3P Technik TC320 User manual

3P Technik
TC320/330/340 Tank Level
Controller
Installation and Operating Manual
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Table o Contents
Safety........................................................................................................................................................3
Installation................................................................................................................................................3
Included Components....................................................................................................................................3
Layout.............................................................................................................................................................4
Control Panel Mounting.................................................................................................................................6
Mains Power Connection...............................................................................................................................6
Output Power Connections............................................................................................................................7
Switch Input Connections..............................................................................................................................7
Tank Level Sensor Connections......................................................................................................................7
BMS connection.............................................................................................................................................7
Troubleshooting........................................................................................................................................7
Fuse Listing.....................................................................................................................................................9
Inputs (le t to right) – Con1...........................................................................................................................9
Pressure Sensor Inputs (le t to right).............................................................................................................9
BMS Output..................................................................................................................................................10
Output Control Outputs (le t to right).........................................................................................................10
Upgrades and Modifications....................................................................................................................10
Specifications..........................................................................................................................................11
Control Panel................................................................................................................................................11
Tank Level Sensor.........................................................................................................................................11
Switched Outputs (pump/solenoid/valve control)......................................................................................11
Operation................................................................................................................................................12
Description o Operation.............................................................................................................................12
Control Panel Operations.............................................................................................................................13
Menus and Functions..............................................................................................................................13
Water Level Display.................................................................................................................................14
Accessing the Menu Options...................................................................................................................14
Status Screen...........................................................................................................................................14
Main Menu..............................................................................................................................................14
Setup Menu (Menu>Setup)................................................................................................................14
Virtual Output Setup (Menu>Setup>Virtual).................................................................................14
Output Setup (Menu>Setup>Outputs)..........................................................................................15
Main Functions..........................................................................................................................15
Virtual Input Selection..............................................................................................................15
Levels.........................................................................................................................................15
Duty Cycle..................................................................................................................................15
Output Con iguration Examples................................................................................................16
Tank Alarms (Menu>Setup>Alarms)..............................................................................................17
Fault Diagnosis........................................................................................................................................17
Diagnostic Menu (Menu>Diags).........................................................................................................17
Input Options (Menu>Diags>Inputs).............................................................................................17
View Inputs (Menu>Diags>Inputs>View Input)........................................................................17
Adjust Probe Stability (Menu>Diags>Inputs>Adjust Probe Stability).......................................18
Activate Outputs (Menu>Diags>Outputs).....................................................................................18
View Logged Fault Codes (Menu>Diags>Faults)............................................................................19
TC Series Fault Codes (all models)......................................................................................................19
Clear Logged Fault Codes (Menu>Diags>Faults>Clear)............................................................21
Run..........................................................................................................................................................21
Stop.........................................................................................................................................................21
Menu (Stop>Menu)............................................................................................................................21
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Wipe Con iguration (Stop>Wipe Con ig)............................................................................................22
Restart (Stop>Restart)........................................................................................................................22
Troubleshooting...........................................................................................................................................22
Fuse Listing..............................................................................................................................................23
Inputs (le t to right) – Con1.....................................................................................................................24
Pressure Sensor Inputs (le t to right)......................................................................................................26
BMS Output (con5)..................................................................................................................................26
Outputs (le t to right)..............................................................................................................................26
Upgrades and Modifications....................................................................................................................27
Specifications..........................................................................................................................................2
Control Panel................................................................................................................................................28
Tank Level Sensor.........................................................................................................................................28
Switched Outputs (pump/solenoid control)................................................................................................28
Sa ety
Mains Voltage – There are exposed electrical conductors inside this appliance. This appliance must be
installed and serviced by a competent electricical technician to the current requirements o BS7671 and
IEEE recommendations.
Be ore servicing this appliance, normal sa e isolation procedures should be implemented.
Do not touch the PCB while energised, it carries mains voltage.
Do not touch any connection terminals while energised.
Do not attempt to service this item when wet, or in a wet or high humidity environment.
I the housing o the control panel becomes damaged, you must shut down and securely isolate this
appliance immediately.
You must connect this appliance to a grounded 3 wire supply, protected by suitable overload protection.
Connected pumps and solenoids are earthed via the control panel, and may otherwise become live.
I the power cables are damaged, either to o rom the controller then shut down and isolate this apliance.
The combined loading o pumps, etc. connected t this appliance must not exceed 20A using the supplied
mains lex. Contact the manu acturer or advice i you need to exceed this rating.
Do not attempt to repair any part o the circuit board. Re er to the manu acturer or advice.
Installation
Included Components
1 x Control Panel
1 x 2m Mains Flex 2.5mm
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Cable Glands (qty depending on model)
1 x Pressure transmitter with 20m cable
Optional - 2nd Pressure transmitter with 20m cable
Layout
Unlike a pressure based controller, the 3P TC Series Tank Controller does not contain any plumbing. This
means you can install the control panel anywhere you wish within the building.
You will need to consider the ollowing constraints,
The control panel cannot be mounted outside, it is not weather resistant (although can be made weather
resistant – call us or advice)
Voltage drop will a ect the cable size needed to take power to your pumps. Over very long runs, you may
ind it more economical to install contactors near to the pumps, allowing you to control the pumps with a
sensible cable size. It is strongly recommended that you calculate voltage drop or cable runs in excess o
20m. Failure to do so may result in aulty operation, cable overheating, conductor migration, and risk o
ire. The same caution applies to solenoid valves, although the current draw is usually so small that only
extreme distances are likely to present a problem.
Also note that all control cabling (sensor and switch wiring) beyond a ew metres and installed in
electrically noisy environments may need to be shielded to avoid alse switch detection or unstable level
readings.
Note – it is recommended that you earth the shielding on cables (where present) to an earth terminal
within the controller. Do not earth to DC 0v as the DC power supply is isolated and will not function as a
ground.
Do not install control cabling next to mains power cables, particularly over long distances. Adequate
separation rom power cables will reduce potential problems. Where control cabling must cross mains
wiring it should be done at right angles and kept to a minimum.
We do not make any recommendation as to the speci ic cable or layout to be used. It is the responsibility o
the installer to install control cabling appropriately giving consideration to length and proximity to
electromagnetic noise.
It is expected that the installer is suitably competent with regard to electrical installation, and the
provisions o and testing in accordance with the current regulations in orce in your area. It is also expected
that the installer is competent to install, validate and resolve any issues with regard to control cabling.
In the event o unresolved inter erence to switch inputs, it is possible to create a separate powered sensor
circuit at low voltage operating relays near to the control panel to act as inputs. This will have much higher
immunity to parasitic voltages than the transistor based inputs on the control panel.
Most instability o the level sensor caused either by inter erence or turbulence in the water itsel can be
compensated in so tware by adjustment o the probe stability setting.
Pressure transmitter cable is o a special type incorporating a vent tube to equalise the pressure within the
transmitter to atmospheric pressure (3P part no. IRVENT or IRVENTX depending on type). The vent should
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terminate in a dry location. I not then it must be extended in vented cable to a suitable location, or
terminated in a sealed box with moisture resistant breather plug.
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Control Panel Mounting
Having selected a suitable location, unlock the 4 locking screws on the corners o the ront cover and
withdraw the ront panel. The LCD display, buttons and alarm LED are connected to the PCB. Remove and
replug these cables a terwards i necessary in accordance with the diagram.
The 4 screw mounting holes are located on the main enclosure in recesses adjacent to the ront panel
mounting holes. Mark drilling points on the wall accordingly. Withdraw the casing rom the wall and drill
holes appropriate or your selected ixings.
Mains Power Connection
The power supply to the control panel enters via a cable gland on the bottom right o the housing. Insert
the cable, connect to the incoming power terminal on the right o the PCB, and tighten the cable gland.
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Output Power Connections
Pumps, solenoids, motirised vbalves etc. are powered rom the rightmost green terminals on the lower
right o the PCB. From le t to right terminals 2,3,4 and 5 supply Outputs 1,2,3 and 4 (ternimal 1 is the BMS
output). The terminal blocks are socketed and can be withdrawn rom the PCB or ease o access.
Switch Input Connections
These inputs are used to connect switches, rain sensors or other control devices into the panel, and are
used alongside the level probes to decide when to switch an output on or o .
They are connected to the 10 pin plug on the bottom le t o the PCB marked “inputs” using the shielded
cable provided, in the ollowing order.
Input 1 Pins 1 and 2
Input 2 Pins 3 and 4
Input 3 Pins 5 and 6
Input 4 Pins 7 and 8
Input 5 Pins 9 and 10
Polarity is unimportant.
Note – If cables need to be routed into the controller other than with the cables glands fitted ensure
they enter the bottom of the casing and do not cross over the circuit board. If necessary use trunking to
route cables appropriately.
Tank Level Sensor Connections
Connect the tank level sensor(s) to con3 and also con4 i you have a 2nd tank level sensor.
White wire to the le tmost pin o the 2 pin connector
Brown wire to the rightmost pin o the 2 pin connector
The level sensor connected to con3 is Tank 1
The level sensor connected to con4 is Tank 2 (i itted)
Note – these inputs sense current in milliamps don't test them by shorting them out the input circuit will
be damaged and you will have to send the board back for repair.
BMS connection
The BMS connection provides a non-voltage relay capable o switching any 230V source up to 10A. Three
contacts are provided, Common, NO and NC. Connect your live conductor rom the BMS system to
Common, and output will be switched to NC in the absence o an alarm condition, switching to NO upon an
alarm.
Troubleshooting
Re er to the Sa ety instructions. No electrical works should be carried out other than by an appropriately
quali ied Electrician. Permits to work may be required at local site conditions. I in any doubt, consult your
system supplier.
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Problem Probable Cause Solutions
No Power – controller
dead – no backlight on
LCD
No power supply rom
distribution board
Fuse ailed
PCB damaged
Check 240 vac 50hz supply at
power input terminals.
Check Fuse F1
Replace PCB, contact
manu acturer.
Backlight on – no
display – no operation
CPU chip missing
CPU chip badly inserted or
bent pins
CPU chip wrong way round
CPU chip aulty
PCB damaged
Insert CPU
Insert CPU correctly or replace i
necessary
Remove and re-insert correctly
Replace CPU
Replace PCB, contact
manu acturer.
Controller Frozen –
operates normally but
keypad unresponsive
Keypad not connected or
connected wrong
Check connection, try reversing
connector direction
Controller Frozen –
does not operate
normally
CPU or oscillator damaged Replace CPU, i no success
replace PCB
Switch input appears
not to unction
Not connected
Cable damaged
Float switch not
constrained properly
Float aulty
Check connection to control
panel
Test continuity, replace i
necessary
Tie loat in tank such that it
switches up/down around
switch point
Replace
Tank level sensor does
not unction
Not connected
Connected wrongly
Sensor aulty
Input circuit aulty
Check wiring to controller
Check wiring polarity and
correct i needed
Test with loop calibrator,
replace sensor i necessary
Test with loop calibrator,
replace PCB i necessary
Tank Level sensor
reads incorrectly
Cable vent tube blocked or
sealed
Ensure vented section o cable
terminates to atmospheric
pressure
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Wrong sensor speci ication
installed
Sensor aulty
Replace with original OEM spec
part
Test with loop calibrator,
replace i necessary
Header tank over low
detected (error 10)
Sensor installed wrong way
up
Sensor installed too low
High level sensor ailure
causes over low
Solenoid stuck open
Check orientation, toggle should
hang downward.
Relocate above other sensors
Test and replace sensor
Isolate power, test and replace
solenoid
Note – References to loop calibrator refer to a current loop calibrator 4-20mA NOT a loop impedance
test.
Fuse Listing
F1 – 500mA 20mm quickblow
F2 – 1A 20mm glass passivated
F3 – 10A 20mm glass passivated
F4 – 10A 20mm glass passivated
F5 – 10A 20mm glass passivated
F6 – 10A 20mm glass passivated
Inputs (le t to right) – Con1
1 – Switch 1
2 – Switch 2
3 – Switch 3
4 – Switch 4
5 – Switch 5
Pressure Sensor Inputs (le t to right)
Con3 (le t) – Tank 1 Level Sensor
Con4 (right) – Tank 2 Level Sensor
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BMS Output
Type – Non contact relay
Terminals – Common, Normally Open, Normally Closed
Power Rating max 10A 230Vac
Output Control Outputs (le t to right)
1 – Output 1
2 – Output 2
3 – Output 3
4 – Output 4
Upgrades and Modi ications
The ollowing parts o the system can be upgraded at any time without any modi ication to the control
panel.
Replacement/upgrade o pump(s)
Replacement/upgrade o solenoid(s)
Note – there is no need to reprogram or adjust the control panel settings when replacing a pump with
one of a different power output or consumption. Diagnostic functions are not dependent on current
monitoring.
Installation o 3 phase pump(s) via external contactor/relay.
So tware upgrade by either on-site reprogramming, or by CPU replacement. Reprogramming is unlikely to
ever be necessary, but is provided or to allow or custom so tware to be retro itted to the control panel. It
is carried out by an approved engineer via an on-board programming port, or via replacement o the CPU.
The CPU is socketed in a 40pin DIP socket or ease o replacement. The CPU is a
When replacing the CPU, always use a proper DIP Extraction Tool, and ollow the instruction provided with
the replacement CPU.
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