Acrolon TankNET TC-1 Instruction Manual

`
TANKNET®
TC-1 Series II
Controller
Quick Start
Installation Guide
Version 4.1
© 2013
Power Line Networking & Expansion I/O
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Introduction
This manual provides information about how to properly install a TankNET TC-1
controller with power line communications. Specifically, it covers:
· General precautions and installation guidelines
· Basic controller dimensions
· Mounting brackets installation
· Mounting of controller onto ice shield of tank
· Controller Inlet connections
· Electrical wiring including: line voltage, cool/heat outputs, 2-wire or 4-wire
TankNET temperature probe input, analog outputs (proportional control) and
optional pump control outputs
· Internal ribbon cable connections (power and communications)
· Final assembly of controller display to power supply
Safety Information
We use note, caution and warning symbols throughout this manual to draw your
attention to important installation, operational and safety information.
A “NOTE” marks a short message to alert you to an important detail
A “CAUTION” safety alert appears with information that is important for protecting your
equipment and performance. Be especially careful to read and follow all cautions that
apply to your application.
A “WARNING” safety alert appears with information that is important to protecting you,
others and equipment from damage. Pay very close attention to all warnings that apply
to your application.
The safety alert symbol (an exclamation point in a triangle) precedes a general warning
or caution statement.
An electrical hazard symbol (an lightening bolt in a triangle) precedes an electrical
shock hazard caution or warning.
CAUTION or WARNING
ELECTRICAL SHOCK HAZARD
CAUTION or WARNING
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Careful adherence to the following precautions will help ensure proper product installation and long-
term performance, reliability and safety.
FAILURE TO FOLLOW THESE PRECAUTIONS MAY VOID PRODUCT WARRANTY.
General Precautions
ELECTRICAL SHOCK HAZARD: Disconnect breaker before servicing or installing
this product!
APPLY ONLY PROPER LINE VOLTAGE TO THE TC-1:
It is the installer’s responsibility to ensure that only the correct line voltage is applied to
the power supply input of the TC-1. Applying improper line voltage may destroy the
product, endanger the safety of the operator and void the product warranty.
The input voltage specification can be found on a label affixed to the top of the internal
power transform (T1) on the TC-1 power supply. DO NOT CONNECT POWER to the
product IF THIS LABEL IS MISSING!
· For label reading “120VAC 60Hz”, connect controller power supply input to:
120VAC 50/60Hz single phase power distribution system.
· For label reading “24VAC 60Hz”, connect TC-1 power supply input to:
24VAC 50/60Hz low voltage power distribution system.
The disconnect for this product must be via breaker which disconnects the line
conductor. The installer of this equipment is responsible for provisioning the
disconnect device, which shall not exceed 20 Amps over current protection.
DO NOT DRILL any new holes or enlarge existing holes in the TC-1 controller
USE ONLY 16-18 AWG WIRE wire unless otherwise specified
HAND TIGHTEN ONLY all screws and fasteners on the TC-1 controller
USE ONLY WATER-TIGHT CONDUIT FITTINGS AND HOLE PLUGS with this
product
ATTACH ONLY FLEXIBLE CONDUIT to TC-1 controller
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

TC-1 Fuses and Internal Connections
CAUTION: For continued protection against risk of fire, replace only with same
type and rating of fuse.
F1:
Main Input Fuse
F2:
Relay 1 Fuse
F3:
Relay 2 Fuse
Display Cable
Communications
Cable
Power and Relay Connections
Removable Plug
4-Wire Temperature Probe
Removable Plug
115VAC
Input Voltage
Specification
CAUTION:
For continued protection against risk of fire, replace only with same type and rating fuse:
F1 : Little fuse, 218P Series, 6.3A/250V time delay, 5 x 20 mm
F2, F3: Wickmann, TE5 Series, 5.0A Time Delay, short pin
CAUTION:
Installer must ensure that only proper input voltage is connected to TC-1 per the specification
labeling (shown above). Failure to do so may void warranty.
TC-1 Power Supply
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Mechanical Dimensions
All dimensions are inches
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Mounting Bracket Installation
TC-1 Power Supply
(Base Assembly)
Mounting Bracket (x4)
Included with TC-1
Bracket Screws (x4)
Included with TC-1
NOTE:
· Use only supplied brackets and screws
· Hand tighten only. Do not over torque screws
· DO NOT DRILL NEW HOLES OR ENLARGE EXISTING HOLES
TC-1 Power Supply
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

NOTE:
· Hand tighten screws only. Do not over torque
· DO NOT DRILL NEW HOLES OR ENLARGE EXISTING HOLES
Mounting Screws
(M4 or #8)
Mounting holes
Ice shield on tank
(supplied by other)
TC-1 Power Supply
(BASE)
Controller Mounting on to Ice Shield
TC-1 Power Supply
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Power Supply Inlet Connections
36" Max.
Conduit support bracket
Flexible Conduit
Water-tight
Conduit Fitting (½
NPT)
½ NPT Water-tight Hole Plug or
conduit and fittings, depending
on I/O requirements
Power Input Wiring
Cool/Heat Output Wiring
Pump-Ctrl Output Wiring
TC-1 Power Supply
Mounted on ice
shield
Ice Shield on Tank
Temperature Probe Cable
(4-Wire Probe Shown)
TC-1 Power Supply
Water-tight cable gland
(included with TC-1)
UNLESS OTHERWISE SPECIFIED
ALL FITTINGS, CONDUITS, WIRE
AND ALL OTHER INSTALLATION
MATERIALS TO BE PROVIDED BY
OTHER
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

TC-1 Display –Internal Connections
CAUTION:
For continued protection against risk of fire, replace only with same type and rating fuse:
F1, F2: Wickmann, TE5 Series, 1.0A Time Delay, short pin
TC-1 Display
- Rear View -
TC-1 Display
(REAR VIEW)
Power Connector
Shown w/ ribbon cable
Communications
Connector
P1 Removable Terminal Block
(RELAY I/O EXPANSION CARD)
F1: RELAY FUSE
(on optional Relay I/O card) F2: RELAY FUSE (on optional RELAY I/O card)
2-WIRE PROBE INPUTS
Removable Terminal Block
(JP4)
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Power Supply Wiring –LINE VOLTAGE, RELAYS, 4-WIRE PROBE
Line Neutral Earth
N.O COM N.C.
RELAY 1 N.O COM N.C. RELAY 2
L N E
INPUT POWER PROBE
ORG O/W B/W BLU
Output
Cool
-or-
Stage-1
Orange
Orange/White
Blue/White
Blue
Shield Drain Wire
(ground this end only)
TankNET 4-Wire
Temperature Probe
OPTION
Power and Solenoid
Wiring
(Use only 16 AWG Wire)
For 4-Wire Probe Only:
· Use only shielded CAT-5e cabling when extending TankNET 4-wire temperature probes
Removable
Probe PLUG
Removable
Power PLUG
IMPORTANT:
TC-1 Series-II Controllers support both 4-Wire or 2-Wire TankNET Temperature probes.
Please first identify the type of temperature probe you have as either 2-wire or 4-wire prior to
installation.
For 2-wire probes, please refer to the 2-wire temperature probe wiring page of this document and
disregard the 4-wire probe wiring shown on this page.
Output
HEAT
-or-
Stage-2
-or-
Humidity
4-WIRE TEMPERATURE PROBE ONLY
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

TC-1 Series II LID
(rear view)
2-Wire
Temperature Probe
Removable Terminal Block
(JP4)
JMP1
JMP2
12V
5V
JMP1 4-20MA
TEMP
JMP2
JUMPER POSITIONS
For optional second 2-Wire
Temperature probe
OPTIONAL EXPANSION CARD
Shown here
2-Wire Temperature Probe Wiring
Factory Default
IMPORTANT
· Use only shielded cabling when extending probe cables. Terminate shield drain wire at
controller end only (see JP4 above)
Shield (drain) Wire
Terminate Shield
at controller end
only
Probe 1
TankNET 2-wire Temperature Probe
TankNET 2-wire Temperature Probe
Probe 2
(Option)
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

TC-1 Series II LID
(rear view)
2-Wire Analog Inputs
Removable Terminal Block
(JP4)
Shield (drain) Wire
Terminate Shield
at controller end
only
JMP1
JMP2
JUMPER POSITIONS
For optional 4-20mA relative
humidity probe (probe 2)
12V
5V
JMP1 4-20MA
TEMP
JMP2
OPTIONAL EXPANSION CARD
(Not applicable)
Temperature + Humidity Wiring
IMPORTANT
· Use only shielded cabling when extending probe cables. Terminate shield drain wire at
controller end only (see JP4 above)
TankNET 2-wire Temperature Probe
Probe 1
RH
4-20mA
Sensor
+-
Probe 2
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

I/O Pump-Control Wiring (OPTIONAL)
NO1
COM 1
GND
External to TC-1
CAUTION:
· TC-1 auxiliary pump control relay contacts are intended only to PILOT an external pump start/stop
starter (CR1). DO NOT ATTACH PUMP MOTOR DIRECTLY TO THESE CONTACTS
· USE ONLY 16 or 18 AWG WIRE
· DO NOT EXCEED 120VAC @ 2 AMPS
I/O 2
I/O 1
COM1 COM 2 NO2
CR1
LINE
NEUTRAL
RELAY I/O EXPANSION CARD
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Stage-3 and Stage-4 Control Wiring (OPTIONAL)
NO1
COM 1
GND
External to TC-1
CAUTION:
· TC-1 relay contacts are intended only to pilot external relays (CR) or solenoids.
· USE ONLY 16 or 18 AWG WIRE
· DO NOT EXCEED 120VAC @ 2 AMPS
I/O 2
I/O 1
COM1 COM 2 NO2
CR
LINE
NEUTRAL
RELAY I/O EXPANSION CARD
CR
STAGE-3
STAGE-4
STAGE-4 Output
STAGE-3 Output
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Analog I/O Wiring (OPTIONAL)
+VA
AIN1
AIN2
CAUTION:
1. Analog Outputs:
a) CONNECT TO 100k OHM OR HIGHER LOAD
b) RANGE 2Vdc to 10VDC
c) DO NOT APPLY VOLTAGE OF ANY KIND TO THESE INPUTS.
DOING SO MAY DESTROY CIRCUITRY AND VOID WARRANTY!
2. Pump Control Relay
a) TC-1 auxiliary pump control relay contacts are intended only to PILOT an external pump start/stop starter
b) DO NOT EXCEED 120VAC @ 1 AMPS
3. USE ONLY 16 or 18 AWG WIRE FOR ALL CONTACTS
GND
AOUT1
AOUT2
RLY
RLY
R
E
D
B
L
K
PROBE1
TankNET
2-Wire
Analog
Temperature
Probe
R
E
D
P1 WIRING
SHLD
B
L
K
PROBE2
(Optional)
TankNET
2-Wire
Analog
Temperature
Probe
-
ANALOG
OUT1
+-+
ANALOG
OUT2 PUMP
CONTROL
RELAY
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

TC-1 Inlets and Internal Connections
36" - 42"
Conduit support bracket
Flexible Conduit
Water-tight Conduit
Fitting (½ NPT)
(2 PLACES)
Power Input Wiring
Cool/Heat Output Wiring
Pump-Ctrl Output Wiring
TC-1 Power Supply
Mounted on ice
shield
Ice Shield on Tank Securely Attach
Communications
Cable
Securely Attach
Power Cable
OPTIONAL
Expansion I/O Wiring
TC-1 Display
OPTIONAL
I/O Expansion Card
(RELAY I/O CARD SHOWN)
Probe Cable:
a) CAT-5 only for 4-wire probe
b) Shielded 18-22 AWG control wire for 2-wire probe
Flexible Conduit
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.

Attaching the TC-1 Display
CAUTION:
· Hand tighten lid screws. DO NOT OVER TORQUE
· Fasten upper-left screw, then lower-right screw, then upper-right screw and then lower-left
screw
· Ensure all conduit and inlet fittings are (water) tight
ELECTRICAL SHOCK HAZARD:
BEFORE APPLYING POWER ENSURE THAT ALL WIRING AND VOLTAGES ARE
CORRECT AND THAT THE TC-1 DISPLAY IS SECURELY FASTENED TO ITS POWER
SUPPLY.
TC-1 for Power Line Networking Quick Start Installation Guide
Acrolon Technologies, Inc.