Data Flow Systems TCU800 Bedienungsanleitung

Installation and

Operation Manual

TCU800

Data Flow Systems, Inc.

Preliminary

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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 specications of the

TCU800 and to the information contained in this document at any time without notice.

This document contains information related to special features and functions that are

only available when the TCU is utilized in a DFS TAC II SCADA System. These special

features and functions may not be available when the TCU800 is utilized in a 3rd party

SCADA System. If you are unsure about the availability of a feature or function, please

contact DFS for clarication.

605 N. John Rodes Blvd., Melbourne, FL 32934

Phone 321-259-5009

Fax 321-259-4006

www.dataowsys.com

DFS-00540-011-01

This document was last updated November 17, 2020.

Notice

Data Flow Systems, Inc.

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TCU800 User Manual

Preface iii

Purpose of this Manual.....................................................................................................................................................................................................iii

Document Conventions....................................................................................................................................................................................................iii

Abbreviations Used in this Manual..................................................................................................................................................................................iii

1. Safety Precautions 1

General Precautions..........................................................................................................................................................................................................1

Connecting/Disconnecting the TCU.................................................................................................................................................................................1

Protecting against Electrostatic Discharge........................................................................................................................................................................1

2. Product Overview 2

Description.......................................................................................................................................................................................................................2

Features............................................................................................................................................................................................................................3

Compatibility....................................................................................................................................................................................................................4

PIN Names/Wiring Denitions........................................................................................................................................................................................5

3. Unit Overview 9

User Interaction................................................................................................................................................................................................................9

Hand-Off-Auto (HOA) Switches.....................................................................................................................................................................................10

Soft Touch Button............................................................................................................................................................................................................10

USB Ports........................................................................................................................................................................................................................11

Touchscreen.....................................................................................................................................................................................................................11

Monitoring and Control...................................................................................................................................................................................................12

Digital Output Control.....................................................................................................................................................................................................13

Analog Input Monitoring.................................................................................................................................................................................................13

Serial Connectivity...........................................................................................................................................................................................................14

Phase Voltage Monitoring................................................................................................................................................................................................14

Internal Monitoring..........................................................................................................................................................................................................15

Automatic/Manual Control..............................................................................................................................................................................................15

Level Sensing Transducers..............................................................................................................................................................................................16

Internal Phase Monitor....................................................................................................................................................................................................17

Outputs.............................................................................................................................................................................................................................17

Electrical Protection........................................................................................................................................................................................................18

Battery Backup (Optional)..............................................................................................................................................................................................18

Principles of Operation...................................................................................................................................................................................................19

Discrete System (Contact Closure Devices)...................................................................................................................................................................19

Analog System (Pressure Transducer)............................................................................................................................................................................21

4. Setup 27

Mounting Instructions.....................................................................................................................................................................................................27

Electrical Installation and Wiring Diagrams....................................................................................................................................................................28

Bias Voltage Source Options............................................................................................................................................................................................33

Installed in RTU...............................................................................................................................................................................................................44

5. User Interface 45

6. Operating Procedures 49

Conguring the Pump Control Process............................................................................................................................................................................49

Main Settings....................................................................................................................................................................................................................50

Alarm Outputs..................................................................................................................................................................................................................51

Floats................................................................................................................................................................................................................................51

Radio................................................................................................................................................................................................................................52

Auxiliary...........................................................................................................................................................................................................................54

Analog..............................................................................................................................................................................................................................55

Pump Monitoring..............................................................................................................................................................................................................57

Phase Monitoring.............................................................................................................................................................................................................57

Contents

MODBUS.........................................................................................................................................................................................................................58

Derived Flow....................................................................................................................................................................................................................59

TCU Settings....................................................................................................................................................................................................................59

Radio Test Mode...............................................................................................................................................................................................................60

Reset Pump Stats..............................................................................................................................................................................................................61

Time..................................................................................................................................................................................................................................61

Auto Conguration...........................................................................................................................................................................................................61

Device Manager................................................................................................................................................................................................................62

Calibrate PMA..................................................................................................................................................................................................................62

Factory Reset....................................................................................................................................................................................................................62

Telemetry Conguration...................................................................................................................................................................................................64

7. Viewing and Troubleshooting Alarms 69

AC Power Fault................................................................................................................................................................................................................69

Auxiliary Input Alarm......................................................................................................................................................................................................70

DC Bias Fault...................................................................................................................................................................................................................70

Float Sequence Fault........................................................................................................................................................................................................71

High Well Alarm...............................................................................................................................................................................................................71

Phase Sequence Fault........................................................................................................................................................................................................71

Phase Voltage Fault...........................................................................................................................................................................................................72

Motor Starter Fault............................................................................................................................................................................................................72

Motor Stop Fault...............................................................................................................................................................................................................73

Transducer Fault................................................................................................................................................................................................................74

Leaving the Alarms Screen...............................................................................................................................................................................................75

8. Modbus Support 76

Appendix

A. Technical Specications 83

B. Checkout Procedure for Pump Controller 84

Step 1: Electrical Termination Review.............................................................................................................................................................................84

Step 2: Operations Testing................................................................................................................................................................................................85

C. Maintenance and Troubleshooting 87

Blown Fuse.......................................................................................................................................................................................................................87

TCU Replacement............................................................................................................................................................................................................88

D. Parts List 89

E. Mounting Instructions 96

F. Well Volume Calculations 101

G. Adding a RIO to the TCU 102

Congure RIO for Learn Mode........................................................................................................................................................................................103

Mount RIO and Wire AC Power and I/O.........................................................................................................................................................................104

Connect RIO to TCU........................................................................................................................................................................................................104

Place the RIO in Learn Mode...........................................................................................................................................................................................105

Conguring the TCU to Poll the RIO...............................................................................................................................................................................105

Verify Communication Between TCU and RIO...............................................................................................................................................................106

Add and Congure the RIO’s I/O in HT4 or Third-Party HMI........................................................................................................................................106

H. CT Module 108

I. TCU Transducer Conguration Examples 114

4-20 mA or 0-5 VDC Transducer with High Float (Pump Down Mode).........................................................................................................................114

4-20 mA or 0-5 VDC Transducer with Floats Backup (Pump Down Mode)...................................................................................................................116

4-20 mA or 0-5 VDC Transducer with Analog Input 2 as Backup (Pump Down Mode).................................................................................................119

Discrete System (Pump Down Mode)...............................................................................................................................................................................121

J. Polling the TCU - DFS Point and Modbus Registers 124

Pump Control Application by Module Letter and Point...................................................................................................................................................124

Pump Control Application by Modbus Register...............................................................................................................................................................130

K. Support, Service, and Warranty 143

Support and Service..........................................................................................................................................................................................................143

Technical Product Assistance............................................................................................................................................................................................143

Return Authorization (RA) Procedure..............................................................................................................................................................................143

Notice................................................................................................................................................................................................................................144

Warranty............................................................................................................................................................................................................................144

Questions or Comments on this Manual...........................................................................................................................................................................145

Glossary 146

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iii

Purpose of this Manual

This manual is a reference guide for installing and operating the TCU800 (Telemetry Control Unit). It contains information

meant to guide and assist in the installation and conguration procedure. This includes mounting and wiring instructions,

product features and specications, I/O listings, instructions for integrating with telemetry, information on Modbus

compatibility, and instructions for conguring and using the TCU’s pump control process. Refer to this manual when

designing, installing, conguring, or troubleshooting systems that use Data Flow Systems’ TCU. For information on

customizing the TCU’s operations, contact DFS.

Document Conventions

The following conventions are used throughout this manual:

• Bulleted lists provide information, not procedural steps.

• Numbered lists provide sequential steps or hierarchal information.

• Bold italic type is used for emphasis.

• All CAPITALIZED ITALIC type is used for terminal names.

Abbreviations Used in this Manual

H-O-A – Hand-Off-Auto

I/O – Input/Output

PCU – Pump Control Unit

PLC – Programmable Logic Controller

RTU – Remote Terminal Unit

SCU – Supervisory & Control Unit

TCU – Telemetry Control Unit

BEM – Bus Extender Module

STAT – Status

SSH – Secure Shell

RX – Receive

TX – Transmit

VA C – Voltage Alternating Current

VDC – Voltage Direct Current

Preface

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