TCS TCS 3000 User manual

Catalog Title
Catalog Subtle
Installaon Manual
TCS 3000
REGISTER

2
Table of Contents
Table of Contents 2
Receipt & Inspecon 3
Noce 3
Introducon 4
System Specicaons 4
700 Meter 6
682 Meter 8
Remote Mount 10
Electronic Air Eliminator 12
3-Way LPG Valve 14
655-21 Single Stage Valve 16
755-21 Single Stage Valve 17
755-31 Single Stage Valve 18
755-20 2-Stage Valve 19
755-30 2-Stage Valve 20
Vibronic Sensor 21
Timing Relay 22
Temperature Probe 23
Printer 26
Remote Display 33
Warning Symbols
CAUTION
Follow the warning instrucons within the
following informaon to avoid equipment
failure, personal injury or death.
TURN POWER OFF
Before performing any maintenance, be
sure to turn system power o to avoid any
potenal electric spark
FLAMMABLE
Flammable liquids and their vapors may
cause a re or explosion if ignited.
EYE PROTECTION
Pressurized systems may cause hazardous
leaks and spray that may be dangerous for
your eyes. Always wear eye protecon
around pressurized systems and its hazard-
ous liquids.
INJURY
Wear gloves for protecon from hazardous
liquids that may cause irritaon or burns.
READ
Read and understand all related manuals
thoroughly. The Engineering and OIM man-
uals will provide the knowledge for all sys-
tems, maintenance and operaon proce-
dures. If you have any quesons, please
consult the factory.
Daisy Chain (Printer) 34
Daisy Chain (Modem) 36
Standard Wiring 38
Quick Disconnect Wiring 39
Soware Update 40
Warranty Informaon 41
Notes 42

3
TCS 3000 Installation
Receipt & Inspecon
Upon receipt of register shipment, be sure to inspect the packaging and the register assembly for any damage before
signing the receipt of the shipment. Nofy the delivery company about possible damage and refuse receipt of the ship-
ment.
Registers are individually boxed and are protected with stac resistant packing material. Each package is idened
with the register assembly part number, descripon, serial number. Verify the register model is the correct model,
size, and conguraon as ordered. Contact your distributor if there is any discrepancy or queson.
Register assemblies should be handled with appropriate methods for the size and weight involved. Appropriate cloth-
ing and shoes need to be ulized. Transport the register package to the installaon site with appropriate transporta-
on methods, careful not to damage the register.
Be careful of any loose or protruding staples from the packaging, as they can be very sharp and may potenally cause
injury.
If foam has been used to protect register, carefully remove top foam layer before aempng to remove register as-
sembly from box. Foam packaging maybe formed around the register assembly making it dicult to remove. Do not
li the register assembly by wires or anything other than the metal body of the register. Do not insert objects or cables
into the register unless stated. Removing register assembly from packaging without adhering these warnings may
cause serious injury to you and/or the register.
Appropriate precauons should be taken regarding any personal, environmental and material compability with the
end use system.
Noce
Total Control Systems (TCS) shall not be liable for technical or editorial errors in this manual or omissions from this
manual. TCS makes no warranes, express or implied, including the implied warranes of merchantability and tness
for a parcular purpose with respect to this manual and, in no event, shall TCS be liable for special or consequenal
damages including, but not limited to, loss of producon, loss of prots, etc.
The contents of this publicaon are presented for informaonal purposes only, and while every eort has been made
to ensure their accuracy, they are not to be construed as warranes or guarantees, expressed or implied, regarding the
products or services described herein or their use or applicability. We reserve the right to modify or improve the de-
signs or specicaons of such products at any me.
TCS does not assume responsibility for the selecon, use or maintenance of any product. Responsibility for proper se-
lecon, use and maintenance of any TCS product remains solely with the purchaser and end-user.
All rights reserved. No part of this work may be reproduced or copied in any form or by any means – graphic, elec-
tronic or mechanical – without rst receiving the wrien permission of Total Control Systems, Fort Wayne, Indiana
USA.

4
ELECTRICAL
Power: 12V, 4A DC INPUT
A fuse shall be provided in the eld to limit the 12VDC power source to 4 amps max.
Current: 1.4 Amp
Solid State Relays: 12/24 Vdc; Passive Solid State
INTERNAL PULSER
Pulse Rao 400:1 PPR; Quadrature
Power 5 Vdc
Hertz 0 — 5000 Hz
EXTERNAL PULSE INPUT
Type Single or Dual Channel (Quadrature)
Power 5 Vdc
ENCLOSURE
Aluminum die cast with epoxy powder coat
Built to Ingress Protecon 66 and Nema 4 rangs
Temperature Range: -40 F to 158 F (-40 C to 70 C)
Ports: Ten 1/2” NPT UL, cUL threaded connecon ports, ATEX
Backlit LED Keypad
Calibraon opcal switch, password and mechanical seal
UL/cUL Rang Class 1, Division 2, Group C + D
The USB0 and USB1 connectors are for maintenance only. To access these connectors, power to the unit is to be
Disconnected or the area known to be free of ignitable gas or equivalent.
Introducon
The TCS 3000 register is a fully integrated custody transfer ow computer that will control all vehicle delivery opera-
ons. The Open Soware Architecture provides the opon of a simple “Pump & Print” delivery or a custom measure-
ment soluon. The TCS 3000 features a 4.5”x 3.5” full color VGA display screen, mulple delivery screens and a exible
mounng with backlit alpha-numeric keypad for the user interface. Available in exible mounng conguraons of 75
or 90 degree displays for meter mounng, and a remote mounng.
As an ow computer with open soware architecture, there will always be a need to add features to the register as the
industry applicaons evolve. Therefore please be reminded to contact the factory for periodic updates.
The TCS 3000 electronic register is a fully integrated ow computer that will control all delivery operaons. The modu-
lar design and open soware architecture provide you with a tailored system that is expandable for future needs. The
TCS 3000 features a large easy view VGA screen, alpha-numeric keypad and open printer interface for simple “Pump
and Print” deliveries. Soware features oer complete exibility of delivery screen informaon and view, preset,
price/tax, cket format and password protecon.
Oponal GPS, Bluetooth, Wi-Fi and Cellular capability enables the TCS 3000 to improve your product security and ease
access to your delivery data to reduce your operaon costs. Many addional features are available (mulple product
delivery, addive injecon, density/temperature correcon, mulple valve & pump control, etc.) to enhance your
measurement soluon.
TCS 3000 - This manual will help guide you with the setup conrmaon and calibraon of the register. Addional infor-
maon will be provided for wiring instrucon and auxiliary devices to integrate into the register.
System Specicaons

5
TCS 3000 Installation
COMMUNICATION
Four RS 485 output, 2-wire half duplex, custom protocol; 9600 baud, 8 bit, no parity, 1 stop bit
One RS 232 output, 9600 baud; 8 bit, no parity, 1 stop bit
WARNINGS:
SUITABLE FOR USE IN CLASS 1, DIVISION 2, GROUPS C AND D HAZARDOUS LOCATIONS, OR UN-
CLASSIFIED LOCATIONS.
WARNING– EXPLOSION HAZARD– DO NOT DISCONNECT EQUIPMENT WHILE THE CIRCUIT IS LIVE
OR UNLESS THE AREA IS KNOWN TO BE FREE OF IGNITABLE CONCENTRATIONS
WARNING– EXPLOSION HAZARD– SUBSTITUTION OF ANY COMPONENT MAY IMPAIR SUITABILITY
FOR CLASS 1, DIVISION 2.

6
Installaon Procedure—TCS 700 Series Meter
Before beginning the installaon of the TCS 3000, unpack the enre contents of the packaging in a safe locaon where
you will not misplace any of the parts. Lay out the parts as they would be installed on the truck. This will ensure that
you have all the correct parts for the installaon. Verifying all the necessary parts were included in the shipment in
advance will reduce the truck downme and avoid any wasted truck preparaon work.
Item Qty TCS P/N
Phillips Pan MS M4X8 6TCS300137
Spring Washer M4 6TCS300138
Terminal Cover 1TCS300164
3000 Reg. 7.5 AMP Fuse 1TCS300192
3000 Reg. Fuse Holder 1TCS300193
Cable Gland, M12 4TCS300244
O-Ring, M12 4TCS300245
USB Fem/Mini Male Cable 1TCS300705
Resistor 1K OHM 2TCS300753
1/4—28X1 Zinc Bolt 2TCS68013
1/4-28X1 Drilled Bolt 2TCS68013D
3/64 X 1 Coer Pin 1TCS790091
3000:700 Meter Drive Sha 1TCS790092
TCS 3000 to TCS 700 Meter Install Kit (TCS300870)
Installaon Procedure:
1. Remove and put aside the four mounng bolts and any mounng adaptor. Remove the exisng mechanical regis-
ter or electronic register, if applicable. Use a box or container to set old equipment and parts in.
2. Remove adjuster dust cover plate from the front of the meter. Remove exisng adjuster and drive sha.
Set adjuster dust cover aside in a box or container where it will not be misplaced. Screw the screws back
into meter unit. Noce the type of vercal drive sha in the meter.
3. Using the sha specic to your installaon, slide the Drive Sha Adaptor on the Pulser and align the holes.
Once the holes are aligned insert the Coer Pin and bend the pin ends back around the Sha Adaptor.
4. Slide the Adaptor onto the Meter Drive Sha.
5. Rotate the TCS 3000 unl the display is facing in the desired direcon and check to see that the meter
holes align with the holes at the base of the TCS 3000.
6. Secure the bolts.

7
TCS 3000 Installation

8
Installaon Procedure—TCS 682 Series Meter
Before beginning the installaon of the TCS 3000, unpack the enre contents of the packaging in a safe locaon where
you will not misplace any of the parts. Lay out the parts as they would be installed on the truck. This will ensure that
you have all the correct parts for the installaon. Verifying all the necessary parts were included in the shipment in
advance will reduce the truck downme and avoid any wasted truck preparaon work.
Item Qty TCS P/N
Phillips Pan MS M4X8 6TCS300137
Spring Washer M4 6TCS300138
Terminal Cover 1TCS300164
3000 Reg. 7.5 AMP Fuse 1TCS300192
3000 Reg. Fuse Holder 1TCS300193
Cable Gland 4TCS300249
O-Ring 4TCS300250
USB Fem/Mini Male Cable 1TCS300705
Resistor 1K OHM 2TCS300753
Coupling 682 to LCR II 1TCS600420
1/4—28 X 3/4 Zinc Bolt 2TCS68004
1/4—28 X 3/4 Drilled Bolt 2TCS68004D
Coupling, 682 1TCS600420
1/4—28 X 1 Zinc Bolt 2TCS68013
1/4—28 X 1 Zinc Drilled Bolt 2TCS68013D
3/64 X 1 Coer Pin 1TCS790091
TCS 3000 to TCS 682 Meter Install Kit (TCS300871)
Installaon Procedure:
1. Remove and put aside the four mounng bolts and any mounng adaptor. Remove the exisng mechanical regis-
ter or electronic register, if applicable. Use a box or container to set old equipment and parts in.
2. Using the sha specic to your installaon, slide the Drive Sha Adaptor on the Pulser Sha and align the holes.
Once the holes are aligned insert the Coer Pin and bend the pin ends back around the Sha Adaptor.
3. Slide the Adaptor onto the Meter Drive Sha.
4. Rotate the TCS 3000 unl the display is facing in the desired direcon and check to see that the meter
holes align with the holes at the base of the TCS 3000.
5. Secure the bolts.

9
TCS 3000 Installation

10
Installaon Procedure—3000 Remote Mount/Pulser
Item Qty TCS P/N
Pulser 1TCS 300160
Pulser Nut 1/2—32 Hex 1TCS 300162
Terminal Cover 1TCS 300164
O-Ring –013 FKM 1TCS 300166
TCS 3000 Pulser Kit (TCS 300866)
TCS 3000 to Wall Mount Install Kit (TCS300877)
Before beginning the installaon of the TCS 3000, unpack the enre contents of the packaging in a safe locaon where
you will not misplace any of the parts. Lay out the parts as they would be installed on the truck. This will ensure that
you have all the correct parts for the installaon. Verifying all the necessary parts were included in the shipment in
advance will reduce the truck downme and avoid any wasted truck preparaon work.
Installaon Procedure:
1. Use the wall mount kit to mount the TCS3000 in your desired locaon.
2. Follow the direcons (TCS900030) to install the Pulser on the meter.
3. Once the Pulser is wired, run the corresponding wire cable into the back of the TCS 3000.
4. Insert the pulser wiring into the cable gland. Wire the pulser into the correct pulser locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the pulser wire.
Item Qty
TCS P/N
Metric
TCS P/N
NPT
Phillips Pan MS M4X8 6TCS300137
Spring Washer M4 6TCS300138
Terminal Cover 1TCS300164
3000 Reg. 7.5 AMP Fuse 1TCS300192
3000 Reg. Fuse Holder 1TCS300193
Cable Gland 1/2” NPT 4TCS300249
O-Ring 4TCS300250
USB Fem/Mini Male Cable 1TCS300705
Resistor 1K OHM 2TCS300753

11
TCS 3000 Installation

12
Installaon Procedure—Electronic Air Eliminator
Installaon Procedure:
1. Locate the air eliminator oat wiring in the metering system.
2. Screw the cable gland into the back of the TCS 3000 and ghten into the housing.
3. Run the air eliminator oat wiring in the cable gland. Wire the air eliminator oat into the correct locaon on the
terminal board. Leave a small amount of slack on the wiring.
4. Compress the cable gland on the TCS3000 unl it is snug on the air eliminator oat wiring.
Air Eliminator Float Wiring

13
TCS 3000 Installation
5. Locate the air eliminator solenoid wiring in the metering system.
6. Screw the cable gland into the back of the TCS 3000 and ghten into the housing.
7. Run the air eliminator solenoid wiring in the cable gland. Wire the air eliminator solenoid into the correct locaon
on the terminal board. Leave a small amount of slack on the wiring.
8. Compress the cable gland on the TCS3000 unl it is snug on the air eliminator solenoid wiring.
Air Eliminator Solenoid

14
Installaon Procedure—3-Way LPG Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS ) for wiring the solenoid.
3. Mount the 3 Way Valve directly to the TCS3000 and follow the instrucons provided with the Valve.
*Note: Use Correct Thread Sealant*
4. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
5. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
6. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.
*When Calibrang the Unit Set Up Valve Type as 1001*

15
TCS 3000 Installation
Versa Valve S1 (Main)
S2 (Bypass)

16
Installaon Procedure—655-21 Single Stage Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS 9000051) for wiring the solenoid.
3. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.

17
TCS 3000 Installation
Installaon Procedure—755-21 Single Stage Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS 9000051) for wiring the solenoid.
3. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.

18
Installaon Procedure—755-31 Single Stage Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS 9000051) for wiring the solenoid.
3. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.

19
TCS 3000 Installation
Installaon Procedure—755-20 2-Stage Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS 9000051) for wiring the solenoid.
3. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.
*When Calibrang the Unit Set Up Valve Type as 1101*
S1 (Main)
S2 (Bypass)

20
Installaon Procedure—755-30 2-Stage Valve
Installaon Procedure:
1. Using the bolts and gasket provided, install the valve on the outlet side of the meter.
2. Follow the instrucons provided with the valve (TCS 9000051) for wiring the solenoid.
3. Once the solenoid is wired, run the corresponding wire as pictured using a minimum of 22gauge shielded cable into
the back of the TCS 3000.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid locaon on the terminal
board. Leave a small amount of slack on the wiring.
5. Compress the cable gland on the TCS3000 unl it is snug on the solenoid wire.
*When Calibrang the Unit Set Up Valve Type as 1101*
S1 (Main)
S2 (Bypass)