Keraflo Tanktronic User manual

Tanktronic

Installation

Guide

keraflo.co.uk 2

Notes

......................................................................................................................................

Contents

Introduction ................................................................................................. 4

Quick Start ................................................................................................. 5

Levels ................................................................................................. 8

Valves ................................................................................................. 10

- Tanktronic Servo Ceramic Valve (SCV) ..................................................... 10

- Tanktronic Control Valve ..................................................... 13

- Generic Non-Latching Valve ..................................................... 14

- Commisioning Valves ..................................................... 14

Manual Config ................................................................................................. 15

Devices ................................................................................................. 17

Modules ................................................................................................. 20

- S-Module ................................................................................................. 20

- Battery Module ................................................................................................. 20

- Repeater Unit ................................................................................................. 20

Holiday Mode ................................................................................................. 21

Sensor ................................................................................................. 22

Menus ................................................................................................. 23

Settings ................................................................................................. 24

Dimensions ................................................................................................. 25

Menu Map ................................................................................................. 26

Specifications ................................................................................................. 28

keraflo.co.uk 3

Control Unit (TT/41, TT/42, TT/43 and TT/44)

The primary monitoring and control hardware for the Tanktronic system. The unit can

manage up to 4 x individual tank sensors, 8 x Tanktronic Servo Ceramic Valves, and 2 x

Tanktronic Control Valves plus additional third party devices.

S-Module (TT/2)

An optional expansion module that increases Tanktronic’s operational capacity. Each

S-Module provides 2 more VFCOs, 2 more VFCIs, 2 more SOLs, and will allow 2 x Control

Valves to be added, plus additional third party devices. Up to two S-Modules can be joined

to a single Control Unit.

Battery Module (TT/3)

An optional back-up power source to the mains supply, providing up to two days of normal

operation before power is expended (Depending on system and usage).

Repeater Unit (TT/100)

An optional interface extension to the Control Unit, allowing you to monitor and control

the Tanktronic system from another location. The Repeater Unit can be located up to 100m

from the Control Unit and does not require a separate power supply.

Battery

Module

Repeater

Unit

S-ModuleControl

Unit

Introduction

Tanktronic system comprises 4 modules, sold separately:

Introduction

keraflo.co.uk 4

Fixings

a. 4 x #6 Screws for mounting Control Unit

b. 4 x #4 Screws for mounting Connection Box

c. 4 x Wall fixing plugs

d. 4 x Self-adhesive pads

e. 4 x Floating washers

a. e.d.c.b.

Quick Start

Tank conguration:

IMPORTANT

NOTES:

Humidity controlled

Connection Box.

Do not get wet.

Do not remove

silica gel.

Do not modify this

box in any way.

Always refit the lid.

Do not cut the

cable.

Use drilling

template and

wall fixings

provided.

Snap out

to connect

S-Module &

Battery

Module

Installing the Control Unit:

Control

Unit

Installing the sensor:

Single Tank Balanced Tanks

Control

Unit

Quick Start

Use tabs

to align

modules

side by side

Select button (use

when prompted during

installation)

To sensor

Control

Valve

Before commencing installation, isolate main power supply and water supply

Rubber Bung

(Supplied)

Sensor to touch

tank floor

To Connection Box

Drill 25mm

hole

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Isolation

Valve

Control

Valve

Ensure

cables

are fed

through

the cable

glands.

A DIN rail

can also

be used

Connection Box

To Control

Unit

(cable not

supplied)

Outputs

24V PSU

6V

B

A

0V

Pre-fitted

at factory

Outputs Input

Volt free

contact input

for adding

devices

VFCO2VFCO1

3800

VFCI2VFCI1SOL2SOL1

Volt free contact

output for devices

Mains

power in

NL

keraflo.co.uk 6

Tanktronic requires a 230v/50Hz single phase supply from a switched fused 3A supply.

Connect with a suitable spec power cable. First slide the cable through the safety sleeve,

then attach it to the socket.

Wiring:

For wiring specifications refer to back cover.

Do not power unit until installation is complete and wiring carried out to BS7671 IEE

regulations.

Isolate water supply before powering up.

Wire the SCV Connection

Box and the Sensor

Connection Box here

Quick Start

Wire the

Battery

Module here

Control Unit

Wire the S-Module,

Battery Module and

Repeater Unit here

Use the rubber safety sleeves provided.

Wire the

Tanktronic Control

Valve here

Setup Wizard:

The Setup Wizard will start when the Control Unit is first powered up. It can also be

accessed from:

Main Menu > System > Config > Setup Wizard

The Setup Wizard will go through simple installation:

1. Enable/disable pin

2. Define type and number of tanks (1 Single Tank, 2 Single Tanks, Balanced Tanks)

3. Define tank area

4. Define level settings (see diagram and notes on the next page)

5. Define temperature alarms

Note: If sensors have previously been setup, you will get the option to reselect all sensors.

This is recommended to avoid confusion between sensors with multiple tanks.

For more advanced set up complete the wizard and use Main Menu > System > Config (see

Page 15).

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Quick Start

Scroll up and

down list

Select Scroll

through

menu steps

Setting Date and Time:

To set the date and time (which is not included in the Setup Wizard) use:

Main Menu > System > Config > Set Clock

Levels

Note: Fill Delay = Close Level minus Open Level.

Note: Override is optional and found in Manual Config not the Setup Wizard (See Page 15).

Setting Levels

When setting tank levels, firstly define your valve Close Level depth measured from the

bottom of the tank.

Then, confirm your Fill Delay depth (from the valve Close Level), which will define your

valve Open Level.

Finally, set your levels for Alarm Level High and Override Level High (measured from the

Close Level), then Alarm Level Low and Override Level Low (measured from the Open

Level).

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Prior to commissioning Tanktronic, it is recommended to list the settings you require by

using the Settings Log checklist on Page 24.

Monitoring Only:

When using Tanktronic for monitoring purposes only, the Fill Delay and Open Level is used

for setting Alarm Levels.

Filling Valves

Three types of filling valves are supported. All valves operate from the tank’s specified

Close Level and Fill Delay settings, as illustrated on Page 8.

• Tanktronic Servo Ceramic Valve (SCV) - See Page 10

• Tanktronic Control Valve - See Page 13

• Generic Non-Latching Valve - See Page 14

Tanktronic Servo Ceramic Valve (SCV):

5 models are available, ranging from 3/4” to 2” fittings.

Up to 8 Servo Ceramic Valves in total per system.

• Installed inside the tank

• Motorised operation

• Uses the Keraflo Aylesbury valve body and ceramic discs

• Manual override control knob (Close/Open)

Tanktronic Control Valve:

Available from 2” fittings to 6” fittings.

Up to 6 Control Valves in total per system, with 2 x S-Modules.

• Installed outside of tank

• Can be used as a shared valve on a pair of Balanced Tanks or individual Tank Control

• For high flow rate applications

Generic Non-Latching Valve:

3rd party valves can also be used, controlled via Volt-Free Contact Output.

Up to 6 Generic non-latching valves in total per system, with 2 x S-Modules.

• Must be a non-latching type valve

• Controlled via a Volt-Free Contact

• Not supplied by Keraflo Wire generic Non-

Latching Valves here

Wire Tanktronic Servo

Ceramic Valves here (via

Connection Box)

Wire

Tanktronic

Control Valves

here

Outputs

24V PSU

6V

B

A

0V

Pre-fitted

at factory

Outputs Input

Volt free

contact input

for adding

devices

VFCO2

VFCO1

3800

VFCI2VFCI1

SOL2

SOL1

Mains

power in

NL

Valves are Devices that are attached to the tanks.

Main Menu > Tank X > Config > Devices > Add Device >

For more information on Devices see Page 17.

Valves

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Tanktronic Servo Ceramic Valve (SCV)

SCV Box Contents:

• Valve (fitted with 3m cable and rubber bung)

• Connection Box to connect to the Tanktronic Control Unit

• Connection Box fixings

• Tanktronic Installation Guide

SCV

Connection

Box

SCV with

cable

Rubber

Bung

Control Unit software version must be Issue 2 or later to work with SCV.

Note: Tanktronic Control Unit and sensors are sold separately from SCV.

Maximum of 8 SCVs per system.

Control Unit

Sensor

Connection

Box

Valves

keraflo.co.uk 10

The software issue can be checked through the menu: Main Menu > System > Status >

About

Remove and discard

the red protective

caps at each end of

the valve

SCV Installation:

Important

DO NOT USE a

wrench on the body

of the valve

Insert valve

tail through

hole in the

tank wall,

connect

supply pipe

then tighten

back nuts to

hold the valve

in place

Only use a wrench

or spanner on the

valve tail when

fitting

Cable not

provided (max

length 15m)

Ensure

correct

polarity Select button,

press when

instructed

during

installation

Valves

Note: Only use the Connection Box provided to connect the SCV to the Control Unit.

Do not tamper with or modify the Connection Box in any way, when fitting the cable

to the Control Unit.

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Wiring the SCV Connection Box:

To

Control

Unit

Mounting

holes

Note: Mount

with screws

or double

sided tape

provided

Tank wall

Mounting valve on tank

IMPORTANT

NOTES:

Humidity controlled

Connection Box.

Do not get wet.

Do not remove

silica gel.

Do not modify this

box in any way.

Always refit the lid.

Do not cut the

cable.

SCV Conguration:

How to add device:

Main Menu > Tank X > Config > Devices > Add Device > select TT SCV

Select SCV valve to add this device. Press select button in connection box and hold until

valve is selected. This may take up to 10 seconds.

Once the SCV is selected, it is ready to operate at the tank open and close levels.

Advanced SCV features:

Auto Clean: Tanktronic can detect valve resistance caused by debris or scale. The SCV will

automatically run an Open/Close cycle to clean the valve. If valve resistance cannot be

cleared automatically, then an alarm is recorded as a “Cleaning” fault.

Auto Retry: Tanktronic can detect if the valve cannot complete a cycle due to debris. The

SCV will automatically release the valve by retrying the Open/Close action. If cycle cannot

be completed, then an alarm is sent as a “Valve Jammed” fault.

Fault messages:

• “S-Module Down” - The valve is connected to an S-Module which is not responding.

• “WF3800NET Down” – Wiring issues, e.g. short circuit.

• “No Response” - The master Control Unit cannot communicate with the SCV.

• “Under-current” fault – The motor or gear train is faulty and the valve may not be moving

(and could be stuck open).

• “Over-current” fault – If the SCV draws too much current this implies it is jammed or there

is a wiring fault. The open/close action is stopped immediately.

• “Cleaning” fault – See Auto Clean details above.

• “Valve jammed” fault – See Auto Retry details above.

• “Low supply” fault – Implies a wiring or panel fault. The action is completed.

Diagnostics:

A “Diagnostics” menu can be accessed under Main Menu > Tank > Status > Devices > select

valve from list > Diag, which displays the following items:

I = “Motor Current” – The average motor current drawn during the last action. This gives an

indication of how free the valve is moving.

U = “Usage Count” – The total number of Open & Close actions.

R = “Retry Count” – The total number of action retries it has done.

C = “Clean Cycle Count” – The number of times it has run a clean cycle on the Valve.

To reset these counts select Main menu > Tank > Status > Devices > select valve from list >

Diag > Read Diag > Start > scroll down the list > Reset

Valves

keraflo.co.uk 12

Tanktronic Control Valve

A range of metal-bodied Tanktronic Control Valves is available, in 2”, 21/2“, 3”, 4” and 6”

sizes. These valves should be specified when high flow rates are required.

Included: Control Valve with solenoid, Discharge Pipe Flanged Assembly, Stub Flange

and Backing Ring. For balanced tanks, Tanktronic Control Valves are also supplied with 2

Discharge Assemblies (reduced by one size from the inlet size), 2 Isolating Valves and 1

Stub Flange (reduced by one size).

How to add device:

Main Menu > Tank X > Config > Devices > Add Device > select TT Control Valve

Closing speed

adjustment

screw

Solenoid Valve

(Wired to SOL1 or

SOL2 terminals)

Valves

keraflo.co.uk 13

Closing Speed Adjustment:

The closing speed of the valve can be adjusted to avoid water hammer developing in the

supply pipe, as the Control Valve closes. If the closing speed is too short, hydraulic shock

can occur.

Turning the screw clockwise will increase the closing time. If the control valve fails to close

or does not close quickly enough, turn the screw anti-clockwise to shorten the closure

time.

Control

Unit

Control

Valve

Isolation

Valve

Fit isolation

valve upstream

of Control Valve

Can be

installed

vertically or

horizontally

(vertically is

preferred if

there is debris

in water)

Control

Unit

Control

Valve

Single Tank Balanced Tanks with Shared Valve

Servicing And Maintenance:

No routine maintenance should be necessary. If debris has entered the water supply, isolate

the supply to the Control Valve assembly and inspect/clean.

Balanced Tanks Installations:

If installed on a pair of Balanced Tanks you will be asked if the valve is shared or separate.

i.e. common fill or individual control.

Generic Non-Latching Valve

A non-latching 3rd party inlet valve may be controlled from the Tanktronic.

The live feed to the valve should be connected through the Volt-Free Contact Outputs on

the Tanktronic Control Unit, as illustrated in the drawing on Page 9 (for VFCO spec please

see Back Page).

How to add device:

Main Menu > Tank X > Config > Devices > Add Device > select Gen Inlet Valve

You will be asked to specify if the valve Volt-Free Contact polarity is normally open or

normally closed.

The valve will close at the specified Close Level for the selected tank and open at the

specified Fill Delay (below the Close Level).

Balanced Tanks Installations:

If installed on Balanced Tanks you will be asked if the valve is shared or separate. i.e.

common fill or individual control.

Commissioning Valves

Once a valve has been installed and the correct Device type added to the system, the valve

can be tested using the Control menu:

Main Menu > Tank X > Control > Devices > select valve to test from device list > Override

Follow the prompt and you can Open/Close the valve for 10 seconds. After 10 seconds the

valve will revert to its previous state.

The state of the valve can be viewed via the Status menu:

Main Menu > Tank X > Status > Devices > select valve to view from device list

This will show the Device name, Device type, Open/Close state and Address.

Balanced Tanks:

Balanced Tanks interlink the level banding for setting the water demand flag for each tank.

If Tank 1 is above the Close Level threshold, then Tank 2 will never demand water (and vice

versa).

If Tank 1 is in the band between Close Level and Open Level thresholds and Tank 2 is below

the Open Level threshold, then Tank 1 will flip to open (turning demand water on).

Valves

keraflo.co.uk 14

Manual

Config

Configuration

The Setup Wizard will configure basic settings. Manual Config is used to set up further

parameters.

Tank Layout:

For multiple tanks options beyond those covered in the Setup Wizard, the tank layout can

be selected from the System Config menu:

Main Menu > System > Config > Tank Layout >

Each tank option will now be listed in the menu:

• 1-4 Single Tanks

• 1-2 Pairs of Balanced Tanks

• Or a combination of the two

Note: The Control Unit can manage up to 4 sensors and each tank requires a sensor. When

modifying tanks the config and devices may be deleted.

Tank Setup:

For options beyond those covered in the Setup Wizard, select the tank to be configured in

the main menu:

Main Menu > Tank X > Config >

• Auto Setup

• Manual Setup

• Devices (see Page 17)

Auto Setup – Allows you to set your water level based on the actual level in the tank.

Manual Setup covers all parameters covered in the Setup Wizard plus Override Levels, Tank

Shape and Holiday Levels (see Page 21).

Override Level:

The Override Level is additional to the Alarm level and available for water level and

temperature. For example you could set a warning alarm at the Alarm level and then install

a shut of valve at the Overide Level. (See Devices Page 17)

Tank Shape:

Tanktronic assumes your tank is a uniform shape and the water volume is a function of

the cross sectional area x water depth. If your tank is a Horizontal Cyclinder and the area

changes with depth, then you must change the default shape:

Main Menu > Tank X > Config > Manual Setup > Tank Shape > Shape > select HORIZONTAL

CYLINDER

Enter the cylinder diameter and length.

keraflo.co.uk 15

Manual

Config

Alarms:

Tanktronic will raise an alarm in the following circumstances, which will cause the LED to

flash red and an alarm log created:

• Alarm level High or Alarm Level Low is exceeded

• Alarm Temp High or alarm Temp Low is exceeded

• Sensor Fault

• System fault

The Alarms are logged and can be viewed in the Alarm menu:

Main Menu > Alarms > Scroll through list of Alarms

The Alarm can be interrogated by selecting an individual alarm and it will display:

• Device

• Fault

• Date and time raised

To use the Alarm to signal or control a 3rd party device, a Device must be added (see Page

17).

Alarms can be cleared by selecting Clear Alarms at the bottom of the list:

Main Menu > Alarms > Clear Alarms

Secondary Tanks:

It is possible to create a second tank profile. This means a second set of levels for a single

sensor – for example: TANK1A using sensor data from TANK1, but controlling its own valves

with its own level and temperature thresholds.

To add a secondary Tank:

Main Menu > System > Config > Secondary Tanks > Add Secondary

For each primary tank in the system, a secondary will be available with the suffix ‘A’. The

secondary tank will appear in the Main Menu below the primary tank with the suffix ‘A’.

keraflo.co.uk 16

Devices

Tanktrionic can take actions based on temperature and level readings. To take an action a

Device must be added.

Devices are controlled using Volt-Free Contact Outputs (VFCO), Volt-Free Contact Inputs

(VFCI), 3800 and SOL output. These can be set up as normally Open or normally Closed

and Auto Reset or Manual Reset, where appropriate.

Outputs

24V PSU

6V

B

A

0V

Pre-fitted

at factory

Outputs Input

Volt free

contact input

for adding

devices

VFCO2VFCO1

3800

VFCI2VFCI1SOL2SOL1

Volt free contact

output for devices

Mains

power in

NL

Devices

keraflo.co.uk 17

Devices can be configured at System Level (they will look at readings from all tanks), or at

a Tank Level (and only respond to readings from an individual tank):

Main Menu > System > Config > Devices > Add Device

Main Menu > Tank X > Config > Devices > Add Device

If the Device is to be installed on an S-Module, then the S-Module will be specified.

Commissioning Devices:

Once a device has been added to the system it can be tested using the Control menu:

Main Menu > Tank X or System > Control > Devices > Select Device to test from device list

> Override

Follow the prompt and you can activate or deactivate the device. The Device will activate/

deactivate for 10 seconds. After 10 seconds the Device will revert to its previous state.

The state of the Device can be viewed via the Status menu:

Main Menu > Tank X or System > Status > Devices > Select Device to view from device list:

• Device name

• Device type

• Active/Inactive state

• Address

Connecting to Building Management Systems (BMS):

Tanktronic can be connected to proprietary BMS systems via the VFC available on the

Control Unit or S-Module.

Reset Latched Devices:

If manual reset is selected the device will require manual intervention to reset the VFC.

To reset all devices:

Main Menu > Alarms > Man Reset All Devs

To reset individually:

Main Menu > Tank X or System > Control > Device > select Device from list > Manual Reset

Note: The

Tanktronic Control

Unit can take a

maximum of 2

VFCOs, 2 VFCIs

and 2 SOLs. Add

an S-Module to

provide 2 more

VFCOs, VFCIs and

SOLs, if required.

Normal inlet valve, as in default config. Opens when level drops to

the fill delay level threshold, and closes when level reaches close

level threshold, or sensor not responding. (For balanced tank shared

inlet valves, both tanks are controlled together)

Active if any alarms are in the log

Non-latching inlet valve, same as above except on VFCO

Normal inlet valve, as in default config. Opens when level drops

below fill delay level threshold, and closes when level reaches close

level threshold, or sensor not responding. (For balanced tank shared

inlet valves, both tanks are controlled together)

Tanktronic SCV

Log Alarm Out

Generic Inlet

Tanktronic Control

Valve

Indicates lock-out state of tank (i.e. if lock-out input or manual lock

is active). If system device, then active if any tank locked out.

Used for leak detectors, BMS override etc. If active, close inlet valves

(but not safety override valves). If shared, and tank is a pair of

balanced tanks, also close inlet valves on balanced tanks. If alarmed,

creates entry in alarm log.

Create a level independent from filling levels to trigger a solenoid

(6V latching valve).

Create a level independent from filling levels to trigger the VFCO.

For controlling safety override inlet valve. Similar functionality to

tank alarm output, it becomes active if the relevant tank override

threshold (level high/low or temperature high/low) is reached. If

shared, then checks both tanks, if system device then checks all

tanks (6V latching valve).

For controlling safety override inlet valve, dump valve, pump set,

etc. Similar functionality to tank alarm output, it becomes active if

the relevant tank override threshold (level high/low or temperature

high/low) is reached. If shared, then checks both tanks, if system

device then checks all tanks

Active if the relevant tank alarm threshold (level high/low or

temperature high/ low) is reached. If shared, then checks both

tanks, if system device then checks all tanks.

Active if any system alarms (mains off, sensor not responding,

S-Module not responding etc).

System Alarm Out

Independent Level

VFC

Override Out

Tank Alarm Out

Override SOL

Lockout In

Independent Level

SOL

Lockout Out

Devices

Device name Description and fuctionality

keraflo.co.uk 18

The following devices can be added to the system, the table below describes their function

and setup parameters:

Tank

Polarity (normally closed)

Shared (separate) polarity (normally open)

Shared (separate)

Polarity (normally closed)

Shared (separate), alarmed (disabled), auto/

manual reset (man), fail-safe state (active),

polarity (normally closed)

Level from bottom of tank (0m), polarity

(close high, open low), fail-safe state (high),

alarm (no)

Level from bottom of tank (0m), polarity

(close high, open low), fail-safe state (high),

alarm (no)

Threshold type (hi level), shared (separate),

auto/manual reset (man,) fail-safe state

(active), polarity (normally closed)

Threshold type (hi level), shared (separate),

auto/manual reset (man,) fail-safe state

(active), polarity (normally closed)

Threshold type (hi level), shared (separate),

auto/manual reset (man), fail-safe state

(active), polarity (normally closed)

Mains off alarm (disabled), battery alarm

(disabled), auto/manual reset (man), polarity

(normally closed)

System

Tank or System

3800

VFCO

SOL

VFCO

SOL

VFCI

SOL

VFCO

Devices

Operation Interface Config parameters (default value)

keraflo.co.uk 19

Tank

Tank or System

System

Modules

S-Module:

Modules are connected to the Control Unit, as

illustrated here:

An S-Module can be added to provide 2 more VFCOs,

2 more VFCIs and 2 more SOLs, if required, in addition

to the Tanktronic Control Unit’s maximum of 2 VFCOs,

2 VFCIs and 2 SOLs.

Up to two S-Modules can be joined to a single

Tanktronic Control Unit.

How to connect:

Main Menu > System > Config > S-Modules > Number

of S-Modules > select 1 or 2 S-Modules > Select

S-Module

Press the select button and hold until S-Module is

selected. This may take up to 10 seconds.

When an S-Module is connected to the Control Unit,

there wil be an option to select the S-Module when

adding devices (valves, sensors etc).

Battery Module:

Provides a back-up power source to the mains supply,

providing up to 2 days of normal operation before

power is expended.

Specification:

Lead acid battery 6 volt - 4 Ah

Modules

Repeater Unit:

Works as an interface extension to the Control Unit,

allowing the user to monitor and control the Tanktronic

system from another location. The Repeater Unit can

be located up to 100m from the Control Unit and does

not require a separate power supply.

Connecting a Repeater Unit to the master Control

Unit requires installation of 4-core 1mm²cable, up to a

maximum of 100m in length.

Note: If you require a greater cabling length, this may

be possible by upgrading the wiring specification.

Contact Keraflo to discuss.

keraflo.co.uk 20

Control Unit Repeater Unit

Max

100m

Connection to

Control Unit

Connection to

Control Unit

Select button,

press when

instructed

during

installation

Battery Module

S-Module

The S-module and Control Unit must have the

same version of software. When the additional

S-Module is installed and selected the Control

Unit will update the S-Module to sync software

versions.

KERAFLO TANKTRONIC User manual

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