running
in automatic to be stopped. The pumps will not start again in automatic until their associated
staging level is reached.
For detailed information on configuring the TCU for a pump control process, see Chapter 10:
Configuring the Pump Control Process.
Failure Modes
The TCU can operate around a pump that has failed, and can be configured to retry the failed pump after
a delay. If the retry function is disabled, the TCU will alternate around the faulted pump until it is taken
out of service via its corresponding H-O-A switch.
If the TCU detects a critical fault in the system, it disables the pumps and activates the alarm outputs.
Any phase fault disables the pumps, but the H-O-A switches can override the TCU and start the pumps.
If the primary analog input device is used to control the pumps, and it is determined to be faulty, the
secondary analog input can then be employed as a backup.
If an analog input device is used to control the pumps, a high and low float may be installed and used as
a backup in the event of a failed transducer.
If the controlling analog input device fails, or if a float sequence is detected, the limp mode timer backup
can be temporarily employed to keep the pump station running.
Refer to the TAC II Telemetry System Installation Planning Guide for additional information on the DFS
TAC II Monitor and Control System.
Notes
S AFETY P RECAUTIONS
Review the following statements before installing, servicing, or replacing the Tack PAC Telemetry
Control Unit (TCU) or any of its components.
G ENERAL P RECAUTIONS
Only trained and qualified personnel should install, service, or replace this equipment.
Carefully read the installation and wiring instructions before connecting the TCU to its power source.
Do not work on the TCU, or connect or 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 maximum recommended
temperature of -10OC (14OF) to 60OC (140OF). The upper temperature limit is 50OC (122OF) when using
the recommended backup battery.
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 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 should conform to federal, state, and local electrical codes.
IMPORTANT: If the TCU’s Power LED is not lit, you should assume that the TCU is still powered.
The Power LED indicates only that the TCU is in the off state, not that AC power has been removed.
To remove power, you must turn off the external circuit breaker.
When disconnecting a cable, pull on its connector or on its strain-relief loop, not on the cable itself.
Some cables have a connector with locking tabs; when disconnecting this type of cable, press in on the
locking tabs before disconnecting the cable. When pulling connectors apart, keep them evenly aligned to
avoid bending any connector pins. Also, before connecting a cable, make sure both connectors are
correctly oriented and aligned.
35
Chapter 3: Before You Begin
S ITE S ELECTION
When selecting a site for the TCU, keep the following in mind:
The TCU requires a 120 VAC power supply.
The TCU is designed to operate at recommended temperature range of -10OC (14OF) to 60OC
(140OF). The upper temperature limit is 50OC (122OF) when using the recommended backup battery.
The TCU requires a NEMA type 12 or equivalent enclosure.
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 and to remove the
connectorized terminal strips. Install the TCU in the panel at a position where the LCD display can
be read comfortably. The LCD is best viewed at slightly below eye level.
R ECEIPT OF E QUIPMENT
When equipment is received, examine the outside of the carton for any damage incurred during
shipment. Remove the packing list and the equipment from the shipping carton. Carefully inspect the
equipment for damage. Resolve any damage with the local carrier. Report damages to Data Flow
Systems (321-259-5009). Include the serial number of the unit and the extent of damage in your report.
The TCU is intended to be permanently installed in a NEMA 12 or higher rated panel that prevents
access to live parts without a tool. The TCU can be mounted in a control panel in several different ways.
The unit can be mounted flush to the back plate of the panel, stood off the back plate, or mounted to a
front panel. Mounting brackets are provided with the TCU that can be used to mount it in any of these
positions. Optional connectors to facilitate the various types of mountings are available as shown in
Figure 4-4, "Optional Connector Types" and may be specified as described in Appendix C: Parts List.
IMPORTANT
A qualified technician should install the TCU.
Precautionary measures must be observed when installing, operating, and servicing the TCU in order
to prevent shock from voltages present.
The TCU is intended to be permanently installed in a NEMA 12 or higher rated panel that prevents
access to live parts without a tool..
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 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 and to remove the
connectorized terminal strips. Install the TCU in the panel at a position where the LCD display can
be read comfortably. The LCD is best viewed at slightly below eye level.
37
Chapter 4: Mounting Instructions
1.00
6.91
1.00
4.55
1.00
4.45
The 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 photo below) which can be ordered
from DFS. See Appendix C: Parts List for information on ordering connectors and the connector tool.
TOOL
WIRE
SCREWDRIVER
WIRE
SCREWDRIVER
WIRE
A dimensional drawing is provided in Figure 4-6, "Dimensional drawing of the TAC Pack TCU" 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. See Figure
4-7, "Control panel installation with TCU mounted to dead front" and Figure 4-8, "Control panel
installation with TCU mounted to front panel", p. 42.
5.75
8.75 9.13
0.74
7.00
1.00
4.45
.125R TYP
Molding,
4 Pieces
Front Panel Cutout
Front Panel Cutout
with Edge Molding
Cutout
Hole for #6 Mounting Hardware
4 Required
(Not required if TAC Pack TCU
is rear panel mounted)
Figure 4-7, "Control panel installation with TCU Figure 4-8, "Control panel installation with TCU
mounted to dead front" mounted to front panel"
The TCU provides support for Modbus slave and master devices via its RS-232 and RS-485 serial
interfaces.
The TCU’s standard RS-232 serial interface allows it to be polled by devices (TCU as Modbus slave
device) that use 9600 baud and numerous Modbus protocol configurations. See “TCU as Modbus
Slave (RS-232 Interface),” below. Note that the TCU must be factory configured by DFS to provide
Modbus slave support.
The TCU’s RS-485 Modbus serial interface enables it to act as a Modbus master device and poll
devices at 1200-9600 baud using Modbus serial ASCII or RTU protocol. The baud rate and protocol
selected for your installation must be identified in the TCU’s configuration. See “Modbus Master
Baud Rate and Protocol” on page 144 for more information.
Note that although the illustrations in this chapter show the TCU acting as either a master or a slave
device, it can be used as both simultaneously. For example, it could respond to queries from a Modbus
master HMI software package (via RS-232) while querying DIN-rail mounted RS-485 slave devices.
For specific instructions on adding a RIO032 to a TCU, see Appendix J: Adding a RIO to the TCU
beginning on page 217.
43
Chapter 5: Modbus Support
TCU MODBUS
MASTER / PLC
G R C R C G
R T R T
N T T T T N
X X X X
D S S S S D
1
TCU MODEM
MODBUS
G R C R C G MODEM MASTER
R T R T
N T T T T N
X X X X
D S S S S D
1
MODBUS
MASTER
TCU RADIO
G R C R C G
R T R T
N T T T T N
X X X X
D S S S S D
1
IMPORTANT: Do not use the TCU to power an external RS-232 Modbus-compatible device (for
example, a radio, modem, or PLC). The device must be powered by a source other than the TCU.
Pins on the TCU’s second bottom connector, P-4, are provided for connecting the TCU to an external
RS-232 Modbus compatible device (see table below for pin descriptions for connector P-4).
Connector P-4 Pin Descriptions
In the wiring diagram supplied below, note that the RTS (request to send) and CTS (clear to send)
connections are optional. They are used only for master devices that require hardware handshaking.
CTS_RAD 10
REQUEST TO SEND
EX_RXD_RAD 9
TX
EX_TXD_RAD 8 RX
RTS_RAD 7
CLEAR TO SEND
EX_GND_RAD 6 GND
EX_SHIELD 5
SHIELD
RS485_A 4 NOTES:
1. The cable shield wire must only be
RS485_B 3 grounded at one end.
2. "Request to Send" and "Clear to Send" connections are optional.
TCU Use only if RS-232 master device requires hardware handshaking.
For example, to give the TCU a device ID of 98, we would leave the bits for the following pins
ungrounded (DIP switches in the OFF position):
pin P3-2 (bit value=2)
pin P3-6 (bit value=32)
pin P3-7 (bit value=64)
When we add the values of these bits together, we get a total value of 98 (2+32+64=98). The remaining
bits would be left grounded (DIP switch in the ON position).
Control Panel
P3-16 (Earth Ground)
P1-7 (Safety Ground) TCU
TCU
Ground
Lug
Mast
RADIO
Antenna
Ground
Rod
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 tables on the following pages list the properties of each of the TCU’s data registers and provide a
description of each register’s function.
Notes:
The information in the table is sorted by register number in ascending order.
Alarm states are listed for some but not all of the TCU’s I/O points. Those listed are common alarms, but
any or all configured telemetry points can be set to alarm in any desired state.
For analog input (AI) and output (AO) points, the Low State Label column gives the point’s Low
Engineering value followed by its Low Raw value; the High State Label column gives the point’s High
Engineering value followed by its High Raw value.
Name Type Register Low State High State Resolution Alarm Description
Label Label State
Name Type Register Low State High State Resolution Alarm Description
Label Label State
Name Type Register Low State High State Resolution Alarm Description
Label Label State
Name Type Register Low State High State Resolution Alarm Description
Label Label State
High Well DI 13827 NORMAL ALARM ALARM Detects the state of the High level
Level sensor
HOA 1 DI 13828 – HAND HAND Detects position of HOA 1 switch
and activates alarm for “Hand”
position
HOA 1 DI 13829 – OFF OFF Detects position of HOA 1 switch
and activates alarm for “Off”
position
HOA 1 DI 13830 – AUTO Detects position of HOA 1 switch
and activates alarm for “Auto”
position
HOA 2 DI 13831 – HAND HAND Detects position of HOA 2 switch
and activates alarm for “Hand”
position
HOA 2 DI 13832 – OFF OFF Detects position of HOA 2 switch
and activates alarm for “Off”
position
HOA 2 DI 13833 – AUTO Detects position of HOA 2 switch
and activates alarm for “Auto”
position
HOA 3 DI 13834 – HAND HAND Detects position of HOA 3 switch
and activates alarm for “Hand”
position
HOA 3 DI 13835 – OFF OFF Detects position of HOA 3 switch
and activates alarm for “Off”
position
HOA 3 DI 13836 – AUTO Detects position of HOA 3 switch
and activates alarm for “Auto”
position
Reserved AI 32945 Factory use only. Do not use.
Reserved AI 32946 Factory use only. Do not use.
Internal AI 32947 0/32 100/212 0.1/F Detects the TCU’s internal
Temperature temperature
Analog Input 1 AI 33713 4/820 20/4095 0.01/mA Settings for the primary analog
input
Analog Input 2 AI 33714 4/820 20/4095 0.01/mA Settings for the auxiliary analog
input
Phase AB AI 33715 0/350 300/3102 1/VAC Settings for Phase AB voltage for
Voltage 240VAC 1- or 3-phase monitor
(240VAC)
Phase AB AI 33715 0/350 600/3114 1/VAC Settings for Phase AB voltage for
Voltage 480VAC 3-phase monitor
(480VAC 3-
phase)
Phase AC AI 33716 0/350 300/3077 1/VAC Settings for Phase AC voltage for
Voltage 240VAC 1- or 3-phase monitor
(240VAC)
Name Type Register Low State High State Resolution Alarm Description
Label Label State
Phase AC AI 33716 0/350 600/3077 1/VAC Settings for Phase AC voltage for
Voltage 480VAC 3-phase monitor
(480VAC 3-
phase)
Remote Level AO 42273 4/820 20/4095 0.01/mA Calibration point for displaying the
level for a remote input
Well Level AO 42276 0/0 60/600 0.1/FT Calibration point for displaying well
level
TCU MODBUS
SLAVE
I/O
A B B A
EX_GND_RAD 6
EX_SHIELD 5
NOTES:
RS485_A 4 1. The cable shield wire must only be
grounded at one end.
RS485_B 3
2. Requires 150-200 ohm resistor.
TCU
After TCU power up, Modbus control registers are updated whenever the corresponding TCU registers
are changed via telemetry. Similarly, when Modbus status registers change, their corresponding TCU
registers are updated. One module of Modbus data is processed approximately every 2 seconds.
Baud Parity
Outgoing Message Structure (binary message image) is built using Hexadecimal (Hex) values starting at
memory location 5C60H. Information on Modbus messaging and function formats can be found in the
Modicon Modbus Protocol Reference Guide (PI-MBUS-300). This reference guide is available for
download from Modicon’s web site (www.modicon.com).
Placing the “:” syntax, LRC (Longitudinal Redundancy Check), and CR-LF (Carriage Return - Line
Feed) characters into memory is not required since the final message building is performed by the
Modbus communications routine.
After the memory locations are set appropriately for the desired command option, call the Modbus
Routine at 3000H (e.g. CALL 3000H).
The finished Modbus message is generated with the appropriate syntax and sent to the Modbus device.
The routine waits 1-3 seconds for a valid response from the device and stores the received message at
memory location 5C61H up to memory location 5C9DH. The message length (number of bytes) is stored
at memory location 5C60H, with the actual received data (not including address, message type, or data
byte length) stored at memory location 5C64H.
If there is no response from the Modbus device or the received message is determined to be bad by the
Modbus Routine, a value of zero is stored in memory location 56C0H.
REM else057:
REM DIGITAL REGISTERS
7342 For MIX = ModLn to 1 step -1
7344 MsgIx = 05C64H + (MIX-1)/8
7346 Push (XBY(MsgIx).and.2**((MIX-1).and.7))<>0
7348 Next
The electrical interface to the TCU is broken down into several groups of signals. Wiring of each group
is detailed in the following paragraphs.
These instructions are written specifically for a TCU using the built-in pump control process. Although
many of them apply to custom applications as well, the Applications Engineer will be primarily
responsible for defining and implementing the TCU’s inputs and outputs. In this chapter, functions
specific to the pump control process are noted as such.
An installation checkout procedure is provided in Appendix A: Checkout Procedure for Pump Controller.
A comprehensive wiring diagram of a typical TCU installation is shown on page 85.
59
Chapter 6: Electrical Installation
AC P OWER
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 (AC neutral)
P1-7, TGND (earth ground)
Terminal P1-7 is designated Earth or Safety ground. The TCU’s case is also connected to the TGND
terminal. Wire in accordance with Federal, State, and Local Electrical Codes.
IMPORTANT: The transformer must provide AC neutral. When wiring to a typical three-phase, 4-
wire, 240 volt transformer that provides AC neutral, refer to Figure 6-1, "Wiring AC Power (typical
240 volt, 4-wire transformer)". Refer to Figure 6-2, "Wiring AC Power (typical 480 volt, 3-wire
transformer)" when connecting to a typical three-phase, 3-wire 480 volt transformer with no neutral
provided.
Note that these diagrams are for typical installations. If your installation deviates from that shown here,
refer to the National Electrical Code® (NEC®) Handbook.
MOTOR
BREAKER BREAKER
L1
FROM TO MOTOR
POWER L2 STARTER
COMPANY CONTACTS
(4-WIRE) L3
AC NEUTRAL
TRANSIENT
FILTER
CONTROL 10 AMP SHIELD CONNECTOR P1
BREAKER BREAKER
1 1 5 AC_PWR
2 2 6 AC_NEUT
3 NC 7 TGND
120VAC 4 NC
N
SURGE
SUPPRESSOR 5 NC
MOTOR
BREAKER BREAKER
L1
FROM
POWER TO MOTOR
COMPANY L2 STARTER
(3-WIRE) CONTACTS
L3
TRANSIENT
480 FILTER
CONTROL 10 AMP SHIELD CONNECTOR P1
BREAKER BREAKER
120 1 1 5 AC_PWR
2 2 6 AC_NEUT
3 NC 7 TGND
120VAC 4 NC
N SURGE
SUPPRESSOR 5 NC
Circuit Wiring", below), and that they are located as close as possible to the TCU to protect the TCU
relays.
CONNECTOR P1
OVERLOAD 3 CONTACT THERMAL MTR STR 3 COIL 1 A FUSE
21 MTR3_STR
SLOW BLOW
NOTES:
1. Fuses on TCU output pins are
required for protection of the
TCU's relays.
2. Motor starter outputs use a
solid-state relay driving
120VAC or 240VAC at 1 amp
with 8mA off-state leakage
OUTPUT VOLTAGE current.
3. Install interposing relays for
starter outputs of NEMA
size 3 or larger.
N
PWR
NOTE: The alarm light output is designed to energize an incandescent lamp. Any other application
requires an interposing relay, especially strobe lights due to their high peak current demands.
See Figure 6-4, “Alarm Horn and Alarm Light Wiring" (next page) for a wiring diagram of the alarm
circuits.
IMPORTANT: Snubbers (devices which suppress voltage transients) must be installed when either of
the TCU’s alarm outputs (Alarm Light or Alarm Horn) are being used for switching inductive loads
(including the coils of any interposing relays). The best place to install the snubbers is either directly
connected across the coil terminals or at the closest practical connection point to the coil terminals of
the inductive load.
The snubbers must be electrically connected across the coil terminals – not to any ground(s).
AC and DC applications require different types of snubbers. Detailed information and diagrams are
provided on the next page.
CONNECTOR P1
ALARM HORN
1 A FUSE 16 ALARM HORN OUT
SLOW BLOW
ALARM LIGHT FLASHER
1 A FUSE 17 ALARM LIGHT OUT
SLOW BLOW
18
ALARM POWER
NOTES:
RTN PWR
AC Applications
We recommend an RC snubber (DFS # 007-0084) using a 0.1uF capacitor in series with a 47 ohm ½ watt
resistor, such as that manufactured by RED LION (Model # SNUB0000).
SLOW BLOW
R
AC Supply C
PWR RTN
DC Applications
We recommend a power diode (DFS # 006-0019) with a minimum 3 amp 100 peak inverse voltage (PIV)
fast acting rating, such as the industry standard 1N4004 (DIGIKEY # 1N4004CT-ND).
IMPORTANT: DC polarity is important. The diode must be connected in reverse bias across the coil
terminals or as close as is practical. That is, the cathode (the side 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.
Supply
+ -
PWR RTN -
P HASE M ONITOR
Three-Phase Option
Connect terminals PHASE_C (P1-1), PHASE_B (P1-2), and PHASE_A (P1-3) through one-amp slow-blow
fuses to phases A, B, and C, respectively, at the load side of the main breaker.
480 VAC three-phase power requires 100K-ohm resistors on PHASE_C (P1-1) and PHASE_B (P1-2)
inputs (see Appendix C: Parts List for information on 480VAC Phase Monitor Kit).
If a phase sequence alarm occurs at initial installation, swap any two legs at the load side of the main
breaker. If the alarm was caused by improper phases, this will clear the alarm. The fuses must be located
as close as possible to the voltage source. Refer to Figure 6-5, "Three-Phase Monitor Wiring", below.
FROM
POWER PHASE B MOTOR
COMPANY
PHASE A
1
NOTES: 1 AMP FUSE
4
SLOW BLOW 2 CONNECTOR P1
1. Fuses on three phase power 3
must be located as close as 3 1
PHASE C
possible to main circuit 4
breaker. 2
PHASE B
2. TCU phase monitor designed 5 3 PHASE A
for 240 or 480 VAC three-phase
power. TRANSIENT
3 Resistors required for 480 VAC FILTER TCU
three-phase power only. SHIELD
4 600 VAC rated fuses required for
480 VAC operation.
The type of phase monitor selected for your installation must be identified in the TCU’s configuration.
See “Phase Monitor Range” on page 140 for more information.
IMPORTANT: The configuration option selected must match the physical wiring. An incorrect
configuration could cause the TCU to not protect pump motors from undesirable power conditions.
Note: Instructions for wiring 240VAC single-phase appear on the next page.
1
2 CONNECTOR P1
1 AMP FUSE 3 1
SLOW BLOW PHASE C
4 2
PHASE B
5 3 PHASE A
TRANSIENT
FILTER TCU
NOTES: SHIELD
1. Single-phase option valid for 240 VAC only.
2. Fuses on phase power must be located as close as possible to the main circuit breaker.
The type of phase monitor selected for your installation must be identified in the TCU’s configuration.
See “Phase Monitor Range” on page 140 for more information.
IMPORTANT: The configuration option selected must match the physical wiring. An incorrect
configuration could cause the TCU to not protect pump motors from undesirable power conditions.
IMPORTANT: Inputs with a common return must use the same bias voltage. No more than two bias
voltage sources can be used to bias the 12 digital inputs – one for biasing inputs using the IN_COM_1
terminal and one for biasing inputs using the IN_COM_2 terminal.
Input commons on the TCU must be either AC neutral (with no voltage potential when referenced to
earth ground) or the negative terminal of a DC power supply.
Figure 6-7, "Using ISO+24V and ISOGND as Common Bias Source", next page, illustrates the use of
ISOGND and ISO+24V as the common bias source for all 12 of the digital monitor point inputs.
INPUT CONTACT
HIGH FLOAT
LAG2 FLOAT
SHUNT
ANALOG-
LEAD FLOAT
ALALOG1+
ANALOG2+
TGND
GND OFF FLOAT
RXD_232
TXD_232
ISO+24V
LOW FLOAT
ISOGND
IN_COM_2
ALM_SIL
EXTERNAL PHASE FAULT RELAY
AUX_IN
HIGH_LVL
LAG2_LVL
LAG1_LVL MOTOR STARTER 3 AUX CONTACT
LEAD_LVL
OFF_LVL
LOW_LVL
MOTOR STARTER 2 AUX CONTACT
IN_COM_1
EXT_PM
MTR1_RUN
MTR2_RUN MOTOR STARTER 1 AUX CONTACT
MTR1_RUN
TCU
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
CONNECTOR P2
ISO+24V 16
ISOGND 15
INPUT
TCU
INPUT VOLTAGE (24 VDC)
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
INPUT CONTACT
1 OR SWITCH
INPUT
INPUT COMMON
TCU
INPUT VOLTAGE
NOTE:
See resistor sizing chart
1
for correct resistor value. RTN
EXTERNAL BIAS
VOLTAGE SOURCE
IMPORTANT: The transformer must provide AC neutral. When wiring to a typical three-phase, 4-
wire, 240 volt transformer that provides AC neutral, refer to Figure 6-10, "Motor Run Monitoring
Signal (4-wire transformer)". Refer to Figure 6-11, "Motor Run Monitoring Signal (3-wire
transformer)" when connecting to a typical three-phase, 3-wire 480 volt transformer with no neutral
provided.
Input commons on the TCU must be either AC neutral (with no voltage potential when referenced to
earth ground) or the negative terminal of a DC power supply.
Note that these diagrams are for typical installations. If your installation deviates from that shown here,
refer to the National Electrical Code® (NEC®) Handbook.
MAIN
MOTOR 1 MOTOR STARTER 1 OVERLOAD 1
BREAKER
BREAKER CONTACT COIL
FROM
POWER
COMPANY MOTOR 1
(4-WIRE)
AC NEUTRAL CONTROL
BREAKER
MOTOR STARTER 1
X 5 AUXILIARY CONTACT
MOTOR 2
MOTOR STARTER 2
5 AUXILIARY CONTACT
MOTOR 3
MOTOR STARTER 3
5 AUXILIARY CONTACT
IN_COM_1 5
MTR3_RUN 3 2
2 2
MTR2_RUN
1 2
MTR1_RUN
NOTES:
INPUT VOLTAGE 1. EXT_PM input shares IN_COM_1 with the MTRX_RUN inputs. All three
N MTRX_RUN inputs and EXT_MR input must be wired with the same bias
BIAS
source and resistor value.
SOURCE
2 See resistor sizing chart for correct resistor values.
3. All power entering the TCU must be from a single phase of the three-phase
system.
4. Transformer must provide AC neutral (4-wire).
5 1 amp 600V fuse
MAIN
MOTOR 1 MOTOR STARTER 1 OVERLOAD 1
BREAKER
BREAKER CONTACT COIL
FROM
POWER
COMPANY MOTOR 1
(3-WIRE)
F F
BREAKER 1 MOTOR STARTER 1
480 AUXILIARY AUXILIARY CONTACT
120
MOTOR 2
MOTOR 3
IN_COM_1 5
MTR3_RUN 3 2
2 2
MTR2_RUN
1 2
MTR1_RUN
NOTES:
INPUT VOLTAGE
1. EXT_PM input shares IN_COM_1 with the MTRX_RUN inputs. All three
N BIAS MTRX_RUN inputs and EXT_MR input must be wired with the same bias
SOURCE source and resistor value.
2 See resistor sizing chart for correct resistor values.
3. All power entering the TCU must be from a single phase of the three-phase
system.
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
2 HIGH FLOAT
2 LAG2 FLOAT
2 LAG1 FLOAT
CONNECTOR P2
2 LEAD FLOAT
14
IN_COM_2
11
HIGH_LVL
10 2 OFF FLOAT
LAG2_LVL
9
LAG1_LVL
8
LEAD_LVL
7
OFF_LVL 2 LOW FLOAT
6
LOW_LVL
TCU
INPUT VOLTAGE
BIAS
RTN SOURCE
NOTES:
1. All six level inputs (XXX_LVL) shown here can monitor the status of dry contact switches. See functional
description of these inputs for more information.
2 See resistor sizing chart for correct resistor values.
3. ALM_SIL, AUX_IN, and all level inputs share IN_COM_2 as a return. These inputs must all be wired with
the same bias source and resistor value.
4. Diagram shows wiring for normally open switches. For normally closed switches, see Appendix F, Connecting a
TCU to a Remote RTU.
IMPORTANT: If this TCU installation is an upgrade from a PCU that was providing power to the
transducer, note that transducer power must be acquired from pin P2-16 of the TCU. In a PCU
installation, power could be acquired from pins P2-21 or P2-16. When upgrading to a TCU, the wire
from P2-21 (PCU) must be moved to P2-16 (TCU). If you find that you are not receiving the analog
signal, verify that the TCU is properly wired.
Wiring Notes:
Because ANALOG1+ and ANALOG2+ are tied to a common isolated ground (ANALOG-), the TCU
must be the last device in a multiple device analog loop (see Figure 6-15, "Externally Powered Non-
submersible Transducer" on page 77 for an example).
When using the isolated bias to power monitor points and the analog loop, the device can’t exceed
100 mA at 24 VDC. Exceeding 100 mA will cause the analog signal to not operate correctly.
Each digital input biased by the same 24V can use up to 4 mA each.
Diagrams for typical analog level transducer connections are provided on pages 76-77.
TCU
1
SHUNT 24
2 LEVEL TRANSDUCER
C
ANALOG- 23
O 1.0A
N ANALOG1+ 22 LINE 1 -
FAST ACTING
N ANALOG2+ 21 LINE 2 +
E
C TGND 20
SHIELD GROUND
T GND 19 X (GND)
O
R RXD_232 18 X
TXD_232 17 X
P 0.25A
2 ISO+24V 16
SLOW BLOW
ISOGND 15
NOTES
1 4-20mA interface shown. Remove jumper from P2-24 to P2-23 for 0-5V interface.
TRANSDUCER PANEL
TCU
1
SHUNT 24
2 - 3
C
ANALOG- 23 METER
O 1.0A +
N ANALOG1+ 22 LINE 1
FAST ACTING
N ANALOG2+ 21 LINE 2
E
C TGND 20
SHIELD -
T GND 19 X (GND) TRANSDUCER
O +
R RXD_232 18 X
TXD_232 17 X
P 0.25A
2 ISO+24V 16
SLOW BLOW
ISOGND 15
NOTES
1 4-20mA interface shown. Remove jumper from P2-24 to P2-23 for 0-5V interface.
3 Meter is optional.
4. Do not ground cable shield in transducer panel.
5. Analog- is bonded internally to ISOGND.
6. The analog shield wire must only be grounded at one end.
TRANSDUCER PANEL
TCU
1
3
SHUNT 24 -
METER
2
C +
ANALOG- 23 LINE 1
O 1.0A
N ANALOG1+ 22 LINE 2
FAST ACTING
N ANALOG2+ 21 -
E SHIELD TRANSDUCER
C TGND 20 (GND) +
T GND 19 X
O
R RXD_232 18 X +
POWER
TXD_232 17 X -
P SUPPLY
2 ISO+24V 16 X
ISOGND 15
NOTES
1 4-20mA interface shown. Remove jumper from P2-24 to P2-23 for 0-5V interface.
3 Meter is optional.
4. Do not ground cable shield in transducer panel.
ISOGND 15
NOTES
3 Meter is optional.
4. Do not ground cable shield in transducer panel.
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 maintain telemetry functions during a power loss.
Based on intended usage, the selected battery can be one of the following:
12V, 3.0Ah model – part number DFS-00363-008-02; rated at 12 volts, 3.2 ampere hours
12V, 7.0Ah model – part number DFS-00363-008-01; rated at 12 volts, 7.0 ampere-hours.
These batteries are interchangeable and maintenance free.
Connect terminal P1-8 (BAT+) to the positive terminal of the battery. Connect terminal P1-9 (BAT-) to the
negative terminal of the battery. It is important to observe polarity when connecting the backup battery,
since this circuit is not diode protected.
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
MOTOR
MOTOR STARTER OVERLOAD
BREAKER BREAKER CONTACT COIL
FROM MOTOR
POWER
COMPANY
EXTERNAL PHASE
FAULT RELAY NOTES:
1. EXT_PM input shares IN_COM_1 with
the motor run inputs (MTRX_RUN).
All three motor run inputs and EXT_PM
must be wired with the same bias source
CONNECTOR P2 CONTACT OPEN and resistor value.
FOR PHASE FAULT See resistor sizing chart for correct
2
IN_COM_2 2 resistor value.
EXT_PM
3. To bypass the TCU's internal phase monitor,
wire the phase monitor input (P2-4) in the
TCU ON state.
RTN BIAS
SOURCE
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
CONNECTOR P2
5 2
IN_COM_1 NOTES:
4
EXT_PM Phase monitor contact
1
closed on good three
TCU phase.
1 See resistor sizing chart
2
for correct resistor value.
RTN BIAS
SOURCE
IMPORTANT: Input commons on the TCU must be either AC neutral (with no voltage potential when
referenced to earth ground) or the negative terminal of a DC power supply.
1 A FUSE CONNECTOR P1
LOAD
19
AUX_OUT
20
AUX_PWR
SLOW BLOW
TCU
NOTES:
IMPORTANT: Maximum wire size to TCU connectors is 12 AWG. Wire all connectors in accordance
with National, State, and Local Electrical Codes.
Input commons on the TCU must be either AC neutral (with no voltage potential when referenced to
earth ground) or the negative terminal of a DC power supply.
L2
FROM MOTOR 1
POWER
COMPANY L1
NOTES:
1. Triplex wiring station shown. MOTOR 2 BREAKER 3 MOTOR STARTER 2 OVERLOAD 2 3
2. Unless otherwise noted, all fuses are slow blow. CONTACT 3 3
3. Omit these components for simplex stations.
N 4. Omit these components for simplex and duplex stations.
5. Fuses on three-phase power must be located as close as possible to the main circuit breaker.
MOTOR 2
6. Fuses on TCU output pins must be located as close as possible to the TCU.
7. Starter power and AC power must both be powered from the same station control breaker.
8. Wire according to national, state, and local codes.
9. Install interposing relays for starter outputs of NEMA size 3 or larger. MOTOR 3 BREAKER 4 MOTOR STARTER 3 OVERLOAD 3 4
10. Terminate IN_COM_1 to IN_COM_2 only when using ISO+24V to bias all contacts. If using different CONTACT 4 4
bias for motor starter contacts or external phase monitor, see Fig. 6-10 "Motor Run Monitoring
SURGE SUPPRESSOR Signal (4-wire transformer)" or Fig. 6-11 "Motor Run Monitoring Signal (3-wire transformer)."
AC JACK
MOTOR 3
BREAKER
AC JACK
AUX BREAKER
HIGH FLOAT
TFS001
1 LAG2 FLOAT 4
H
1A FUSE 5
2 TCU
N
CHASSIS
5 1A FUSE GROUND LAG1 FLOAT 3
85
3
H P1 P2
120VAC 240VAC 5 1A FUSE 1 24
PHASE_C SHUNT X
SURGE SURGE 4 2 23
H PHASE_B ANALOG - X
SUPPRESSOR SUPPRESSOR 3 22 LEAD FLOAT
PHASE_A ANALOG1+ X
4 21
5
X
UNUSED ANALOG2+ X
H 5 20
AC_PWR TGND X
6 19
AC_NEUT GND X
7 18
TGND RXD_232 X OFF FLOAT
8 17
BAT+ TXD_232 X
9 16
BAT- ISO+24V
10 15
X
BEMGND ISOGND
DFS TCU001
12V BATTERY 11 14 10
BACKUP
X
BEM_PWR IN_COM_2
12 13 LOW FLOAT
X
BEM_CTS ALM_SIL
X 13 12
ALARM BEM_RXD AUX_IN X
14 11
HORN X
BEM_TXD HIGH_LVL
15 10
1A FUSE 6 X
BEM_RTS LAG2_LVL
16 9
ALM_HORN LAG1_LVL 4 MOTOR STARTER 3 AUX CONTACT
17 8
ALM_LITE LEAD_LVL
18 7
ALARM ALM_PWR OFF_LVL
LIGHT FLASHER 19 6
AUX_OUT LOW_LVL
1A FUSE 6 20 IN_COM_1
5 3 MOTOR STARTER 2 AUX CONTACT
AUX_PWR 4
21 EXT_PM X
MTR3_STR 3
22 MTR3_RUN
MTR2_STR
OVERLOAD 3 MOTOR STARTER 3 23 2 MOTOR STARTER 1 AUX CONTACT
MTR1_STR MTR2_RUN
CONTACT 4 THERMAL 4 COIL 1A FUSE 4 6 24 1
4 9 STRT_PWR MTR1_RUN
7
GROUND
N
Chapter 6: Electrical Installation
Notes
Setting up the TCU as a component of the telemetry system enables you to remotely monitor conditions
at the site and control equipment from a central location via the HT3 SCADA software. For example,
you can determine if a pump is currently running and force it on if necessary.
In order for the TCU to interface with the central site and the HT3 server, it must have access to radio or
network communications and be properly configured in HT3’s Configuration Editor.
H ARDWARE C ONFIGURATION
There are several options for connecting the TCU to the telemetry system. A TCU can be installed with a
DFS RTU station, or it can interface with industry standard radios using the TCU’s RS-232 Modbus
radio interface. Alternately, the TCU can operate as a stand-alone unit and communicate with the central
computer or server via its integrated radio or network interface.
Using the TCU in conjunction with a radio-based telemetry system requires that you obtain an FCC-
licensed radio frequency if you do not already have a licensed frequency that can be utilized. 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.
87
Chapter 7: Telemetry Configuration
IMPORTANT: Do not jumper pins 43, 41, 39, 37, and 35 on the BEM.
43
41 42
39 40
37 38
35 36
33 34
31 32
6-CONDUCTOR
29 30
28
25-GA. SHIELDED
27
25 26 CABLE. MAXIMUM
23 24 LENGTH 1000 FT.
21 22
19 20
17 18
15 16
13 14
11 12 10 BEM_GND
9 10 11 BEM_PWR
7 8 15 BEM_RTS
5 6 12 BEM_CTS
3 4 13 BEM_RXD
1 2 14 BEM_TXD
TCU
Module Slot
Pin Numbers
Station Address
The TCU’s station address is configured by turning on bits that add up to the desired station number.
Each bit (pin on the P3 connector) has a corresponding value (see table above). The TCU is set to a
specific station address by leaving particular DIP switches on the configuration connector ungrounded
(in the OFF position). The station address is calculated by totaling the bit values of the DIP switches that
are not grounded.
For example, to give the TCU a station address of 98, we would leave the bits for the following pins
ungrounded (DIP switches in the OFF position):
pin P3-2 (bit value=2)
pin P3-6 (bit value=32)
pin P3-7 (bit value=64)
When we add the values of these bits together, we get a total value of 98 (2+32+64=98). The remaining
bits would be left grounded (DIP switch in the ON position).
To address the station at 0 (zero), we would leave all of the bits grounded (all switches in the ON
position). By removing the configuration connector altogether, we can give the station an address of 511,
which is the sum of all of the bits.
Data Format
The TCU’s radio can be configured to invert data or swap data by grounding pins P3-11 and P3-12. This
is useful in situations where the station is experiencing interference from a telemetry system at another
location that is on the same frequency. These pins are used to change the data format by byte inverting or
nibble swapping.
To invert data, ground the configuration connector’s INV DIP switch (place the switch in the ON
position). The INV switch corresponds to pin P3-11.
To swap data, ground the configuration connector’s SWAP DIP switch (place the switch in the ON
position). The SWAP switch corresponds to pin P3-12.
Typical Setups
Refer to the TAC II Telemetry System Installation Planning Guide supplied with the TAC II telemetry
equipment for detailed wiring instructions.
Control Panel
P3-16 (Earth Ground)
Mast
"Pigtail"
Coaxial
Ground Rod
Antenna
Ground
Rod
Mast
"Pigtail"
Coaxial
Panel
Ground
TCU Control Lug
Panel Panel Ground
Stud
Surge
Ground Arrestor
Polyphaser Lug
Panel to Panel
Conduit
Antenna
Ground
Rod
Ground Rods
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.
Point # Point Name Point Type Modbus Low State High State Alarm Description
Register Label Label State
5 Low Float Input DI 12549 OFF ON Detects the state if the Low Float.
95
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 state of the Lead float.
8 Lag Float Input DI 12552 OFF ON Detects the state of the Lag float.
9 Lag2 Float Input DI 12553 OFF ON Detects the state of the Lag2 Float
10 High Float Input DI 12554 OFF ON Detects the state of the High Float
11 Any Pump DI 12555 OFF RUNNING Detects the status of any pump in the
telemetry system
12 Auxiliary Input DI 12556 OFF ON Detects the state of the Auxiliary input.
Point # Point Name Point Type Modbus Low State High State Alarm Description
Register Label Label State
5 Alarm Light DI 12805 OFF ON Detects the state of the alarm light
Status
96
6 Alarm Horn DI 12806 OFF ON Detects the state of the alarm horn
Status
7 Alarm Silence DI 12807 OFF ON Indicates the status of the external alarm
Input silence switch
8 Station Disable DO 520 OFF ON In the ON state, allows telemetry to
remove power from all pump motors
9 AC Power DI 12809 NORMAL FAULT Allows telemetry to sense AC power
failure and activate the alarm.
10 DC Bias DI 12810 NORMAL FAULT Allows telemetry to sense DC bias failure
and activate the alarm.
11 Phase Sequence DI 12811 NORMAL FAULT FAULT Allows telemetry to sense phase sequence
failure and activate the alarm.
12 Process DI 12812 RUNNING STOPPED STOPPED Allows telemetry to sense if the TCU’s
BASIC program is running
* These points need not be configured when the TCU is running the pump control process, because they are being controlled by the TCU’s
BASIC 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 Modbus Low State High State Resolution/ Alarm Description
Type Register Label* Label** Units State
1 Analog Input 1 AI 33713 4/820 20/4095 0.01/mA Settings for the primary analog input
2 Analog Input 2 AI 33714 4/820 20/4095 0.01/mA Settings for the auxiliary analog input
3 Phase AB AI 33715 0/350 300/3102 1/VAC Settings for Phase AB voltage (240
Voltage (240) option)
Phase AB AI 33715 0/350 600/3114 1/VAC Settings for Phase AB voltage (480
Voltage (480) option)
4 Phase AC AI 33716 0/350 300/3077 1/VAC Settings for Phase AC voltage (240
Voltage (240) option)
97
Phase AC AI 33716 0/350 600/3077 1/VAC Settings for Phase AC voltage (480
Voltage (480) option)
5 Float Sequence DI 13089 NORMAL FAULT FAULT Allows telemetry to sense float sequence
faults and activate the alarm
7 Phase Voltage DI 13091 NORMAL FAULT FAULT Detects the presence of AC Power and
activates the alarm when absent
* 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 followed by its
High raw value.
Point # Point Name Point Type Modbus Low State High State Alarm Description
Register Label Label State
98
6 Pump 3 Override DO 1030 OFF ON Allows telemetry to turn on Pump 3
regardless of pump’s TCU state
7 Pump 1 Starter DI 13319 NORMAL FAULT FAULT Allows telemetry to sense a Pump 1
starter failure and activate the alarm
8 Pump 2 Starter DI 13320 NORMAL FAULT FAULT Allows telemetry to sense a Pump 2
starter failure and activate the alarm
9 Pump 3 Starter DI 13321 NORMAL FAULT FAULT Allows telemetry to sense a Pump 3
starter failure and activate the alarm
10 Pump 1 Stop DI 13322 NORMAL FAULT FAULT Allows telemetry to sense a Pump 1 stop
failure and activate the alarm
11 Pump 2 Stop DI 13323 NORMAL FAULT FAULT Allows telemetry to sense a Pump 2 stop
failure and activate the alarm
12 Pump 3 Stop DI 13324 NORMAL FAULT FAULT Allows telemetry to sense a Pump 3 stop
failure and activate the alarm
Module E – ACM001
Point # Point Name Point Modbus Low State High State Resolution/ Alarm Description
Type Register Label* Label** Units State
1 Remote Level AO 42273 4/820 20/4095 0.01/mA Calibration points for displaying the level
for a remote input
2 Unused
3 Unused
4 Well Level AO 42276 0/0 60/600 0.1/FT Calibration points for displaying well
level
* For analog points, the Low State Label column gives the point’s Low engineering value followed by its
99
Low raw value.
** For analog points, the High State Label column gives the point’s High engineering value followed by its
High raw value.
Point # Point Name Point Type Modbus Low State High State Alarm Description
Register Label Label State
2 Low Well Level DI 13826 NORMAL ALARM ALARM Detects the state of the Low level sensor
Chapter 7: Telemetry Configuration
100
6 HOA 1 DI 13830 - AUTO Detects position of HOA 1 switch and
activates alarm for “Auto” position
Point # Point Name Point Type Modbus Low State High State Alarm Description
Register Label Label State
4 Aux Out Disable DO 1796 OFF ON Detects if the auxiliary output is in the
auto or disabled state
5 Alarm Light DO 1797 OFF ON Detects if the alarm light is in the auto or
Disable disabled state
101
6 Alarm Horn DO 1798 OFF ON Detects if the alarm horn is in the auto or
Disable disabled state
7 Pup Override DO 1799 OFF ON When set, allows the Off level input to
Reset reset pump overrides
8 Analog Updating DO 1800 OFF ON This is a legacy PCU function, and only
applies to a TCU being used as a PCU. It
has no application in a standard TCU
installation. This setting is an on/off
switch for logging analog values. It
enables the TCU to respond with full
analog status each time it is polled. This
setting should be used judiciously as it
will have a large impact on the radio
polling rate.
Point # Point Name Point Modbus Low State High State Resolution/ Alarm Description
Type Register Label* Label** Units State
1 Battery test DO 1 OFF ON ON Control point used to turn off the TCU’s
AC power and go to battery power
2 - 10 Unused
Chapter 7: Telemetry Configuration
11 Bias Voltage DI 12299 OFF ON OFF Detects the presence of Isolated DC Bias
102
15 Internal AI 32947 0/32 100/212 0.1/F Detects the TCU’s internal temperature
Temperature
* For analog points, the Low State Label column gives the point’s Low raw value followed by its
Low Engineering value and includes the units.
** For analog points, the High State Label column gives the point’s High raw value followed by its
High Engineering value and includes the units.
Chapter 7: Telemetry Configuration
Legacy PCU
The table below, “Point Values for Legacy PCU ,” lists the properties of the legacy PCU template. Point
49 has two possible configurations (labeled 49a and 49b), depending on the device’s type (4-20mA or 0-
5 V). The template defaults to a 4-20mA device. If necessary, edit the point to fit your system.
The “Point Descriptions for Legacy PCU ” table on page 105 provides a description of each point’s
function.
Point Point Name Point Low State High State Alarm State Resolution /
# Type Label * Label ** Units †
1 Low Float Input DI OFF ON
2 Off Float Input DI OFF ON
3 Lead Float Input DI OFF ON
4 Lag 1 Float Input DI OFF ON
5 Lag 2 Float Input DI OFF ON
6 High Float Input DI OFF ON ON
7 Auxiliary Input DI OFF ON
8 Alarm Horn Cond. DI ENABLED SILENCED
9 Pump #1 Status DI OFF RUNNING
10 Pump #2 Status DI OFF RUNNING
11 Pump #3 Status DI OFF RUNNING
12 Phase Monitor Bypass DI OFF ON
13 Phase Voltage DI OK FAULT FAULT
14 Phase Sequence DI OK FAULT FAULT
15 Pump #1 Starter DI OK FAULT FAULT
16 Pump #2 Starter DI OK FAULT FAULT
17 Pump #3 Starter DI OK FAULT FAULT
18 Pump #1 Stop DI OK FAULT FAULT
19 Pump #2 Stop DI OK FAULT FAULT
20 Pump #3 Stop DI OK FAULT FAULT
21 Float Sequence DI OK FAULT FAULT
22 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
Point Point Name Point Low State High State Alarm State Resolution /
# Type Label * Label ** Units †
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 Switch 3 DI - OFF OFF
39 HOA Switch 3 DI - AUTO
40 Auxiliary Output DI OFF ON
41 Alarm Horn Status DI OFF RINGING
42 Alarm Light Status DI FLASHING OFF
43 Any Pump DI OFF RUNNING
44 PCU Configuration DI - UPDATED UPDATED
49a Analog Input AI 0/0 20/255 1 / mA
49b Analog Input AI 0/0 5/255 .1 / V
50 Phase AB Voltage AI 151/0 300/255 5 / VAC
51 Phase AC Voltage AI 151/0 300/255 5 / VAC
52 Well Level AI 0/0 60/600 0.5 / ft
58 Pump #1 Override DO OFF ON
59 Pump #2 Override DO OFF ON
60 Pump #3 Override DO OFF ON
61 Aux. Output Override DO OFF ON
62 Alarm Horn Override DO OFF ON
63 Alarm Light Disable DO OFF ON
64 Station Disable DO OFF ON
65 Pump #1 Disable DO OFF ON
66 Pump #2 Disable DO OFF ON
67 Pump #3 Disable DO OFF ON
68 Aux. Output Disable DO OFF ON
69 Alarm Horn Disable DO OFF ON
70 Alarm Light Override DO OFF ON
71 RESERVED DO OFF ON
72 Override Reset DO DISABLE ENABLE
73 Analog Updating DO OFF ON
* 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 followed by
its High raw value.
† Resolution and units apply to analog points only.
Notes
I NTRODUCTION
If the TCU is being used in a non-pump control application or in an application that requires control
processes beyond those provided in the TCU’s built-in pump control process, a customized program can
be developed. Using DFS BASIC-52, the TCU can be programmed to perform a variety of automated
tasks when interfaced with other DFS or Modbus-compatible telemetry equipment and field
instrumentation.
This section of the manual provides an overview for programming the TCU. Refer to the TCU
Programming Reference for information on the DFS BASIC-52 commands and syntax that can be used
when programming the TCU. Instructions and diagrams for power, phase monitor circuitry, individual
I/O point, and telemetry wiring can be found in Chapter 6: Electrical Installation.
A PPLICATIONS
As a customizable device, the TCU is designed to operate using three asynchronous communications and
control functions.
Running a foreground Industrial BASIC program
Conducting local (internal) module communications
Communicating with the central computer via a radio or network connection.
The TCU’s non-pump control applications include:
The TCU’s digital monitor, digital control, and analog monitor points can be used as non-intelligent
I/O, or they can be manipulated logically with a BASIC program (much like a PLC).
The TCU can be incorporated into a larger Remote Terminal Unit (RTU) using a Bus Extender
Module (BEM).
The TCU can operate as a simple central site and monitor and/or control up to 15 remote I/O
function modules.
The TCU can operate as a central polling backup device, which allows it to poll its own local
modules if the central site stops polling.
109
Chapter 8: Programming the TCU
modules, it automatically monitors RIM status points and radio communications data for every defined
remote station.
The polling loop of a DFS BASIC central program runs much slower than the polling loop of the central
computer or server. Every POLLON loop the BASIC central:
Requests status from every module defined in its program
Obtains radio communications data and RIM status for each site defined
Uses normal control point updating (fast control point updating is not available for control modules
at remote RTUs)
The remote polling loop can run asynchronously to the local polling and foreground program. In order to
synchronize the data, however, a general POLLOFF statement is customarily used. When the BASIC
central is attempting to close out a remote polling loop, the foreground program and local polling will
stop at that line of code.
Much care must be taken when developing a BASIC central that is responsible for controlling modules in
RTUs that include other intelligent devices (PCMs, PCUs, PLCs, SCUs, or TCUs). The central polling
loop can become locked up because it is attempting to update a digital or analog control point that is
being controlled differently by the remote RTU’s intelligent device. The TCU central expects to have
ultimate control over all of the defined control points. If the status of a control point at a remote site does
not match the command of the TCU central, the central will keep repeating the control point command
and wait for status verification before moving on. If an intelligent device at the remote RTU is setting the
control point differently than the TCU central, the TCU central will become locked in the remote polling
loop. By default, the TCU central will attempt to turn all remote control points off and analog controls to
zero.
The remote polling loop will run faster and will never lock up due to uncontrollable control points when
a remote module is off-line. When bench testing a BASIC central program, make sure all of the defined
remote modules are on-line and operating with real simulated I/O.
If remote polling appears to lock up, verify that all control points are under the sole control of the
TCU central.
If bench testing passes but startup fails, again verify that all control points are under the exclusive
control of the TCU central.
Installed in RTU
When 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. For more information
on using a TCU in an RTU, see “TCU Installed in DFS RTU” on page 87 and the section titled
“Internally Defined Modules,” below.
DFS BASIC-52
The DFS BASIC-52 interpreter is an enhanced Industrial BASIC that was developed in order to enable
telemetry communications within BASIC language syntax. It provides most of the features of standard
BASICs and includes features unique to process control applications. Some of the unique hardware and
software features of DFS BASIC-52 include the ability to:
Store and execute the user program out of an on-board write-protected memory.
Maintain an accurate battery backed up time/date clock function that is synchronized by telemetry.
One of the more powerful features of DFS BASIC-52 is its ability to execute and save programs stored in
write-protected memory. The programs are stored sequentially in the protected memory in a location
referred to as the ROM File. Any program stored in the ROM File can be retrieved and executed.
Programs are downloaded to the TCU via a communications cable that connects the TCU’s RS-232
service port to a serial communications port on a computer. WinRTU Test’s BLOAD form is used to
download new and updated programs to the TCU. Terminal programs such as HyperTerm, Procom, or
Kermit can be used to temporarily insert lines of code for debugging purposes.
or an all-pump shutdown and can be monitored in the TCU like regular monitor points (for example, with
the statement DGIN B7 : POP B7STAT). Any other desired control or status signals, such as set points
and out-of-range phase voltages, must be passed to the Hyper SCADA Server/central computer using
dummy modules (not shown here).
Station 1, “Generic TCU Configuration”
Module B, Type=C8
Module B, Type=C8
Module C, Type A
In the case where the TCU output is being manually controlled from the Hyper SCADA
Server/central computer, the PLC will pass the state of the manual control point from the central
computer/Hyper SCADA server to the TCU as usual. The TCU should not be "PUSHing" a
command to the output point in this circumstance.
In the example below, the PLC is toggling the TCU’s B7 control point to allow the TCU to monitor PLC
communications. If the toggling ever stops, the TCU (sensing that the PLC has stopped communicating)
will control the outputs directly (section 300). Otherwise, the control command sent to the PLC through
an arbitrary dummy monitor point (D6) is appropriately mirrored in the PLC back to points B1 and B6.
>LIST5
5 REM *** PLC PROGRAM ***
10 DEFMOD A,DMM002 : REM TCU MODULE A
12 DEFMOD B,DCM001 : REM TCU MODULE B
14 DEFMOD C,AMM002 : REM TCU MODULE C
16 DEFMOD D,DMM001 : REM TCU DUMMY MODULE
100 POLLON : POLLOFF
102 FLASH=NOT(FLASH)110 PUSH FLASH : DGOUT B7112 DGIN D6 : POP SCUCAL
120 PUSH NOT(SCUCAL) : DGOUT B1
122 PUSH (SCUCAL) : DGOUT B6
150 GOTO 100
READY
>
READY
>
P OLLING
Polling is a function where a control device actively requests status from and sends control messages to
other static devices, which do not respond unless requested. The TCU polls its internal modules and can
poll up to 15 modules located at remote stations 1 through 15 if operating as the central site.
H-O-A S WITCHES
The three 3-position switches on the front of the TCU are hardwired internally to control points B1, B2,
and B3. In the event of a program disruption, the devices wired to these points can be manually
controlled from the H-O-A switches. These switches can also be monitored in the BASIC program (for
more information, see DGIN statement in Chapter 2: Commands and Statements of the TCU
Programming Reference) to allow the program to control the devices when the associated switch is in the
“Auto” position. Additionally, if these points are to be controlled from the central computer/server as
non-intelligent I/O, the corresponding H-O-A switch must be in the “Auto” position.
In the TCU’s BASIC program, the switch positions are designated as follows (e.g., DGIN SL1 : POP
L_HOA_1):
SL1 = Left switch in “Hand” position SR1 = Left switch in the “Auto” position
SL2 = Center switch in the “Hand” position SR2 = Center switch in the “Auto” position
SL3 = Right switch in the “Hand” position SR3 = Right switch in the “Auto” position
LCD M ENUS
The TCU’s LCD may be used to display program variables, status conditions, or lists of items.
When the MENU feature is OFF, the LCD displays information sent from the BASIC program with
the PRINT @ Statement.
When the MENU feature is ON, the LCD is controlled by a routine to display defined menu items
and respond correctly to the up, down, right, and left arrow keys.
The LCD’s backlight may be turned on or off with the DGOUT statement (see Chapter 2: Commands
and Statements of the TCU Programming Reference).
Although the number of displayable menu items is limited to 16 (1-16) at any one time, the use of sub
menus allows the total number of menu items to be virtually unlimited. By programming the Enter key to
switch to a sub menu, each of the primary 16 menu items can have up to 16 sub menu items, and so on. If
one of the sub menus contains only one item (MENU 1), the Up and Down arrow keys can be monitored
to allow an operator to adjust set point values. The Enter key can be monitored then to set the new value
while returning to the previous menu list. For information on manipulating the LCD Menus, refer to the
MENU statement in Chapter 2: Commands and Statements of the TCU Programming Reference.
K EYPAD
The keys on the TCU’s keypad can be used to page through menus items, navigate through configuration
options, and enter numeric data.
Three keypad functions are not programmable:
When the one (1) key is held down on power up, the TCU will switch into program, or debug, mode.
When the MENU is ON and any key is pressed and released, the backlight of the LCD remains lit for
20 seconds.
When more than one menu item is defined and the MENU is ON, the up-, down-, right-, and left-
arrow keys are used to cycle through the defined menu items.
In the TCU’s BASIC program, the keys are read using the GET command. The GET command retrieves
the ASCII value of the key press.
The up arrow key generates the ASCII code 50 from the GET command.
The down arrow key generates the ASCII code 56 from the GET command.
The left arrow key generates the ASCII code 52 from the GET command.
The right arrow key generates the ASCII code 54 from the GET command.
The Esc/decimal key generates a decimal point ( . ) from the GET command.
It is important to note that each key is interpreted according to what the program is expecting. For
example, when you are entering a set point on the LCD screen, pressing a key on the TCU’s keypad will
generate the expected numeric value.
The GET command also gets characters from the service port. Pressing the 1 (one) key on the TCU’s
keypad is equivalent to typing a 1 (one) on the keyboard of a computer connected to the TCU’s service
port. See the GET command in Chapter 2: Commands and Statements of the TCU Programming
Reference for more information on this command.
Note that the DGIN SBx designation (for example, DGIN SB1 : POP BUT1) is still supported for SCU
compatibility.
SB1 = Up-arrow key
SB2 = Down-arrow key
SB3 = Enter key
LED S
The LEDs, which operate in a simple off/on manner, are controlled with the DGOUT statement [see
DGOUT statement in Chapter 2: Commands and Statements of the TCU Programming Reference for
more details]. Thirteen of the LEDs are controllable from within the BASIC program: DS1-DS13). In
the TCU’s BASIC program, the LEDs are designated as follows (e.g., PUSH 0 : DGOUT DS13):
DS1: LED below left switch DS6: Top right LCD LED DS11: Bottom left LCD LED
DS2: LED below middle switch DS7: Second left LCD LED DS12: Bottom right LCD LED
DS3: LED below right switch DS8: Second right LCD LED DS13: Alarm LED
DS4: LCD backlight* DS9: Third left LCD LED
DS5: Top left LCD LED DS10: Third right LCD LED
* You can control the LCD backlight with DGOUT when the menu is off. The menu function automatically
controls the backlight when the menu is on.
H ARDWARE I NTERFACE
The TCU may be programmed and monitored from a personal computer (PC), laptop, or any VT-100
terminal. The interface between the PC/laptop and the TCU is an RS-232 cable connected from a serial
communications (COM) port on the PC/laptop to the service port of the.
The service cable, WinRTU Test Software, and this manual are available in the TCU, PCU & SCU Test
Kit. See Appendix C: Parts List for ordering information.
S OFTWARE I NTERFACE
The recommended method for programming the TCU is to create the BASIC program using a good text
editor and then download the program to the TCU via WinRTU Test. The WinRTU Test software
enables you to perform a variety of tasks, including testing analog and digital modules, collecting status
information, and viewing radio traffic. The Bload form is used to download new and updated BASIC
programs to TCUs, PLCs, and SCUs. WinRTU Test can be installed on any PC/ laptop running a version
of the Windows operating system. Once the PC/laptop and the TCU are connected (see Hardware
Interface, above), you can start WinRTU Test and download the desired TCU program. WinRTU Test
can also be used to download edited programs. Unchecking Bload’s “New” option enables it to only send
lines that have changed since the last download.
If you need direct interaction with the DFS BASIC-52 program for debugging purposes, you can use
terminal emulation software to temporarily insert debug lines of code. Any terminal emulation program,
such as HyperTerm, Procom, or Kermit, that allows a PC/laptop to act as an ANSI / VT-100 terminal
will work in establishing a connection to the TCU via a communications port on a PC/laptop.
Below are the MS-DOS KERMIT commands used to set up the PC/laptop communications to the TCU:
Before you can program the TCU, you must place it in debug/program mode (see next section) For
additional information on setting up the communications link, refer to the RTUTest Software Disk, or
your PC manual. Included on the disk are all of the utility programs necessary to establish a connection
and download a program to the TCU. The Utility software, service cables, and this manual are available
in the TCU, PCU & SCU Test Kit.
When the TCU is connected to an active terminal screen and started in Debug Mode, a startup screen
similar to the following example will appear ending with the DFS BASIC-52 command prompt (‘>’).
READY
>
At this time a new or existing program can be written, edited, run, and debugged in the TCU.
D OWNLOADING
WinRTU Test’s Bload form (BASIC Program Loader) enables you to download a BASIC program to a
programmable device (PLC, TCU, or SCU) from any personal computer on which WinRTU Test has
been installed. To load the Bload form, choose Bload from WinRTU Tests’ Form menu
To download a program,
1. Connect the TCU to a PC/laptop on which WinRTU Test is installed.
2. Place the TCU in Debug mode by pressing and holding the TCU’s 1 (one) key while powering up the
TCU.
3. Start WinRTU Test and load the Bload form (choose Bload from the Form menu).
The Bload form includes the following options:
New – Clears the device's RAM (Random Access Memory) location before the selected program
is loaded into RAM.
Save (eprog) – Copies the program currently stored in RAM into the device's onboard EPROM
(Erasable Programmable Read-Only Memory).
Erase – Erases all existing programs from the devices' EPROM before the selected program is
loaded into EPROM. This option is normally selected when uploading a program to the EPROM
using the Save (eprog) option. If this option is not selected, the Save (eprog) command "stacks"
the program into EPROM (that is, it copies the program into the next available memory location
of the EPROM).
Run – Executes the program located in the device's RAM or ROM location after the selected
program is loaded. When Run is executed, all variables are set to zero (0), all BASIC-evoked
interrupts are cleared, and program execution begins with the first line number of the selected
program.
4. Select the desired Bload options.
If a new program is being installed, select the Bload form’s “New” option (this clears the RAM
location). If you are downloading an edited program, uncheck the “New” option. This enables
WinRTU Test to only send the lines of code that have changed since the last download.
5. Click Change, locate the program you want to download (must have the extension .bld), and click
OK. The file name and path of the program you selected is displayed in the File box.
6. Click Load. The Completion bar shows the upload progress. When it reaches 100%, upload is
complete.
E DITING
If the program on the TCU requires changes, open the program in a text editor, make the desired
changes, and then resave the program. You can then download the edited program using WinRTU Test’s
Bload form. Be sure to uncheck Bload’s “New” option. This enables WinRTU Test to only send the lines
of code that have changed since the last download. For detailed information on downloading a program
to the TCU, see the previous section.
D EBUGGING /T ESTING
To debug/test a program already programmed into EPROM, it must be transferred to RAM. In the
following example, the program in the ROM 2 location is copied into the RAM location.
READY
>ROM 2
READY
>XFER
READY
>
The program can be modified by retyping existing lines of code and/or adding new lines of code. The
DFS BASIC-52 only allows line editing. Refer to the previous section, Editing, if you need to make
changes to a large number of lines. If the Backspace key does not seem to work properly while editing
lines of code, try using the Delete key instead.
The program can be executed, tested, and debugged while resident in RAM by using the RUN command
[type: RUN]. Once the program is edited correctly, it can be copied back into the EPROM. In the
example above the program was taken out of the ROM 2 location. To place the edited program back into
the second location, type ERASE 2 to erase the ROM 2-8 locations, and then type EPROG to copy the
program that is currently in RAM into the ROM 2 location.
Keep in mind that the RAM memory is automatically erased on power up unless the following line of
code is typed in all capital letters before the TCU power is turned off: 0 REM DEBUG.
Notes
The information contained in this chapter refers to the TCU’s built-in pump control process. It does not
apply to a TCU with a custom program installed.
Navigation Keys
The TCU features four keys – identified by arrows – that enable you to navigate (up ▲, down ▼, left ◄,
and right ►) through menu and configuration options.
The ◄ and ► keys are used to navigate through the status, alarm, and configuration screens.
When the TCU is in Configure Mode, the ▲ and ▼ keys are used to navigate to the previous or next
configuration option on that screen. To navigate to the next or previous configuration screen,
use the ◄ and ► keys.
Enter Key
The Enter key is used to:
Access the TCU’s configuration screens.
Select a configuration option to change.
Accept configuration changes.
The Enter key has no function when displaying status information and alarm messages.
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Chapter 9: Pump Controller User Interface
Esc Key
The Esc (escape) key is used to return to the previous menu option and to exit a configuration option
without accepting the change.
Numbers 0 – 9
The TCU’s keypad includes the numbers 0 through 9. These can be used to input numeric data, such as
the number of pumps or the station’s computed flow volume.
Silence Key
The Silence key is used to silence the TCU’s own alarm horn and an external alarm horn if one has been
connected. Note that if the TCU is being used with telemetry, this key is monitored at point B7 (see
“HT3 Software Configuration: TCU Pump Control Application” beginning on page 94 for more
information on telemetry points).
On/Off Key
When pressed and held, the TCU’s On/Off key cycles the state of the TCU. When the TCU is on, the
Power LED is lit and the TCU is fully functional. When the TCU is off, bias power and all outputs are
turned off, and communications cease. The LEDs and LCD display are off and all keys except the
On/Off key are deactivated.
IMPORTANT: If the TCU’s Power LED is not lit, you should assume that the TCU is still powered.
The Power LED indicates only that the TCU is in the off state, not that AC power has been removed.
To remove power, you must turn off the external circuit breaker.
LED I NDICATORS
LED indicators on the front panel of the TCU provide you with quick status and alarm information.
When the TCU's on/off state is cycled, all of the TCU’s LEDs turn on momentarily for a self-test.
The following paragraphs describe the status and alarm functions of the LEDs.
The twelve LEDs (Inputs 1-12) located along the bottom edge of the TCU work independently of the
TCU’s internal computer. They provide field status of the following 12 digital inputs:
Input 1: P2-1 (MTR1_RUN) Input 7: P2-8 (LEAD_LVL)
Input 2: P2-2 (MTR2_RUN) Input 8: P2-9 (LAG1_LVL)
Input 3: P2-3 (MTR3_RUN) Input 9: P2-10 (LAG2_LVL)
Input 4: P2-4 (EXT_PM) Input 10: P2-11 (HIGH_LVL)
Input 5: P2-6 (LOW_LVL) Input 11: P2-12 (AUX_IN)
Input 6: P2-7 (OFF_LVL) Input 12: P2-13 (ALM_SIL)
IMPORTANT: If the TCU’s Power LED is not lit, you should assume that the TCU is still powered.
The Power LED indicates only that the TCU is in the off state, not that AC power has been removed.
To remove power, you must turn off the external circuit breaker.
disabled. Only using the H-O-A switches, which continue to function under a CPU Fault condition, can
continue operation of the pumps. The disabled state of the alarm light relay activates an alarm light
connected to the TCU.
Alarm Status
The Alarm LED flashes when there are active alarms and is static on (continuously lit) until all alarms
have cleared and all corresponding alarm messages have been viewed. The Alarm LED is cleared when
the alarm screen is exited and there are no active alarms.
When the TCU is used as a remote in conjunction with the telemetry system, active alarms will be
displayed both locally (at the TCU) and on HT3’s Alarm Viewer screen. Note that the TCU’s alarm
messages and alarm LED are not cleared via telemetry; they must be cleared locally. See Chapter 12:
Viewing and Troubleshooting Alarms for details on alarm messages.
The information contained in this chapter refers to the TCU’s built-in pump control process. It does not
apply to a TCU with a custom program installed.
The TCU’s configuration screens make customizing the TCU’s operation a simple process.
Configuration options include the number of pumps at the station, level sensor type, pumping method
(Pump Up/Pump Down), staging levels, and well volume. Configuration options are displayed on the
unit’s LCD. The keypad is used to select options and enter data. From the configuration screens, you can
also set the TCU’s internal clock and reset the timers (Total Run, AverageRun, Avg Pump Rate, and
TFlow).
Configurations can also be transferred to the unit through an RS-232 service port, or over a radio link
using HT3 telemetry equipment.
127
Chapter 10: Configuring the Pump Control Process
Pressing the Esc key from any screen except the Set Time and Reset Timers screens causes the TCU
to exit configure mode without saving any changes made during the current session. The old
configuration is retained. Note that the Esc key cannot be used to exit configure mode in the
Configure Dialer or Configure Modbus sections.
The following methods do not save the current changes. They are considered safeguards:
Pressing the Esc key from any of the TCU’s configuration screens except the Set Time and Reset
Timers screens causes the TCU to exit configure mode and abort any changes made during the
current session. Note that the Esc key cannot be used to exit configure mode in the Configure Dialer
or Configure Modbus sections.
Changing an H-O-A switch to the “Auto” position before selecting the Save command forces the
TCU to exit configure mode and abort the current changes.
Leaving the TCU unattended for over five minutes without selecting the Save command causes the
TCU to abort any changes and return to the main display screen.
Cycling the TCU’s power (press and hold the TCU’s On/Off key) before selecting the Save
command causes the TCU to reload the old configuration from non-volatile memory and return to
the main display screen.
C ONFIGURATION S CREEN 1
From the first screen, you can:
No. Pumps = 3
Configure the number of pumps
Xducer Type : Floats
Select transducer type
Low Float : Disabl
Enable or disable a low float High Float : Enable
Enable or disable a high float
Number of Pumps
Configuration option: No. Pumps
The TCU can be configured to control one, two, or three pumps for simplex, duplex, or triplex stations,
respectively.
Note that the number of pumps configured affects the number of elapsed time meters (Total Run screen),
average motor run-time meters (AverageRun screen), and average pump flow rate meters (Avg Pump
Rate screen) that the TCU displays. One meter is displayed for each pump that has been configured.
To configure the TCU to operate as a general RTU and use its points as non-intelligent I/O, set
No. Pumps to 0 (zero).
Transducer Type
Configuration option: Xducer Type
The TCU provides four options for configuring a transducer:
4-20mA – analog current-type device.
0-5Vlt – analog voltage-type device (pressure or linear resistive).
Remote – device located at a remote location; data is sent to the TCU via telemetry.
Floats – digital-type device, such as contact closures, float switches, and pressure switches.
Low Float
Configuration option: Low Float
Modes: Enable or Disable
The TCU is designed to accommodate both a low-level float and high-level float (see next section) for
backup alarms. These are recommended in both discrete and analog level detection systems.
If a low level float is being used, Low Float must be enabled.
Low Float must be disabled if a low level float is not connected. If Low Float is not disabled in this
situation, the Low Well alarm will interfere with station operation.
In a Pump Down Mode (Lift Station) system, all pumps are stopped on a low-level float condition. In
a Pump Up Mode (Storage Tank) system, all pumps are stagger-started on a low-level float
condition.
High Float
Configuration option: High Float
Modes: Enable or Disable
The TCU is designed to accommodate a high-level float and low level float (see previous section) for
backup alarms. These are recommended in both discrete and analog level detection systems.
If a high level float is being used, High Float must be enabled.
If a high level float is not connected and High Float is enabled, there is no effect on the operation of
the TCU.
In a Pump Down Mode (Lift Station) system, all pumps are stagger-started on a high-level float
condition. In a Pump Up Mode (Storage Tank) system, all pumps are stopped on a high-level float
condition.
C ONFIGURATION S CREEN 2
From the TCU’s second configuration screen, you can:
Configure how transducer faults are handled Fault Mode : Disable
Enable or disable the alarm horn Alarm Horn : Disable
Enable or disable the alarm light Alarm Light : Enable
Auto Retry : Enable
Configure the TCU to retry a faulted pump after 10
minutes
time, the high float condition takes precedence and pumps will continue to run until the high float
condition clears.
In a Discrete Pump Up Mode (Storage Tank) system, all pumps are stagger-started on a low level float
condition. The pumps will remain on until the low float condition clears. (NOTE: to prevent the pumps
from short cycling on a low float, configure minimum run and off times for the pumps. See Minimum
Pump Run and Off times beginning on page 138.) All pumps will be stopped on a high level float
condition; the same pump timer rules apply. In the event of a Low and High float condition at the same
time, the Low float condition takes precedence and pumps will continue to run until the Low float
condition clears.
Alarm Horn
Configuration option: Alarm Horn
Modes: Enable or Disable
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
Configuration option: Alarm Light
Modes: Enable or Disable
When the alarm light option is enabled, alarms are reported both at the station and through telemetry.
Disabling the alarm light option does not prevent alarms from being reported via telemetry.
Auto Retry
Configuration option: Auto Retry
Modes: Enable or Disable
The TCU can be configured to retry a faulted pump - one that fails to start when called (Motor Start
Fault) or one that is running when it has not being called to run (Motor Stop Fault). The TCU and PCU's
responses to Motor Start Faults and Motor Stop Faults with the Auto Retry function enabled are
identical. The response to Motor Stop Faults differs if the Auto Retry function has been disabled.
C ONFIGURATION S CREEN 3
From the third configuration screen, you can:
Alternate : All
Configure the TCU to alternate pumps Fl Eq Lead = 14 ft
Configure a motor start fault timer Start Fault = 5 Sec
Configure a motor stop fault timer Stop Fault = 5 Sec
Note: For more information on the Fl Eq Lead option, refer to the pump management documentation,
which can be obtained by contacting DFS’ Sales Department.
Pump Alternation
Configuration option: Alternate
Modes: All, Pmp1&2, Pmp2&3, None
The TCU features an option that enables it to start a different pump each time the station is called to
pump. This type of configuration ensures that pumps are exercised equally; one pump isn’t doing all of
the work.
All alternates among all available pumps.
Pmp1&2 alternates between pumps 1 and 2 (High Service mode). In this mode, pump 3 (high
service pump) will only come on if the tank level reaches the Lag2 level. Additionally, when the
Lag2 level is reached, both pumps 1 and 2 will be turned off. The high service pump (pump 3)
remains on until the Off level is reached.
Pmp2&3 alternates between pumps 2 and 3 (Jockey Pump mode). In this mode, pump 1 always
comes on with the Lead level. If the Lag1 level is reached, the lead pump is turned off and pump 2
or 3 comes on.
None disables pump alternation. When Alternate is set to None, pump 1 becomes the Lead pump,
pump 2 becomes the Lag pump, and pump 3 becomes the Lag2 pump.
If pump alternation is enabled (set to All, Pmp1&2, or Pmp2&3) and a pump fails to start, the alternator
advances to the next available pump. If a pump is taken out of service with the H-O-A switches, the TCU
continues to alternate the remaining pumps.
One example of the auxiliary feature is to operate a redundant bubbler system. The auxiliary input would
monitor an airflow fault switch to activate a backup bubbler compressor. Alternatively, the auxiliary
input can be used independent of the output as a simple status input.
For example, the TCU can be programmed to turn the auxiliary output ON ten seconds after the auxiliary
input turns OFF. If the Time Delay Relay feature is disabled, the AUX_OUT and AUX_IN terminals
function as standard control and monitor points for the telemetry system.
The time delay relay option requires that the following three settings be configured: AuxOut Turns
(On/Off), (xxx) Seconds after, AuxIn Turns (On/Off).
Does the state of the auxiliary output follow the state of the auxiliary input?
AUX_OUT turns ON when AUX_IN turns ON
AUX_OUT turns OFF when AUX_IN turns OFF
Or is the relationship inverted?
AUX_OUT turns OFF when AUX_IN turns ON
AUX_OUT turns ON when AUX_IN turns OFF
Configuration options: Xdcr1 Low, Xdcr1 High, Xdcr2 Low, and Xdcr2 High
Range: 0-60 ft in one-tenth foot increments
For analog transducer applications only. The TCU can accommodate both a primary and a backup analog
transducer. The primary transducer’s (Xdcr1’s) positive current or voltage signal is connected to terminal
ANALOG1+ (P2-22). The backup transducer’s (Xdcr2’s) positive current signal is connected to terminal
ANALOG2+ (P2-21).
Analog transducers are configured by entering the 4 mA or 0 V level reading into the Xdcr1 Low/
Xdcr2 Low field and the 20 mA or 5 V level reading into the Xdcr1 High/Xdcr2 High field. These
values are configured from the range of the transducer. The TCU uses these points for calculating the
well or tank level. The Xdcr1 High/Xdcr2 High value can be less than the Xdcr1 Low/
Xdcr2 Low value for transducers that provide signals that decrease when the measured distance
increases.
Low SetPnt
Pump Up mode – In tank filling operations, all pumps are running and alarms are activated when the
tank’s level falls below this set point. This level must be set below all other levels.
Pump Down mode – In well emptying operations, pumps 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.
LeadOff Pt
Pump Up mode – For tank filling operations, this is the tank’s maximum operational level. The TCU
turns off the Lead, or first, pump when the tank’s level rises above this set point.
Pump Down mode – For well emptying operations, this is the well’s minimum operational, or Off,
level. The TCU turns off the Lead, or first, pump when the well’s level falls below this set point.
LagOff Pt
Note: This setting is used for duplex (two-pump) and triplex (three-pump) stations only.
Pump Up mode – In tank filling operations, the TCU turns off the Lag, or second, pump when the
tank’s level rises above this set point.
Pump Down mode – In well emptying operations, the TCU turns off the Lag, or second, 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.
Lag2Off Pt
Note: This setting is used for triplex (three-pump) stations 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.
LeadOn Pt = 10.0 ft
LagOn Pt = 15.0 ft
Lag2On Pt = 20.0 ft
High SetPt = 25.0 ft
LeadOn Pt
Pump Up mode – In tank filling operations, the TCU starts the Lead, or first, pump when the tank’s
level falls below this set point.
Pump Down mode – In well emptying operations, the TCU starts the Lead, or first, pump when the
well’s level rises above this set point.
LagOn Pt
Note: This setting is used for duplex (two-pump) and triplex (three-pump) stations only.
Pump Up mode – In tank filling operations, the TCU starts the Lag, or second, pump when the tank’s
level falls below this set point.
Pump Down mode – In well emptying operations, the TCU starts the Lag, or second, pump when the
well’s level rises above this set point.
Lag2On Pt
Note: This setting is used for triplex (three-pump) stations only.
Pump Up mode – In tank filling operations, the TCU starts the Lag2, or third, pump when the tank’s
level falls below this set point.
Pump Down mode – In well emptying operations, the TCU starts the Lag2, or third, pump when the
well’s level rises above this set point.
High SetPt
Pump Up mode – In tank filling operations, the TCU stops all three pumps and activates alarms
when the tank’s level rises above this set point. This level must be set above all other levels.
Pump Down mode – In well emptying operations, the TCU starts all three pumps and activates
alarms when the well’s level rises above this set point. This level must be set above all other levels.
C ONFIGURATION S CREEN 8
From the TCU’s eighth configuration screen, you can:
Establish the minimum time that a pump must run before MinmumRun= 0.1 Min
it can be turned off MinmumOff = 0.2 Min
Establish the minimum time that a pump must remain off LoPhaAlm = 200VAC
before it can be started again HiPhaAlm = 260VAC
Set low and high phase-to-phase voltage limits
C ONFIGURATION S CREEN 9
From this screen, you:
Specify the volume of the well WellVolume = 500 Ga
Flow Units = MGD
Indicate how flow is measured
Set Clock
Set the TCU’s internal clock
Reset Timers
Reset the TCU’s run timers
Set Clock
The TCU’s internal clock can be set from the Set Clock screen.
1. Navigate to the Set Clock line and press the Enter key.
2. Enter the current time in hours, minutes, and seconds, by scrolling to the corresponding line and
entering a value.
3. When all desired changes have been made, press the Enter key.
Reset Timers
Meters for each of the pumps can be reset from the Reset Timers screen. When a timer for a particular
pump is reset, the following meters are set to zero:
Total Run – total amount of time the pump motor has run.
AverageRun – average amount of time the pump motor has run over the last 16 pump cycles.
Avg Pump Rate – average amount of flow pump moves per pumping cycle.
TFlow – total amount of flow station has moved.
C ONFIGURATION S CREEN 10
On the tenth configuration screen, you can:
Specify the station’s pumping mode Pump Mode : Down
Set the phase monitor’s range PhMon Rng : 240VAC
AuxIn Alm : Enable
Enable the auxiliary input’s alarm
AuxAlm On : Open
Configure the auxiliary input’s alarm state
Pumping Mode
Configuration option: Pump Mode
Modes: Down or Up
The TCU can operate in two pump arrangements: "pump up" or "pump down.” Pump up is used to
maintain a fill level in a tank system. Pump down is used to keep a well below a set level.
IMPORTANT: The configuration option selected must match the physical wiring. An incorrect
configuration could cause the TCU to not protect pump motors from undesirable power conditions.
C ONFIGURATION S CREEN 11
The 11th configuration screen allows you to:
Specify the number of modules on the RTU Bus that are
connected by the BEM BEM Mod's : 0
Supply a trend rate for the default status screens trend Trend Rate : 30
Configure Modbus
Configure the TCU to poll Modbus slave devices
Select the baud rate and protocol to use when polling
Modbus slave devices
Trend Rate
Configuration Option: Trend Rate
Range: 2-999 seconds
Trend rate is the update frequency for the default status screen’s trend. The default trend rate is 30
seconds; the trend can display the last eleven (11) updates. At the default trend update rate of 30 seconds,
the length of time that can be displayed is 5 ½ minutes (11 x 30 seconds). Shorten or lengthen the trend
rate as suits your needs.
ModX Adr
ModX Adr (address) is a combination of the Modbus device ID/node and the starting register address to
be queried. The ID and starting register are separated with a dot. For example, 3.30001 for a TCU polling
a Modbus device ID of 3 starting with register 30001 of that device.
Valid range for Modbus device IDs is 1-247; valid range for starting registers is 0001 to 49999.
ModX Lth
ModX Lth (length) is the number of registers to query. Valid length values are:
1-12 for digital status registers
1-8 for digital control registers
1-4 for analog registers
Analog registers require an additional piece of information – a bit mask value that represents the number
of bits the TCU is emulating when it communicates with Modbus devices.
The TCU has a 12-bit resolution with a full-scale (20mA) output of 4095. When communicating with
devices with a greater resolution and output, you must add a 2-digit value to the end of the length
parameter. This enables the TCU to use the appropriate value when converting the higher-resolution
value into a 12-bit value that it can understand.
A bit value of 00 applies the default resolution of 12 bit. These are the valid bit mask values:
00 or 12 – 12-bit resolution with a full-scale output of 4095
13 – 13-bit resolution with a full-scale output of 8190
14 – 14-bit resolution with a full-scale output of 16380
15 – 15-bit resolution with a full-scale output of 32760
16 – 16-bit resolution with a full-scale output of 65520
The most common bit mask is 15, which applies to a 16-bit signed integer with a full scale value of
32767. The most significant bit (MSB) is the sign bit that designates a positive or negative number. The
TCU applies only to unsigned integers; therefore the sign bit in this configuration does not apply. A bit
mask of 16 would apply to an unsigned integer with a full scale value of 65535.
For analog registers, the length and the bit mask value are separated with a dot. For example, 4.15 for a
TCU querying for 4 analog registers with a bit masking value of 15 (full-scale output of 32760).
The above Mod(X) Adr and Mod(X) Lth examples of (3.30001 4.15) would allow the T2000 to get
stored data from registers 30001, 30002, 30003, and 30004 from a Modbus slave device ID of 3 using a
16-bit word and put it in the TCU's Module(X) points as it relates to the HT3 configuration.
Once the correct Modbus device information has been configured in the TCU, the TCU will
automatically poll the devices. The TCU polls Modbus registers as follows:
Digital Status (10001-19999) and Analog Status (30001-39999) registers are polled continually.
Digital Control (0001-9999) and Analog Control (40001-49999) registers are updated using the
multiple register update command. At TCU power up, the status of Control registers is read once.
You can view a device’s status and initiate controls via telemetry by adding the corresponding module
and point to HT3. After TCU power up, Modbus control registers are updated whenever the
corresponding DFS points are changed via telemetry. Similarly, when Modbus status points change, their
corresponding DFS points are updated. One module of Modbus data is processed approximately every 2
seconds.
More information on the TCU Modbus capabilities can be found in Chapter 7: Telemetry Configuration.
Baud Rate
With the cursor on the Baud line, press the Enter key to make the option editable (a question mark will
appear). Use the numbered keys to enter the baud rate. Valid rates are 1200, 2400, 4800, or 9600. Note
that if you enter a rate other than those listed here, the TCU will resolve the baud rate to the closest valid
value.
Protocol
With the cursor on the Protocol line, press the Enter key to make the option editable (a question mark
will appear). Use the numbered keys to enter the number of the desired selection.
Option # Description
The information contained in this chapter refers to the TCU’s built-in pump control process. It does not
apply to a TCU with a custom program installed.
The TCU features seven screens that provide you with important information on the station’s status,
including current well level, total and average run time for each pump, and the number of times each
pump has started.
You can move through the TCU’s status screens using the ◄ and ► navigation keys.
When the TCU is turned on, it briefly displays firmware revision level, station and radio configuration
information, and process ID and version, and then displays the default status screen.
Simultaneously press and hold the three (3) and Alarm Silence buttons to view serial number, station
address, radio data configuration, BASIC chip firmware version, and radio chip firmware version.
147
Chapter 11: Viewing Status
D EFAULT S CREEN
S TATION S CREEN
The Station screen displays the following:
TFlow – Derived total flow for the station; used in well applications (Pump Down mode) only.
Pwr @ AB – Phase voltage between legs A and B
Pwr @ AC – Phase voltage between legs A and C
TFlow is only updated when the TCU has called the pumps to run automatically, and does so when
the Off float closes (the beginning of a new pump cycle).
TFlow requires that a volume be calculated as outlined in “Flow Volume Configuration,” p.139. This
calculated volume must be entered as the TCU’s WellVolume configuration. Please note that a
TFlow value will be displayed even if WellVolume has not been configured. However, this will
result in an inaccurate total flow value, since the TFlow calculation relies on a correct well volume.
Total flow data can be viewed on the TCU’s LCD or can be collected via the TCU’s service port.
Note that the value for total flow automatically rolls over after 999,999,999 units (gal, liters, cf, etc.).
If the TCU is being used with the HT3 telemetry system, total flow can be generated as a report in
HT3.
TFlow can be reset as outlined in “Reset Timers,” p. 139.
*Influent Rate is equal to the time it takes to fill the well or tank from Lead Off to Lead level. For
instructions on calculating volume, see Appendix F: Well Volume Calculations.
As indicated by the equation, the calculation requires that a volume be calculated and input in the TCU’s
configuration. The average pump flow rate for each pump is only updated when the TCU has called the
pump to run automatically, and does so after the called pump turns off. For information on configuring
the TCU for volume, see “Flow Volume Configuration,” p. 139.
Avg Pump Rate can be reset as outlined in “Reset Timers,” p. 139.
A NALOGS S CREEN
Analogs: C1 = xx.xx mA/V; C2 = xx.xx mA; Remote = xx.xx mA
The Analogs screen displays the current values of the TCU’s two 12-bit analog inputs: C1 – ANALOG1+
(P2-22) and C2 – ANALOG2+ (P2-21). C1 can be displayed as mA or V depending on the TCU’s setup
and configuration.
A current value for Remote is displayed if a remote monitor point is being used. The TCU can accept
data via telemetry from a monitor point and use this data to control another point (referred to as an auto
control). For example, a sensor at a well two miles away is sent to the TCU, which uses this information
to start a pump. This setup requires that an auto control be configured in the telemetry system
The information contained in this chapter refers to the TCU’s built-in pump control process. It does not
apply to a TCU with a custom program installed.
The TCU’s Alarm LED illuminates if there are any alarms to view. The LED flashes for active alarms
and is steady for inactive (cleared) alarms that have not been viewed from the TCU’s Alarm screen or
acknowledged via telemetry.
To view alarms, use the ◄ and ► keys to navigate to the Alarms screen (If you are at the TCU’s initial
screen, pressing the ◄ key once will bring you to the Alarms screen). If the alarm horn is active, press
the TCU’s “Silence” button. Additionally, navigating to the Alarms screen will silence the alarm horn.
Alarms are displayed in 3 rows of 3 columns (see graphic below).
151
Chapter 12: Viewing and Troubleshooting Alarms
An alarm message flashes if there is an active alarm. If the alarm condition clears while the alarm
message is being viewed, the 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 alarm messages have been viewed. The Alarm LED is cleared when
the alarm screen is exited and there are no active alarms.
When the TCU is used as a remote in conjunction with the telemetry system, active alarms will be
displayed both locally (at the TCU) and via the telemetry system at workstation computers. Note that the
TCU’s alarm messages and alarm LED are not cleared via telemetry; they must be cleared locally.
AC P OWER F AULT
Alarm message: ACPwr
The ACPwr alarm is activated when the TCU determines AC power has been interrupted. The TCU
must be on backup battery power in order for this fault to function when the primary AC power fails.
STRT_PWR (P1-24) and AC_PWR (P1-5) must also be connected to the station control power to ensure
that all pumps receive an emergency shutdown when AC power fails. Multiple pumps could be
commanded to start at the same time if this is not done.
IMPORTANT: Be sure that STRT_PWR (P1-24) and AC_PWR (P1-5) are both connected to the
station’s control power. This ensures that all pumps under local control receive an emergency shutdown
when AC power drops. If this is not done, multiple pumps could be commanded to start at the same
time.
DC B IAS F AULT
Alarm message: DCBias
The ISO+24V voltage, which is provided for biasing the digital monitor inputs and/or powering up to two
analog transducers, is monitored by the TCU. If a fault occurs with the ISO+24V voltage, the DCBias
alarm is activated.
IMPORTANT: ISO+24V is provided only for biasing the 12 digital monitor inputs of the TCU and/or
powering up to two analog transducers while not exceeding the maximum current of 100mA.
If a DC bias fault alarm occurs, measure the voltage between the ISO+24V and ISOGND terminals. The
voltage should be 20-24 VDC.
Check for a short circuit condition between the ISO+24V and ISOGND terminals if the measured
voltage is 0 (zero) VDC.
If the voltage is low, check the current 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 isolated, the TCU may require factory service. See Appendix L: Support, Service, and
Warranty for removal, replacement, and servicing instructions.
L OW W ELL A LARM
Alarm message: LoWell
The LoWell alarm indicates that the LOW_LVL input terminal is OFF. Alternatively, if an analog
transducer is being used, LoWell indicates that the level has dropped below the Low-level set point.
If a LoWell alarm occurs, take the following steps:
If a low level or pressure switch is not being used, disable the function in the configuration.
If a low level or pressure switch is used and an erroneous alarm occurs, check the switch and wiring.
When the switch is closed, 10-30 VAC or VDC should be measured at the LOW_LVL input.
Measure the voltage between the LOW_LVL and IN_COM_2 terminals.
Make sure the return for the LOW_LVL input bias source is connected to the IN_COM_2 terminal.
If the problem cannot be resolved, the TCU may require factory service. See Appendix L: Support,
Service, and Warranty for removal, replacement, and servicing instructions.
IMPORTANT: The internal Phase Monitor of the TCU is only compatible with a 240 VAC phase-to-
phase system (without external drop resistors) or a 480 VAC phase-to-phase system (with external drop
resistors).
If a fault occurs, measure the TCU’s Phase A-B and Phase A-C line-to-line voltages. If a voltage is
missing, turn off the main breaker and check the external phase monitor fuses.
The phase voltage set points establish the range used by the TCU to detect a phase voltage fault. If an
erroneous alarm occurs, check to see that the upper and lower voltage limits are set properly. See
Configuration Screen 8: Low- and High-Limit Phase Voltage” (p. 138) in Chapter 10: Configuring the
Pump Control Process for instructions on setting voltage limits.
If the problem cannot be resolved, the TCU may require factory service. See Appendix L: Support,
Service, and Warranty for removal, replacement, and servicing instructions.
The TCU's starter relays are solid-state devices with up to 0.1 mA off-state leakage current. This should
not cause any problems with starter coils. However, it may force a solid-state starter with a high-input
impedance to energize. If this occurs, there are two options to try.
Try connecting a bleed resistor across the solid-state starter input. Select a resistance and wattage to
shunt the leakage current.
Install isolating relays between the TCU and the solid-state starter. Connect the TCU's starter relays
to the coils of the isolating relays and control power through the isolating relay contacts to the solid-
state starter inputs.
Check the starter circuit for faults by using the H-O-A switches to control the pumps. Verify that the
pump run LED and the corresponding pump motor turn on when the H-O-A switch is in the “Hand”
position and off when the switch is in the “Off” position. Switching the H-O-A switch out of the “Auto”
position should clear the flashing pump run LED. If the LED does not turn on when the motor starts and
turn off when the motor stops, check the wiring and verify that:
Only one bias source is used to bias all motor run inputs.
The same voltage-dropping resistor is used for all motor run inputs.
The return for the bias voltage is properly connected to the IN_COM_1 terminal.
If the EXT_PM input is used, make sure that it uses the same bias voltage and dropping resistor as the
motor run inputs.
Verify that the TCU’s configured motor start fault delay (Start Fault) is set to an adequate length of
time. If necessary, increase the Start Fault delay.
If the problem cannot be resolved, the TCU may require factory service. See Appendix L: Support,
Service, and Warranty for removal, replacement, and servicing instructions.
assumption that the pump run status is accurate and will delay another pump from starting until the
number of pumps required is one more than the failed number of pumps. For example if pump 2 has
failed, and pump 1 is the lead pump, pump 1 will not start until the Lag 1 level is reached.
If a motor stop fault occurs, verify that:
The TCU’s configured motor stop fault delay (Stop Fault) is set for an adequate length of time. If
necessary, increase the Stop Fault delay.
The mechanical auxiliary contacts on the motor controller’s starter contactor are functioning
properly. If they have been damaged and are stuck in the closed position, the motor controller will
not receive the pump stop signal.
The motor controller’s starter contactor is functioning properly. If it has been damaged and is stuck
in the closed position, the motor controller will not receive the pump stop signal.
If a sufficient Stop Fault has been configured and the starter contactor and its mechanical auxiliary
contacts are determined to be functional, the TCU may require factory service. See Appendix L: Support,
Service, and Warranty for removal, replacement, and servicing instructions.
T RANSDUCER F AULT
Alarm message: Xducer
A transducer fault alarm is generated when an analog transducer's current/voltage falls outside the normal
operating range (4-20 mA / 0-5 V). The TCU's response to an analog transducer failure is dependent on
its configuration.
If high and low floats are enabled as the sole backup method, they will be used for pump control
until the analog transducer returns to normal operation.
If Transducer Fault Mode* is set to Timer, The TCU will control pumps based on the station's
pumping history (average cycle per each hour of the day) until the analog transducer returns to
normal operation. Please note that if high and/or low floats have also been enabled and the level
reaches a critical stage, the TCU will start/stop pumps based on the float reading. It will continue
operating this way until the float clears.
If Transducer Fault Mode* is set to Transducer2, the TCU will use a secondary analog transducer for
pump control until the primary analog transducer returns to normal operation. Please note that if high
and/or low floats have also been enabled and the level reaches a critical stage, the TCU will
start/stop pumps based on the float reading. It will continue operating this way until the float clears.
* See Transducer Fault Mode (p. 130) in Chapter 10: Configuring the Pump Control Process for
more information on this option.
If none of these options have been implemented (floats, timer, secondary transducer) and the primary
analog transducer malfunctions, the TCU will be unable to provide automatic control until the
malfunction is resolved. The pump motor outputs will be disabled, and the alarm light and horn relays
may be activated. See “Configuration Screen 2” beginning on page 130 for more information on enabling
the alarm horn and light.
When using an analog transducer, measure the voltage across the ANALOG1+ and ANALOG- terminals.
This voltage should be 1-5 VDC for a 4-20 mA transducer and 0-5 VDC for a 0-5 VDC transducer. The
voltage measured between the ANALOG1+ and ANALOG- terminals should vary according to the well
or tank level.
IMPORTANT: Only 4-20 mA transducers should have a jumper installed between the ANALOG- and
SHUNT terminals. If you are using a 0-5 VDC transducer, verify that the jumper is not installed.
If the transducer is determined to be functional, the TCU may require factory service. See Appendix L:
Support, Service, and Warranty for removal, replacement, and servicing instructions.
159
Appendix A: Checkout Procedure for Pump Controller
10. Verify that the proper fuses are installed in the output circuits of the motor starter, alarm light and
horn, and auxiliary.
11. If telemetry is used, verify the wiring of the interface cable.
control outputs should respond by alternating the lead pump position with alternation enabled. Allow
for some delay on pump start after the level input is activated.
11. Verify, as the LAG1 and LAG2 inputs are toggled, that the TCU starts additional pumps that the
level input demands. Allow for some delay 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.
Notes
M AINTENANCE
The TCU itself is designed for a minimum amount of maintenance. It is more important to maintain the
station and the components connected to the TCU.
When cleaning the TCU's front panel, use only mild detergents and a damp rag. Do not use solvents to
clean the TCU's front panel.
The TCU can accommodate a backup battery. When installing or replacing the backup battery, select one
of the recommended backup batteries listed below.
12V, 7.0Ah Rechargeable Battery (Part No. DFS-00363-008-01)
12V, 3.2Ah Rechargeable Battery (Part No. DFS-00363-008-02)
The TCU001 includes one replaceable fuse. If this fuse should fail, replace it with a new identical
one (.375AT).
To restore the TCU to the factory default configuration, hold down the 8 (eight) key while powering
up the TCU.
Note: The restore to factory default feature does not apply to a TCU with a custom program installed
(i.e., one that has replaced the factory default pump control program). Please refer to the O&M manual
that was supplied by DFS when your TCU was installed.
T ROUBLESHOOTING
Troubleshooting of the TCU and station control panel should only be performed by DFS personnel or a
certified electrical technician. Ensure that all breakers have been turned off before modifying any panel
wiring or removing any device from the station control panel. Use caution when making voltage and
current measurements. The TCU’s H-O-A switches can be used to manually control the pump motors
during troubleshooting.
If the problem occurs with a new wiring installation, first review all wiring. Refer to Appendix A:
Checkout Procedure for Pump Controller for new-installation checkout procedures.
163
Appendix B: Maintenance and Troubleshooting
IMPORTANT: To prevent an overcurrent reset from occurring, do not hold down the 2 (two) button
for more than 3 seconds. An overcurrent condition is indicated by the RX and TX LEDs blinking
simultaneously.
While in test mode – and after an initial successful attempt at communication with the CTU – the TCU’s
LCD will display a series of 1’s and 0’s to indicate poor or good communications, respectively. Zeroes
(0's) indicate good communications with the Central Radio. Ones (1's) indicate poor communications
with the Central Radio.
A typical good link is determined by achieving a solid LCD display of 0's (zeroes) with the maximum
attenuation.
Ones (1’s) displayed are an indicator that the TCU is receiving communications from the CTU
radio, but the CTU radio is not receiving good communications from the TCU.
Zeroes (0’s) displayed indicate that the TCU and the CTU radio are in good communication with
each other.
Having neither Ones (1’s) nor Zeroes (0’s) displayed at the TCU is an indication that the TCU may
not be receiving or understanding communications from the CTU radio.
Regardless of communication status, the TCU will remain in test mode – waiting to establish
communications – until a test mode time-out or a manual TCU reset. While waiting for communications
from the CTU radio, the TCU will not display any digits and will remain idle with only the initial
question marks (????...) displayed as described above. The same will occur during testing (idle TCU
display) if communications are lost after they had been established.
Typical example: 200 MHz radio links should achieve 21 dB minimum fade margin. The final result
would be all 0's displayed on the TCU's LCD with 21 dB of attenuation inserted inline of the antenna
path.
To exit radio test mode, simply cycle power to the TCU or let the TCU time out of radio test mode. [The
TCU automatically exits radio test mode after six (6) minutes.]
Alarm Messages and the Alarm LED (Pump Control Process only)
The TCU monitors itself and the station for alarm conditions. If an alarm condition is detected:
The TCU activates the appropriate alarm output relays and flashes the Alarm LED.
If the alarm light relay has been enabled, it becomes active for all alarm conditions.
If the alarm horn relay has been enabled, it becomes active for critical alarms, such as High and Low
Level faults, Phase faults, transducer faults, and TCU memory faults.
The TCU generates the appropriate alarm message. Alarm messages can be viewed from the TCU’s
Alarm screen
The TCU’s Alarm LED:
Flashes if there are active alarms.
Remains steady if there are inactive alarms that have not been viewed or acknowledged.
Goes out when all alarm conditions have cleared and all alarm messages have been viewed or
acknowledged.
Alarm messages on the TCU’s Alarms screen:
Flash for active alarms. Messages for active alarms continue to flash after they have been viewed.
Remain steady (non-flashing) for inactive alarms that have not been viewed. Messages for inactive
alarms disappear from the Alarms screen after they have been viewed.
Alarm messages, probable causes of the alarms, and troubleshooting steps are detailed in Chapter 12:
Viewing and Troubleshooting Alarms. If the problem is determined to be with the TCU, see Appendix L:
Support, Service, and Warranty for removal, replacement, and servicing instructions.
CPU Fault
Internal circuitry is used to monitor the TCU’s main microcontroller and radio microcontroller.
Main microcontroller – If the circuitry detects a fault with the main microcontroller, it attempts to
reset the main microcontroller and flashes the CPU Fault LED. If the main microcontroller fails to
reset, additional circuitry disables the outputs and flashes the CPU Fault LED.
Radio microcontroller – If the circuitry detects a fault with the radio microcontroller, it first attempts
to reset the radio microcontroller and flashes the CPU Fault LED on each attempt. If the radio
microcontroller is locked in reset mode, the CPU Fault LED will remain steadily lit (not flashing).
Note that failure of the radio processor only shuts down telemetry; the TCU’s main microcontroller
will continue to control the site.
The disabled state of the alarm light relay activates an alarm light connected to the TCU. The H-O-A
switches continue to function under a CPU Fault condition and can be used to control operation of the
pumps.
If a CPU fault occurs, try cycling power to the TCU. If a backup battery is connected, disconnect it. If the
CPU Fault LED remains lit, the TCU requires Factory service. See Appendix L: Support, Service, and
Warranty for removal, replacement, and servicing instructions.
TCU R EPLACEMENT
The TCU can easily be removed and replaced with a backup TCU if it is determined that the TCU needs
servicing.
1. Before removing the TCU, either make a note of the TCU configuration or download the
configuration to a computer.*
2. Turn off all circuit breakers before attempting to remove the TCU.
3. The terminals are connectorized for removal. Use an insulated screwdriver and gently pry the
connectors free.
4. Remove the mounting fasteners that connect the TCU to its mounting brackets. You should be able
to easily lift the TCU from its mounting brackets.
5. Install the replacement 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” position.
*TCU configurations can be uploaded/downloaded through telemetry using PCU Editor. You can also connect the
TCU directly to a laptop computer and use the WinRTU Test software to download/upload configurations. Refer to
the help files of these applications for more information.
F URNISHED P ARTS
O PTIONAL P ARTS
Batteries
167
Appendix C: Parts List
Enclosures
Fuse
Harness
Wire/Component Harness
Part No. DFS-00396-108-02
Installation Kits
Polyphaser Kit
Power Diode
Resistors
Snubber
RC Snubber
Part No. 007-0084
Surge Protection
Surge Suppressors
Test Kit
175
Appendix D: Key-Invoked Functions
177
Appendix E: Configuring Level Input Devices
Calculate Volume
Liquid Height 3 feet
x Area x 78.5 ft2
Volume (cu. ft) 235.5 ft3 (Enter 236 if configuring Volume in cubic feet)
The display shows VOLUME in the same terms as you have entered. For instance, if you entered “236”
in this example, VOLUME would display in cubic feet; if you entered 1762, VOLUME would display in
gallons.
179
Appendix F: Well Volume Calculations
Notes
In some instances, it is necessary to detect a float failure (such as in a high-well float) during normal
operation. Such failure can be detected by using an inverted float (contacts closed when in the “down”
position) and using the connections to the TCU as indicated below.
Connector P2
5K OHM
1/4 V
16 INVERTED
ISO+24V
FLOAT
11
HIGH_LVL
14
IN_COM_2
15
ISOGND
TCU
181
Appendix G: Inverted Float Interface
Notes
O VERVIEW
Product Overview
The TCU001-AD (TCU001 with optional autodialer; DFS-00367-008-10) is a stand-alone device that
enables utilities to be alerted of active alarm conditions at remote well/storage tank stations that aren’t
part of a SCADA telemetry system. When a station experiences one or more of the 22 statically-coded
alarm conditions, the autodialer uses its onboard, V.92 voice modem to call a series of preconfigured
telephone numbers (up to four) and announce the alarm via prerecorded voice messages. The alarm
announcement includes the station number and a description of the alarm (for example, “high well”).
The autodialer uses a code to prevent an unauthorized person from acknowledging alarms. The recipient
of a call must enter a one- to four-digit code, using the keys on their touch-tone phone, before any alarms
will be announced. The autodialer then announces the first alarm and prompts the recipient to press 1
(one) to acknowledge or press 2 (two) to replay the message. If there are multiple alarms, each will be
announced once the preceding alarm has been properly acknowledged.
The TCU001 can be retrofitted at the factory if you want to add this feature to your existing TCU001.
Contact DFS for more information.
Principles of Operation
The autodialer can be configured with up to four telephone numbers to call in the event that any of the 22
possible alarm conditions occurs. Each alarm condition can be configured with a delay of up to 9,999
seconds (~167 minutes). Any of the alarm conditions can be disabled for call out by entering a 0 (zero) in
the dial delay field for that alarm.
When there is an active alarm at the station, the autodialer waits the configured delay time for that alarm
and then dials the first number on the list. The autodialer calls each telephone number in sequence until
all of the alarms are acknowledged.
Once an alarm has been acknowledged, the autodialer will not call out again unless the alarm clears and
then becomes active again. If an alarm occurs and then clears within the alarm’s configured delay time,
you will not be notified.
Once call out begins, all alarms are announced regardless of their current status – active or cleared – and
they remain in the queue until they are acknowledged. The autodialer checks the status of all points
between each phone call. If a call isn’t answered and an alarm clears before the next phone call is placed,
the autodialer will change the status of the point to “cleared” and will announce it as such when the
phone call is eventually answered. Similarly, if a new alarm occurs between calls, it will be added to the
alarm list. Alarms will continue accumulating this way until they are all acknowledged.
Before any alarms are announced, the recipient is given three opportunities to enter the correct
acknowledgement code. Once the correct code is entered, the autodialer begins playing voice messages
for each alarm condition.
After each alarm message is played, the call recipient is prompted to press 1 (one) on the phone’s keypad
to acknowledge the alarm or to press 2 (two) to replay the message. If the alarm isn’t acknowledged after
183
Appendix H: TCU001-AD Autodialer
it is announced for the third time or if the time out period expires, the autodialer will hang up and call the
next number on the list.
If the autodialer gets to the end of the list and there are still unacknowledged active alarms, it cycles back
to the first telephone number. This process is continued until all of the alarms have been acknowledged.
High well level Indicates that the HI_LVL input terminal is ON.
Alternatively, if an analog transducer is being used, this
HiWell Delay
alarm indicates that the level has risen above the High-level
set point
Low well level Indicates that the LOW_LVL input terminal is OFF.
Alternatively, if an analog transducer is being used, this
LoWell Delay
alarm indicates that the level has dropped below the
Low-level set point.
Float out of sequence Indicates that the TCU001-AD has detected floats out of
sequence.
Level transducer fault Indicates that an analog transducer's current/voltage FltSeq Delay
has fallen outside the normal operating range
(4-20 mA / 0-5 V).
Motor 1 failed to start Indicates that the TCU001-AD is trying to run pump 1 but
has no indication that the pump is on (associated input is
MtrFlt Delay
off). This can occur if the pump is called to turn on but
does not, or if the pump turns off prematurely.
Motor 1 failed to stop Indicates that the TCU001-AD sees that pump 1 is on
without being called to run. This can occur if the pump fails
to turn off when the call is removed (associated output
turned off), or if the pump comes on without being called.
[The second condition is common if someone is on site and
turns the pump on from outside of the TCU001-AD (not
using the TCU001-AD’s H-O-As).]
Motor 2 failed to start Indicates that the TCU001-AD is trying to run pump 2 but
has no indication that the pump is on (associated input is
off). This can occur if the pump is called to turn on but
does not, or if the pump turns off prematurely.
Motor 2 failed to stop Indicates that the TCU001-AD sees that pump 2 is on
without being called to run. This can occur if the pump fails
to turn off when the call is removed (associated output
turned off), or if the pump comes on without being called.
[The second condition is common if someone is on site and
turns the pump on from outside of the TCU001-AD (not
using the TCU001-AD’s H-O-As).]
Motor 3 failed to start Indicates that the TCU001-AD is trying to run pump 3 but
has no indication that the pump is on (associated input is
off). This can occur if the pump is called to turn on but
does not, or if the pump turns off prematurely.
Motor 3 failed to stop Indicates that the TCU001-AD sees that pump 3 is on
without being called to run. This can occur if the pump fails
to turn off when the call is removed (associated output
turned off), or if the pump comes on without being called.
[The second condition is common if someone is on site and
turns the pump on from outside of the TCU001-AD (not
using the TCU001-AD’s H-O-As).]
AC power failure This alarm is activated when the TCU001-AD determines
AC power has been interrupted. Note that the TCU001-AD
must be on battery backup power in order for the autodialer
to call out for this alarm.
Phase voltage fault Indicates that the voltage measurement on the three phase
inputs (A - B or A - C) went above or below the configured
fault parameters. When this occurs, the TCU001-AD shuts PwrFlt Delay
off all pumps, because a high or low voltage can damage
the pumps.
Phase voltage sequence Indicates that the phases are not in the correct order on the
(or phase reversal) fault TCU001-AD. When this occurs, the TCU001-AD will shut
off the pumps, because a phase reversal will cause the
pump motors to run backwards.
Auxiliary input alarm The TCU001-AD monitors the AUX_IN terminal (p2-12)
and can be configured to activate this alarm when the
terminal is open or closed. If the auxiliary input alarm has AuxIn Delay
been enabled and AUX_IN enters its configured alarm state
(open or closed), an auxiliary input alarm is generated.
H-O-A switch 1 is in Indicates that H-O-A switch 1 has been placed in the Off
the Off position position. This condition allows the TCU001-AD's control to
HOAOff Delay
be overridden and forces the corresponding pump motor
off.
H-O-A switch 2 is in Indicates that H-O-A switch 2 has been placed in the Off
the Off position position. This condition allows the TCU001-AD's control to
be overridden and forces the corresponding pump motor
off.
H-O-A switch 3 is in Indicates that H-O-A switch 3 has been placed in the Off
the Off position position. This condition allows the TCU001-AD's control to
be overridden and forces the corresponding pump motor
off.
H-O-A switch 1 is in Indicates that H-O-A switch 1 has been placed in the Hand
the Hand position position. This condition allows the TCU001-AD's control to
be overridden and forces the corresponding pump motor
off.
H-O-A switch 2 is in Indicates that H-O-A switch 2 has been placed in the Hand
the Hand position position. This condition allows the TCU001-AD's control to
be overridden and forces the corresponding pump motor
off.
H-O-A switch 3 is in Indicates that H-O-A switch 3 has been placed in the Hand
the Hand position position. This condition allows the TCU001-AD's control to
be overridden and forces the corresponding pump motor
off.
DC bias fault Indicates that a fault with the ISO+24V voltage has
occurred. The ISO+24V voltage is provided for biasing the
digital monitor inputs and/or powering up to two analog
transducers. HdwFlt Delay
Process fault Indicates that a fault has occurred with the TCU001-AD’s
internal process software.
Alarm Process
NORMAL
No active alarms.
ACKNOWLEDGED ALARMS
All active alarms have been
acknowledged. Dlr LED
ACTIVE ALARM turns off.
Dlr LED begins flashing;
Alarm delay timer starts
counting down.
UNACKNOWLEDGED,
ACTIVE ALARM
Alarm delay timer has expired;
Dlr LED has stopped blinking
and is solid on. Autodialer
calls out continuously until
all unacknowledged, active
alarms have been acknowledged.
It is important that you not connect the TCU001-AD to a digital-type system – doing so will cause
damage to the TCU001-AD. If you are unsure what type of system you have, contact the person or
department that oversees your telephone system before connecting the telephone line to the TCU001-
AD.
IMPORTANT: Do not connect the phone line to the service port that is located on the front of the
TCU001-AD. The service port is used for factory service, BASIC programming, and troubleshooting
only. Connecting a phone line to the service port could cause serious damage to the TCU001-AD if a
phone call were to come in while the telephone line was connected to the service port.
H-O-A switches
4 x 20 LCD
Dialer (Dlr) LED
Service port
T2000 Power LED (Do not connect to
telephone line)
Receive &
Transmit LEDs
12-key keypad
Digital Input LEDs
Connectorized terminals P2 & P4
For example, to give the TCU001-AD a station address of 98, we would leave the bits for the following
pins ungrounded (DIP switches in the OFF position):
pin P3-2 (bit value=2)
pin P3-6 (bit value=32)
pin P3-7 (bit value=64)
When we add the values of these bits together, we get a total value of 98 (2+32+64=98). The remaining
bits would be left grounded (DIP switch in the ON position).
Leaving all of the bits grounded (all switches in the ON position) gives the station an address of 0 (zero),
which is an invalid address. Removing the configuration connector altogether, gives the station an
address of 511 (the sum of all of the bits). This is also an invalid address. An indication that the unit has
been incorrectly addressed is that the TX Data LED will not blink when the device is up and running.
This is an indication that the device is unable to transmit.
Leaving the TCU001-AD unattended for over five minutes without selecting the Save command
causes the TCU001-AD to abort any changes and return to the main display screen.
Cycling the TCU001-AD’s power (press and hold the TCU001-AD’s On/Off key) before selecting
the Save command causes the TCU001-AD to reload the old configuration from non-volatile
memory and return to the main display screen.
Configuration overview
1. Place the TCU001-AD in configure mode.
2. Use the 4 or 6 key to navigate to the screen that reads Change Configurations. Press the Enter key
to enter the configuration section. (If you are at the TCU001-AD’s default screen, pressing the 4
key twice will bring you to the Change Configurations screen.)
Change
Configurations
(enter)
3. Page through the TCU001-AD configuration screens until you reach the screen that includes the
Configure Dialer option.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
4. Use the 8 key to place the cursor on the line that reads Configure Dialer and then press the
Enter key.
5. Use the directional keys 2 4 6 8 on the TCU001-AD keypad to move through each of the four
configuration screens and through each screen’s configuration options.
6. Select the configuration that you want to edit and press the Enter key. A question mark will appear.
7. Use the numbered keys on the keypad and the Silence key to enter the data and then press the
Enter key.
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
8. When you are finished entering all data, press the Esc key.
4 6
9. Use the and keys to move to the screen that reads Press Enter to Save Esc to Abort.
10. Press the Enter key to save your changes.
Selecting alarms
Each alarm condition can be configured with a delay of up to 9,999 seconds (~167 minutes). If an alarm
occurs, the autodialer will wait the specified period of time before dialing out. To disable dial out for a
specific alarm condition, enter a 0 (zero) in the dial delay field for that condition. When you enter a
0 (zero) in the field and press the Enter key, the 0 (zero) will change to read Disab to indicate that the
alarm has been disabled.
There are eight options that control call out for the 22 available alarm conditions. For example, MtrFlt
Delay controls the alarms for six motor fault conditions (motor 1 failed to start; motor 1 failed to stop;
motor 2 failed to start; motor 2 failed to stop; motor 3 failed to start; motor 3 failed to stop). To enable
call out for these alarm conditions, you only need to enter a single delay time in the MtrFlt Delay field.
The table below lists the configuration screen that the option appears on, the field (configuration label)
that must be set, the alarms the option controls, and a brief description of the option.
Detailed directions for configuring call out for these alarms conditions can be found directly following
the table.
HiWell Delay High well level Length of time (in seconds) before the
autodialer should begin calling out when a
high well level alarm occurs. Enter a 0
(zero) to disable call out for this alarm.
Maximum delay time is 9,999 seconds
(~ 167 minutes).
LoWell Delay Low well level Length of time (in seconds) before the
autodialer should begin calling out when a
low well level alarm occurs. Enter a 0
(zero) to disable call out for this alarm.
Maximum delay time is 9,999 seconds
(~ 167 minutes).
FltSeq Delay Float out of sequence Length of time (in seconds) before the
Level transducer fault autodialer should begin calling out when a
1 float out of sequence or level transducer
fault occurs. Enter a 0 (zero) to disable call
out for this alarm. Maximum delay time is
9,999 seconds (~ 167 minutes).
MtrFlt Delay Motor 1 failed to start Length of time (in seconds) before the
Motor 1 failed to stop autodialer should begin calling out when a
motor start/stop fault occurs (motor 1, 2,
Motor 2 failed to start or 3). Enter a 0 (zero) to disable call out
Motor 2 failed to stop for this alarm. Maximum delay time is
Motor 3 failed to start 9,999 seconds (~ 167 minutes).
Motor 3 failed to stop Note: If the TCU001-AD is installed at a
simplex or duplex station (where motor 2
and/or motor 3 have not been configured
or connected) dial out is automatically
disabled for those motor starter contacts.
PwrFlt Delay AC power failure Length of time (in seconds) before the
Phase voltage fault autodialer should begin calling out when
an AC power failure, phase voltage fault,
Phase voltage sequence (or or phase voltage sequence fault occurs.
phase reversal) fault Enter a 0 (zero) to disable call out for this
alarm. Maximum delay time is 9,999
seconds (~ 167 minutes).
AuxIn Delay Auxiliary input alarm Length of time (in seconds) before the
autodialer should begin calling out when
an auxiliary input fault occurs. Enter a 0
(zero) to disable call out for this alarm.
Maximum delay time is 9,999
seconds (~ 167 minutes).
HOAOff Delay H-O-A switch 1 is in the Length of time (in seconds) before the
Off position autodialer should begin calling out when
H-O-A switch 2 is in the any of the TCU001-AD’s HOA switches
2 are in the Off or Hand position. Enter a 0
Off position
(zero) to disable call out for this alarm.
H-O-A switch 3 is in the Maximum delay time is 9,999 seconds
Off position (~ 167 minutes).
H-O-A switch 1 is in the IMPORTANT: If the TCU001-AD is
Hand position installed at a simplex or duplex station
H-O-A switch 2 is in the (where H-O-A switch 2 and/or H-O-A
Hand position switch 3 are not being used), the unused
H-O-A switch 3 is in the H-O-A switches must be left in the Auto
Hand position position to disable call out for those
switches .
HdwFlt Delay DC bias fault Length of time (in seconds) before the
Process fault autodialer should begin calling out when a
hardware fault occurs (DC bias fault or
process fault). Enter a 0 (zero) to disable
call out for this alarm. Maximum delay
time is 9,999 seconds (~ 167 minutes).
Determine the alarm conditions that you want to enable for call out and the delay desired for each. The
delay is the amount of time the autodialer waits to call out once an alarm occurs. To disable an alarm
condition, enter 0 (zero) in the corresponding delay field. When you enter a 0 (zero) in the field and press
the Enter key, the 0 (zero) will change to read Disab to indicate that the alarm has been disabled.
1. Place the TCU001-AD in configure mode. Use the 4 and 6 keys on the keypad to navigate to the
screen that reads Change Configurations. Press the Enter key to enter the configuration section.
Change
Configurations
(enter)
2. Page through the TCU001-AD configuration screens until you reach the screen that includes the
Configure Dialer option.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
3. Use the 8 key to place the cursor on the line that reads Configure Dialer and then press the Enter
key. The first autodialer configuration screen features HiWell Delay, LoWell Delay, FltSeq Delay,
and MtrFlt Delay.
4. Use the 2 and 8 keys on the keypad to place the cursor on the line you want to edit (for example,
the LoWell Delay line) and then press the Enter key. A question mark will appear at the end of the
line.
HiWell Delay = 60
LoWell Delay = ?
FltSeq Delay = Disab
MtrFlt Delay = Disab
5. Use the numbered keys on the keypad to enter the desired delay time. For example, to enter a delay
time of two (2) minutes, enter 120. Press the Enter key after entering the time.
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
6. Repeat step four for each of the options on the first configuration screen.
HiWell Delay = 90
LoWell Delay = 90
FltSeq Delay = 60
MtrFlt Delay = 60
7. When you are finished with configuration screen 1, use the 6 key on the keypad to navigate to the
next screen. The second configuration screen features PwrFlt Delay, AuxIn Delay, HOAOff Delay,
and HdwFlt Delay.
8. Repeat step four for each of the options on the second configuration screen.
PwrFlt Delay = 60
AuxIn Delay = 60
HOAOff Delay = 60
HdwFlt Delay = 60
9. If you need to enter call out telephone numbers, proceed to the next section “Entering phone
numbers.” Otherwise, scroll through all of the configuration screens until you reach the screen that
reads Press Enter to Save, Esc to Abort. To save your changes, press the Enter key on the keypad. To
exit without saving, press the Esc key.
After cycling to the desired special character, you must press the Enter key to register the entry. (Note
that this does not apply to the Delete function. As soon as the Silence key is pressed for the fourth time,
the last character on the current line is deleted.)
Determine which telephone numbers the autodialer should call when an alarm occurs as well as the order
they should be called in. The autodialer will call the phone number entered in field #1 first. If the alarms
aren’t acknowledged by recipient #1, the autodialer will move on to the telephone number in field #2,
then #3, and finally #4. If it gets to the end of the list and there are still unacknowledged alarms, it will
cycle through the numbers again.
Note that when entering telephone numbers, you must enter a number in field #1 and the fields must be
configured in order from #1 - #4.
1. If you have just finished configuring alarm delays and are still in configure mode, skip to step
four (4). Otherwise, continue to step two (2).
2. Place the TCU001-AD in configure mode. Use the 4 and 6 keys on the keypad to navigate to the
screen that reads Change Configurations. Press the Enter key to enter the configuration section.
Change
Configurations
(enter)
3. Page through the TCU001-AD configuration screens until you reach the screen that includes the
Configure Dialer option. Use the key to place the cursor on the line that reads Configure Dialer and
then press the Enter key.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
4. Use the 6 key on the keypad to navigate to the screen that displays the options #1, #2, #3, and #4.
These fields hold the telephone numbers that the autodialer will call.
#1 =
#2 =
#3 =
#4 =
5. Use the 2 and 8 keys on the keypad to place the cursor on the line you want to edit (for example,
the #1 line) and then press the Enter key. A question mark will appear at the end of the line.
#1 = ?
#2 =
#3 =
#4 =
6. Use the numbered keys on the keypad to enter the desired telephone number and then press Enter. If
the telephone number requires a pause (for example, between the telephone number and an extension
number), use the Silence key on the keypad to enter a comma (which represents a pause). Multiple
commas can be entered if necessary. Pound (#) and star (*) characters can also be entered using the
Silence key. The Silence key cycles through these special characters each time the key is pressed.
When the desired character appears on the display, press the Enter key to register the entry.
#1 = 9,5551212,,481
#2 = 9,5554545,,,25#
#3 = 9,5552323,,,,
#4 =
In the example above, all of the numbers start with “9,”. This causes the autodialer to dial 9 to get an
outside line and then wait four seconds before dialing the number.
Field #1 dials the phone number, waits eight seconds, and then dials a three digit extension.
Field #2 dials a pager, waits 12 seconds, enters a key sequence (the number of the station that is
experiencing the alarm), and then enters the pound character to indicate that the message is
finished.
Field #3 dials an answering machine, waits 16 seconds and then begins playing the alarm
messages. It won’t announce the alarms, since no one is there to enter the acknowledgement
code. But, it will announce that there is an alarm at station 25.
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
7. Repeat step six for each of the telephone number fields on the third configuration screen.
8. If you need to enter an acknowledgement code, proceed to the next section “Configuring
acknowledgement code.” Otherwise, scroll through all of the configuration screens until you reach
the screen that reads Press Enter to Save, Esc to Abort. To save your changes, press the Enter key on
the keypad. To exit without saving, press the Esc key.
Ack Code One- to four-digit code that must be correctly entered before any alarms are
4
announced.
Determine the four digits to be used for the acknowledgement code. Make sure that everyone on the call
out list knows the code, so they can properly acknowledge alarms when they are called.
IMPORTANT: Although the Ack Code can be anywhere from one to four digits long, we recommend
that you create a four-digit code to make if more difficult for an unauthorized person to guess your
Ack Code.
1. If you have just finished entering telephone numbers and are still in configure mode, skip to step
four (4). Otherwise, continue to step two (2).
2. Place the TCU001-AD in configure mode. Use the 4 and 6 keys on the keypad to navigate to the
screen that reads Change Configurations. Press the Enter key to enter the configuration section.
Change
Configurations
(enter)
3. Page through the TCU001-AD configuration screens until you reach the screen that includes the
Configure Dialer option. Use the 8 key to place the cursor on the line that reads Configure Dialer
and then press the Enter key.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
4. Use the 6 key on the keypad to navigate to the screen that displays the option Ack Code. This field
holds the acknowledgement four-digit acknowledgement code that must be entered by call recipients.
Ack Code =
Retry Time =
5. Use the 2 and 8 keys on the keypad to place the cursor on the Ack Code line and then press the
Enter key. A question mark will appear at the end of the line.
Ack Code = ?
Retry Time =
6. Use the numbered keys on the keypad to enter the desired four-digit acknowledgement code. Press
Enter.
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
7. If you need to enter a retry time, proceed to the next section “Configuring dial-out retry time.”
Otherwise, scroll through all of the configuration screens until you reach the screen that reads
Press Enter to Save, Esc to Abort. To save your changes, press the Enter key on the keypad. To exit
without saving, press the Esc key.
Retry Time Length of time (in seconds) before the next phone number in the dial-out list is
called. If the autodialer calls out and the alarms are not acknowledged within
4
this time period, the next phone number will be called. Maximum Retry Time
is 9,999 seconds (~167 minutes).
Determine the optimal, acceptable interval for the Retry Time. The table below is provided for your
convenience. It converts common minute and hour intervals into seconds.
Minutes/Hours Seconds
1. If you have just finished entering the acknowledgement code and are still in configure mode, skip to
step five (5). Otherwise, continue to step two (2).
2. Place the TCU001-AD in configure mode. Use the 4 and 6 keys on the keypad to navigate to the
screen that reads Change Configurations. Press the Enter key to enter the configuration section.
Change
Configurations
(enter)
3. Page through the TCU001-AD configuration screens until you reach the screen that includes the
Configure Dialer option. Use the key to place the cursor on the line that reads Configure Dialer and
then press the Enter key.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
6
4. Use the key on the keypad to navigate to the screen that displays the option Retry Time.
5. Use the 2 and 8 keys on the keypad to place the cursor on the Retry Time line and then press the
Enter key. A question mark will appear at the end of the line.
6. Use the numbered keys on the keypad to enter the desired retry time. Press Enter.
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
7. If you are finished configuring all of the autodialer properties, scroll through all of the configuration
screens until you reach the screen that reads Press Enter to Save, Esc to Abort. To save your changes,
press the Enter key on the keypad. To exit without saving, press the Esc key.
Factory settings
The table below shows the factory default settings for the TCU001-AD’s autodialer.
IMPORTANT: Although it is possible to return these settings to their factory default values, doing so
will cause all of the TCU001-AD’s settings to revert to default values. Please consider carefully before
taking this action.
Hold down the 8 (eight) key during TCU001-AD power up. This will clear all configuration changes
you’ve made to the TCU001-AD and restore all options to their factory default settings. Before removing
all configurations, you may want to download the TCU001-AD’s current configuration using WinRTU
Test. If you find in the future that you need this configuration, you can easily use WinRTU Test to
download it to a TCU001-AD. WinRTU Test is included in the TCU001 Test Kit. See Appendix C: Parts
List for ordering information.
M AINTENANCE M ODE
The TCU001-AD features a maintenance mode that enables you to temporarily suspend call out. This is
useful when you are doing periodic maintenance or repairs on a station that requires you to turn off
equipment (actions that would normally cause the autodialer to call out).
The TCU001-AD is placed in maintenance mode by pressing and holding the Silence key while cycling
power to unit. The Dlr LED will begin exhibiting a slow, irregular flash (on-on-on-off-on-on-on-off) to
indicate that the unit is in maintenance mode.
The TCU001-AD will remain in maintenance mode until you manually cancel maintenance mode by
pressing and holding the Silence Button until the Dlr LED stops flashing and turns on solid.
When the unit comes out of maintenance mode, it will call out for any alarms that occurred during
maintenance mode, provided the alarm is still active. Call out will not begin until the delay for that alarm
expires; the delay timer starts running as soon as the unit comes out of maintenance mode.
C ONFIGURATION L OG S HEET
Use the table to record the autodialer’s current configuration values. This information can be used to
restore the TCU001-AD’s autodialer configuration should the unit experience a technical difficulty that
causes it to lose its configuration data or necessitates replacement.
Station ID List
Use this table to record the station number and corresponding common name (for example, Washington
Park) or street address (for example, 123 Main Street). This “cheat sheet” will allow you to easily cross-
reference and identify a location by its station number.
FCC Requirements
1. The Federal Communications Commission (FCC) has established rules which permit this device to
be directly connected to the telephone network. Standardized jacks are used for these connections.
This equipment should not be used on party lines or coin phones.
2. If this device is malfunctioning, it may also be causing harm to the telephone network; this device
should be disconnected until the source of the problem can be determined and until repair has been
made. If this is not done, the telephone company may temporarily disconnect service.
3. The telephone company may make changes in its technical operations and procedures; if such
changes affect the compatibility or use of this device, the telephone company is required to give
adequate notice of the changes. You will be advised of your right to file a complaint with the FCC.
4. If the telephone company request information on what equipment is connected to their lines, inform
them of:
a. The telephone number to which this unit is connected.
b. The Ringer Equivalence Number [0.8B].
c. The USOC jack required [RJ11C].
d. The FCC Registration Number [EMRUSA-30496-AL-E].
Items (b) and (d) are indicated on the label. The Ringer Equivalence Number (REN) is used to
determine how many devices can be connected to your telephone line. In most areas, the sum of
REN’s of all devices on any one line should not exceed five (5). If too many devices are attached,
they may not ring properly.
Service Requirements
In the event of equipment malfunction, all repairs should be performed by our company or an authorized
agent. It is the responsibility of users requiring service to report the need for service to our company or to
one of our authorized agents. Refer to Appendix L: Support, Service, and Warranty for information on
obtaining service.
The TAC Pack TCU is now offered with an optional integrated 10/100 network adapter. When
combined, the two products become model TCU001-IP (Part # DFS-00367-008-09).
The TCU001-IP presents an ideal solution where radio may not be preferred, and where networking is
available (for example, frame relay, cable internet service, wireless Ethernet, local area network, etc.).
The protocol utilized for network communications is Modbus TCP. Although the TCU supports Modbus
ASCII and RTU potocol devices via its RS-232 and RS-485 serial interfaces, it must be noted that
RS-232 is no longer available for use with the TCU001-IP. The RS-485 serial interface remains available
and will operate as specified in Chapter 5: Modbus Support. The TCU001-IP will convert the RS-485
Modbus ASCII protocol interface to Modbus TCP for network communications.
Refer to Chapter 5: Modbus Support and “Poll Modbus Slave Devices” (beginning on page 142) in
Chapter 10: Configuring the Pump Control Process for information on using the TCU as a Modbus
master (via RS-485).
IMPORTANT: The TCU001-IP cannot be polled as a Modbus slave via its RS-232 serial interface. In
this instance, the RS-232 interface is used internally for network-specific operations. The RS-485
interface is not affected; it retains normal functionality.
H-O-A switches
4 x 20 LCD
Receive &
Transmit LEDs
12-key keypad
Network connection
(RJ-45, female)
209
Appendix J: Adding a RIO to the TCU
B EFORE Y OU B EGIN
We suggest that you configure the network portion of the TCU001-IP before doing any other
configuration and wiring (other than AC power).
Suggested installation order:
Obtain an available, unique IP address for each TCU001-IP from your MIS/IS department or the
person/department in charge of your network.
Configure the subnet portion of the TCU001-IP’s IP address. The last octet (subnet) of the IP address
is obtained from the TCU001-IP’s configured station address.
Configure the TCU001-IP’s gateway address (optional). If the TCU001-IP is communicating through
a gateway, the gateway’s full IP address must be entered in the #3 phone number field of the Auto
Dialer phone number configuration screens.
Configure the network portion of the TCU001-IP’s IP address. The network portion of the
TCU001-IP’s IP address must be entered in the #4 phone number field of the Auto Dialer phone
number configuration screens.
Connect the TCU001-IP to your network. We suggest that you use network surge protection to
insulate the TCU001-IP from voltage surges.
Use the PING command to verify that you can communicate with the TCU001-IP via the network.
Finish TCU001-IP installation by wiring and configuring appropriate external devices (pump motors,
transducers, alarm lights, etc)
U NIQUE IP A DDRESS
In addition to the configurations for such items as number of pumps, transducer type, and set point levels,
the TCU001-IP requires a configured IP address in order for it to communicate over the network. This
requires that you assign a unique IP address to each TCU001-IP that is on the same network in order to
avoid network addressing conflicts.
Before installing a TCU001-IP, contact your MIS/IS department, or the person/department that oversees
your network, to obtain a unique IP address for each TCU001-IP being installed.
The two components of the TCU001-IP’s IP address (subnet and network) are configured as follows:
The first three octets (network portion) of the IP address must be entered in the #4 phone number
field of the Auto Dialer configuration screens.
The last octet (subnet) of the IP address is obtained from the TCU001-IP’s configured station
address.
the OFF position. The station address is calculated by totaling the bit values of the DIP switches that are
not grounded (are in the OFF position). The valid station address range for the TCU001 IP is 1-254.
For example, to give the TCU001-IP a station address of 98 (equivalent to subnet of 98), we would leave
the bits for the following pins ungrounded (DIP switches in the OFF position):
pin P3-2 (bit value=2)
pin P3-6 (bit value=32)
pin P3-7 (bit value=64)
When we add the values of these bits together, we get a total value of 98 (2+32+64=98). The remaining
bits would be left grounded (DIP switch in the ON position).
Changing an H-O-A switch to the “Auto” position before selecting the Save command forces the
TCU001-IP to exit configure mode and abort the current changes.
Leaving the TCU001-IP unattended for over five minutes without selecting the Save command
causes the TCU001-IP to abort any changes and return to the main display screen.
Cycling the TCU001-IP’s power (press and hold the TCU001-IP’s On/Off key) before selecting the
Save command causes the TCU001-IP to reload the old configuration from non-volatile memory and
return to the main display screen.
IMPORTANT: The #1 phone number field must be cleared of all characters. If any characters
are present in the #1 phone number field, the TCU001-IP will be unable to communicate via its
network card.
1. Place the TCU001-IP in configure mode. Use the 4 and 6 keys on the keypad to navigate to the
screen that reads Change Configurations. Press the Enter key to enter the configuration section.
Change
Configurations
(enter)
2. Page through the TCU001-IP configuration screens until you reach the screen that includes the
Configure Dialer option. Use the 8 key to place the cursor on the line that reads Configure Dialer
and then press the Enter key.
Bem Modules: 0
Trend Rate = 30 secs
Configure Modbus
Configure Dialer
6
3. Use the key on the keypad to navigate to the screen that displays the options #1, #2, #3, and #4.
#1 =
#2 =
#3 =
#4 =
4. Use the 2 and 8 keys on the keypad to place the cursor on the line you want to edit (for example,
the #1 line) and then press the Enter key. A question mark will appear at the end of the line.
#1 = ?
#2 =
#3 =
#4 =
5. Use the numbered keys on the keypad to enter the gateway (optional) and the desired IP address [first
three octets only followed by a 0 (zero)]. Use the Silence key to enter a comma between each octet.
The Silence key cycles through the comma, pound, and asterisk characters each time the key is
pressed. When the desired character appears, press the Enter key to register the entry. When all
characters have been entered, press the Enter key.
#1 =
#2 =
#3 = 198,15,26,5
#4 = 198,15,26,0
Note: If you make a mistake while entering data, press the Silence key four times to delete the last
character on the current line. The Silence key enables you to cycle through the special characters
pound (#), comma (,) and asterisk (*) as well as access the delete function.
6. Scroll through all of the configuration screens until you reach the screen that reads Press Enter to
Save, Esc to Abort. To save your changes, press the Enter key on the keypad. To exit without saving,
press the Esc key.
When connecting the TCU001-IP to your network, we suggest that you use network surge protection to
prevent the TCU001-IP from being damaged from voltage surges. Model 24540 in the ZoneBarrier
series from Atlantic Scientific is recommended. This 100Base-T network surge arrestor with RJ-45
connector can be purchased from DFS. Order DFS part number 002-0136.
The TCU001-IP comes equipped with a short section of CAT5 network cable terminated with an RJ-45
male connector. The male connector is plugged into an RJ-45 female-to-female coupler.
Using CAT5 cable, connect the TCU001-IP to a network surge arrestor.
From the surge arrestor, make a connection to the client network (via a device such as a hub, switch, or
router) using CAT5 cable. [IMPORTANT: To minimize signal interference, avoid installing CAT5 cable
near florescent lighting or other AC conduit.]
3. A DOS window appears on screen and indicates if a reply has been received from the TCU001-IP.
The TCU can poll Modbus slave devices, such as the RIO032 and RIO128, and store their data in the
TCU’s unused modules (referred to as modules H-O in the TCU’s configuration screen). This
information can then be made available to your telemetry system by adding and configuring the modules
in HT3.
More information on the TCU’s Modbus capabilities can be found in Chapter 5: Modbus Support
Notes:
The instructions below are for the typical application of adding a RIO032 to the TCU. The procedure
for adding a RIO128 would be similar except for the additional I/O that must be configured in the
TCU and your telemetry system (HT3 or third-party HMI).
If you are using an HMI other than HT3, you will need to configure that software with the correct
Modbus register information in order to poll the TCU as a Modbus slave. See Appendix K: DFS to
Modbus Register Map for a list of equivalent Modbus registers for each DFS module type.
If the TCU is 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 wire AC power 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 Learn mode.
6. Configure the TCU to poll the RIO by entering and saving RIO’s I/O information in the TCU.
7. Verify communication between TCU and RIO.
8. Add and configure the RIO’s I/O in HT3.
217
Appendix J: Adding a RIO to the TCU
corresponding value (see table below). The RIO032 is set to a specific device/station address by leaving
particular pins on the address board’s DIP switch ungrounded, or in the Off position. The device/station
address is calculated by totaling the bit values of the pins that are not grounded. The valid device/station
address range for the RIO032 is 1-255.
Pin # Name Description
P6-1 ADDR0 Station address bit 0 (value=1 bit)
P6-2 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 value=1) ungrounded
(in the Off position). Leave the remaining bits grounded (in the ON position).
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
TCU
(CONNECTOR P4)
CTS_RAD 10
EX_RXD_RAD 9
EX_TXD_RAD 8
RTS_RAD 7
EX_GND_RAD 6
EX_SHIELD 5
2
RS485_A 4
RS485_B 3
1
2
A
4. After a minimum of three polls are received (may take up to ten polls), the RXD will blink three
times. The TXD, RXD and Status LED’s will turn on and then off indicating that Learn (auto
configuration) is complete.
During the Learn process, the RIO032 uses the CTS (clear to send) signal to determine if it is connected
to a radio. Radios, unlike other devices, don’t activate the CTS signal until an RTS (request to send) is
asserted. If the RIO032 determines that is it connected to a radio, it will communicate using the RTU
Radio protocol. 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.
The table below provides the information required for a RIO032 using all 32 I/O points.
I/O Type Module Letter Address (ModX Adr) Length (ModX Lth)
8 digital inputs H 1.10001 8
8 digital outputs I 1.00001 8
4 analog inputs J 1.30001 4.15
4 analog inputs K 1.30005 4.15
4 analog outputs L 1.40001 4.15
4 analog outputs M 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.
IMPORTANT: When the new settings are saved, they are written to a temporary memory location.
In order for the TCU to begin running on the new configurations, you must cycle power to the TCU.
If the TCU’s power is cycled before selecting the Save command, the last saved values are loaded on
power up.
Notes
If you are using an HMI other than HT3, you will need to configure that software with the correct
Modbus register information in order to poll the TCU as a Modbus slave as well as any devices
connected to the TCU. See the “DFS to Modbus Register Map” (below) for a listing of equivalent
Modbus registers by module letter for each DFS module type.
H I J K L M N O
1 14337 14593 14849 15105 15361 15617 15873 16129
2 14338 14594 14850 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 14345 14601 14857 15113 15369 15625 15881 16137
10 14346 14602 14858 15114 15370 15626 15882 16138
11 14347 14603 14859 15115 15371 15627 15883 16139
12 14348 14604 14860 15116 15372 15628 15884 16140
H I J K L M N O
1 2049 2305 2561 2817 3073 3329 3585 3841
2 2050 2306 2562 2818 3074 3330 3586 3842
3 2051 2307 2563 2819 3075 3331 3587 3843
4 2052 2308 2564 2820 3076 3332 3588 3844
5 2053 2309 2565 2821 3077 3333 3589 3845
6 2054 2310 2566 2822 3078 3334 3590 3846
7 2055 2311 2567 2823 3079 3335 3591 3847
8 2056 2312 2568 2824 3080 3336 3592 3848
223
Appendix K: DFS to Modbus Register Map
H I J K L M N O
1 34993 35249 35505 35761 36017 36273 36529 36785
2 34994 35250 35506 35762 36018 36274 36530 36786
3 34995 35251 35507 35763 36019 36275 36531 36787
4 34996 35252 35508 35764 36020 36276 36532 36788
H I J K L M N O
1 43041 43297 43553 43809 44065 44321 44577 44833
2 43042 43298 43554 43810 44066 44322 44578 44834
3 43043 43299 43555 43811 44067 44323 44579 44835
4 43044 43300 43556 43812 44068 44324 44580 44836
*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.
225
Appendix L: Support, Service, and Warranty
Phone – RA# will be issued over the phone by calling DFS at 321-259-5009 during normal operating
hours. The following information will be needed.
Customer/Utility Name and Ship to Address
Contact Name and Phone Number
Products to be returned and Serial Numbers
Detailed description of failure
PO#
Note: The lack of “Detailed description of failure” could result in the return of equipment due to the
inability to properly determine the nature of the failure or testing resulting in “No Problem Found”
STEP 3: Place the function module(s) individually in an electrostatic discharge bag and then wrap with
foam or bubble wrap. Pack the wrapped module(s) in a sturdy box filled with popcorn-type or bubble
wrap packing material. Include a packing slip with the following information:
Module(s) model, serial number, probable cause of failure, and the RA number
Shipping address
Shipping instructions (shipping costs greater than UPS ground are charged to the customer)
STEP 4: Address the box to:
RA Department # {the RA number you received here}
Data Flow Systems, Inc.
605 N John Rodes Blvd.
Melbourne, FL 32934-9105
STEP 5: Ship the box to DFS using any typical shipping carrier (for example, UPS, FedEx, etc.). If
circumstances permit, have a DFS employee hand carry the package to the headquarters for you. NOTE:
DFS employees are not permitted to hand carry unpacked modules.
Modules are typically repaired and shipped back to the customer within a 2-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 any of your equipment in for repair, contact the DFS - RA
Department at rma@dataflowsys.com or 321-259-5009.
Replacement of equipment may be necessary in the event that the equipment and/or parts are
unrepairable. Warranty equipment will be replaced with out prior notification as warranty replacement.
The customer will be notified by phone, if equipment not under warranty cannot be repaired, with
information of available options.
DFS reserve the right to return any material received without an RA# or not conforming to the
requirements of this RA process.
N OTICE
The intended purpose of the TCU is telemetry control. Using the TCU for purposes other than telemetry
control is not recommended and will void the warranty.
W ARRANTY
Data Flow Systems, Inc. (DFS) offers a one (1) year on-site warranty covering defects in materials and
workmanship. All DFS “plug-in” function modules, Pump Control Units (PCU), Hyper Server Modules
(HSM), Network Interface Modules (NIM), Fiber Interface Modules (FIM), Network Switch Modules
(NSM), Network Fiber Modules (NFM), and Back Pack Radios (BPR) carry an extended two (2) year
return-to-factory warranty. This extended warranty does not cover misuse, vandalism, or Acts of God.
However, these items are warranted against damage due to lightning for the entire three-year period.
Notes
alternation. To pass the turning on of pumps from one pump to another in succession.
bias voltage. Voltage used to bias (or hold) an input in the ON state. Absence of the voltage forces the
input in the OFF state.
configure. Choosing from a menu the operating conditions of the station controlled by the PCU.
external. Equipment outside the PCU and not supplied with the PCU.
Failure mode. Failure conditions displayed in the Alarm display mode of the TAC Pack TCU's LCD.
flow volume. Well or tank volume between the Off level and the Lead level set in the system.
Ground. Zero-voltage reference point of a circuit. May be connected to earth ground or used as a
common connection point.
input. Inputs to the PCU consist of 3 phase monitor inputs, 6 telemetry inputs, and 12 digital monitor
inputs.
input common. Point where multiple leads are terminated
LCD. Liquid-crystal display used to display messages
LED. Light-emitting diode used to indicate 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 monitor output of the PCU
override. Set aside and replace by another
pump mode. Selected method of pumping for either a well (pump down) or storage tank (pump up)
return. AC neutral or ISO.
set points. Those points selected in a station using an analog transducer. Pseudo levels corresponding to
the desired levels are selected for the analog input voltage (0-5 volts) or current (4-20 mA) from the
transducer. After calibrating the minimum and maximum points of the station, the points (equivalent in
feet) for starting or stopping pumps and for turning on alarms are selected.
source. External voltage, AC or DC.
staging levels. Levels in a well or tank at which an action (pump start or stop, or alarm activation)
occurs.
telemetry. Radio system used to monitor and control a remote unit or units.
Total Flow Volume. The Total Flow Volume is calculated as an average based on the total time it takes
the liquid level to move from the Off level to the Lead level. .
229
Notes
231
Index