Balcrank Synergy 3110-021 Reference manual

SERVICE BULLETIN SB 3077 Rev. A 3/12
Tank Surveillance Module
3110-021
Synergy
Monitoring System

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 1
CHAPTER
1. INTRODUCTION ............................................................................................................................................... 2
2. MECHANICAL INSTALLATION....................................................................................................................... 2
3. ELECTRICAL INSTALLATION......................................................................................................................... 2
4. KEY SWITCH .................................................................................................................................................... 2
5. CARD CONNECTORS...................................................................................................................................... 4
5.1. TANK CONTROL CONNECTORS (PORTS).................................................................................................... 4
5.2. SYNERGY COMMUNICATION CONNECTORS................................................................................................ 4
5.3. MISCELLANEOUS..................................................................................................................................... 4
6. TO CONNECT DISCRETE LEVEL SENSORS 23 132/138/171 AND SOLENOID VALVES.......................... 5
6.1. FRESH OIL TANK,23138 (2-LEVELS)........................................................................................................ 5
6.2. FRESH OIL TANK,23171 (1-LEVEL).......................................................................................................... 5
6.3. FRESH FLUID,23183 (1-LEVEL)............................................................................................................... 6
6.4. WASTE OIL TANK,23132 (2-LEVELS) ....................................................................................................... 6
6.5. ONE TSM PORT CONTROLS A NUMBER OF PUMPS..................................................................................... 6
7. EX-BARRIER 23187 ......................................................................................................................................... 7
7.1. CONNECTING A FRESH OIL TANK 23171/23183 (1-LEVEL)......................................................................... 7
7.2. CONNECTING A WASTE OIL TANK 23132 (2-LEVELS).................................................................................. 8
8. TO CONNECT ANALOGUE LEVEL SENSOR 23 417 .................................................................................... 8
9. TECHNICAL SPECIFICATION......................................................................................................................... 9

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 2
1. Introduction
The Synergy TSM module, (Tank Surveillance Module), is used to control pumps through discrete level sensors. A
TSM can be used both for fresh and waste oil tanks, as a stand-alone unit or integrated within a Synergy
Monitoring system.
NOTE! The Synergy installation guide (SB3080) should be available when installing and configuring a TCM
integrated into a Synergy system
2. Mechanical installation
The TSM is delivered mounted in a metal box with power supply. On the lid there are control lights and a light test
button.
The TSM is mounted on a wall or other suitable place using the four ø0.197” (ø5 mm) holes in the bottom corners of
the box. Preferred orientation is key-switch downwards.
3. Electrical installation
3.1. Main, 110 VAC/60 Hz (or 230 VAC/50Hz)
The MPDM should be connected to 110VAC/60Hz power using load, neutral and ground.
Balcrank recommends that the connection is done through a double pole lockable working switch.
The “knock-out” holes on the lower right hand (see picture) should only be used for main power supply to
separate it from the circuit board (DC) side of the module.
4. Key switch
The TSM has a key switch that has three positions.
“OVERRIDE” position activates all four control outputs. This can be used to prime
the system or in case of some failure.
“OFF” position deactivates all four control outputs. This is used to shut the system
down during nights or holidays to reduce the risk of leakage.
“NORMAL” position should be used to let the input signals activate their respective control output. This position is
used during work hours.
The key can be removed or inserted in all three positions.
The connector (D) on the TSM card is used for the key switch and chassis key position diodes.

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 3

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 4
5. Card connectors
The TSM card has a number of connectors with different purposes.
5.1. Tank control connectors (Ports)
There are four connectors (E) market +24 V, OC, A, B and
GND, one for each pump/tank. Solenoid valves and level
sensors are connected to these connectors.
“A” of a TSM port is connected to “order oil/emptying” of the
level sensor.
“B” of a TSM port is connected to “Stop level” of the level
sensor.
“GND” of a TSM port is connected to common of the level
sensor.
“+24V” of a TSM port is connected to one of the terminals of a solenoid valve and “Sol” is connected to the
other.
TIP! If a TSM is used for a tank containing flammable liquid it could be necessary to use an EX
protection.
There are two diodes (F) for every port. These indicate the status of entry points A and B, the level in the
tank.
One diode (G) on each port indicates if the solenoid valve is open or not.
5.2. Synergy communication connectors.
It has five connectors (A) for the Synergy communication. More information about these connectors can
be found in the OriLink TCM manual
5.3. Miscellaneous
The RESET-button (B) can be used to reset the module or reset the module address. Power supply is
connected to the connector (C).
NOTE! Check polarity, GND is closest to the hole!
ALARM
Solenoid valve
STOP
+24 V
A
GND
B
Sol

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 5
If the diode (H) is flashing the module is operational and working properly. A steady light or completely off
indicates a problem.
DIL switches for termination and BIAS are located at (I). For a stand-alone TSM all four should be in ON
position.
(J) Shows the position of the replaceable communication driver. The SetupLock jumper at position (K)
has no function for a TSM.
A LED (L) shows if an analogue sensor is detected or not, lit if detected. The analogue sensors are
connected to the 2-pole connectors marked (M). The polarity is marked on the PCB.
6. To connect discrete level sensors 23 132/138/171 and solenoid valves
The examples in this chapter are primarily intended for 23430 in stand-alone use so no configuration of the TSM is
needed. If the TSM is used together with a Synergy system see also TCM (23408) manual.
6.1. Fresh oil tank, 23138 (2-Levels)
To achieve a proper function, that is the pump is on only if there is enough oil in the tank, the following
connection should be made. Sensor must be active closed.
6.2. Fresh oil tank, 23171 (1-Level)
To achieve a proper function, that is the pump is on only if there is enough oil in the tank, the following
connection should be made. Sensor must be active closed. To achieve this remove the lower clip on the
sensor and turn the floater upside-down and put the clip back. Verify the function and trim it by moving the
clips if necessary. The floater is a little conic and the small diameter should then be down.

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 6
6.3. Fresh fluid, 23183 (1-Level)
To achieve a proper function, that is the pump is on only if there is enough fluid in the tank, the following
connection should be made. Sensor must be active closed. To achieve this remove the lower clip on the
sensor and turn the floater upside-down and put the clip back. Verify the function. The floater is a little
conic and the small diameter should then be up.
6.4. Waste oil tank, 23132 (2-Levels)
To achieve a proper function, that is the pump stops if the physical tank is full or if the sensor is
disconnected, the following connection should be made. Sensor must be active closed.
6.5. One TSM port controls a number of pumps
It is possible to control several pumps with only one TSM control port that is all pumps starts if the level
sensor says that it should. To do this the current sum of all solenoids has to be calculated. If it is below 1A
one TSM port cam be used. If it is over 1A 2 or more ports must be used or a relay has to be used.

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 7
7. EX-barrier 23187
In some countries an EX-barrier is needed between the level sensor and the tank
module if the liquid is classed as flammable. For this purpose the EX-barrier
23178 and a special EX approved cable 23164 can be used.
The EX-barrier, the solenoid valve that controls the air to the pump and the tank
module should be placed outside the EX-classed area. The EX approved cable
should be used to connect the level sensor on the tank inside the EX-classed
area with the EX-barrier outside the EX-classed area.
7.1. Connecting a fresh oil tank 23171/23183 (1-Level).
To achieve a proper function, that is the pump starts only if there are enough oil in the tank, a dispense
point is open and the sensor works properly, the following connection should be made.

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 8
7.2. Connecting a waste oil tank 23132 (2-Levels)
To achieve a proper function, that is the pump stops if the physical tank is full or if the sensor is
disconnected, the following connection should be made. The EX function switches should be set in
position I.
8. To connect analogue level sensor 23 417
To be able to use an analogue level sensor with a TSM in stand-alone use a Keypad (23401) or a LED (23404)
must be used to show tank level and a PC must be used to configure the port. The PC is not needed after
configuration is done.
The four analogue inputs on the TSM supports any standard industrial 2-lead / 4-20mA / 24VDC sensors. To
connect sensors a 2-pole connector is used.
The submergible pressure based level
sensor 23 417 is a robust sensor that
can be used with good accuracy for
tanks with a height of 1 –5 meters. Max
height depends on density of fluid. The
measuring resolution for a TSM with a
23 417 sensor is 4 mm for water and
about 4.5 mm for mineral oil.
Connect the red wire to +24VDC and the
black wire to Sense. +24VDC and Sense
are printed on the PCB.
If the sensor cable (6.5 m) is to short to
reach the TSM it can be lengthen using
a standard 2-lead wire with copper area
of 0.5 mm2 for each lead. For this
purpose use the by-packed connection
box.
It is not necessary to use the shield to
obtain a good signal because the signal
Solenoid valve
TSM (23430)
Cabel 23164
Cabel 23164
+24 V
A
GND
B
Sol
&
Red Yellow
Rev
I<0,1mA
I>6,0mA
Green
&
Red Yellow
Rev
I<0,1mA
I>6,0mA
14
10
9
16
12
11
+13 (L)
-15 (N)
5+
6+
7-
1+
2+
3-
230VAC
EX area
EX-barrier (23187)
Level sensor (23132)
LOW
HIGH
1 C
2 NO
3 NC
4 C
5 NO
6 NC

Synergy –Tank Surveillance Module 3110-021
SERVICE BULLETIN SB 3077 Rev. A 3/12
Balcrank Corporation, Inc. 9
is current based. The shield can be used for protection grounding purposes if needed.
Observe! –It is important that the transparent tube is not blocked and that the humidity protection
filter is used.
A blocked tube will cause measuring failure.
Not using the humidity protection could cause sensor malfunction due to corrosion caused
by condensed water.
Observe! To use analogue sensors a Synergy keypad (23401) or LED (23404) is needed to show the
tank volume.
9. Technical specification
Net ports: 5 Synergy ports (A)
for data
communication, 2
without +24VDC.
Discrete level inputs:4 (E), for one or two levels. Switch or active signal max 50 V. Supports reorder and stop set-up for both fresh and waste oil.
Analogue level inputs: ....................................... 4 (M) 4 - 20mA, 24VDC with 10-bit A/D-converters.
Control outputs: 4 (E) for solenoid
valve 24 VDC max
1,25 A. Closes after
about 30 s when
short circuited, this
is logged in the
database.
Other: RISC-based
microprocessor
EEPROM, 64 KB.
Connector (D) for 3-
pos key switch.
Connector (C) for 24
VDC 5A power supply.
SetupLock jumper (F), not used.
Power supply: Primary 230 VAC 500mA
Secondary 24 VDC 5 A
Max current: 500 mA + 4x1.25 A for solenoid valves
Casing: Strong black powder painted steel box
Outer measures: 303 x 228 x 65 mm.
Fitting: 4 x ø5mm
CC = 250 x 175 mm
Weight: 3,9 kg