TECALEMIT TC100D2 User manual

TC100D2-V6 0 MANUAL Apr 08 A4 (reflowed).docx Page 1 of 6
TC100D2
(24 VOLT DC)
Automatic Lubrication System Controller
WIRING INFORMATION
Refer also to the diagram of the Controller Printed Circuit Board shown on Page 5 of 5
SCREW TERMINAL CONNECTORS: 6 x 2-way plug (Part # MSTB 2.5/2-ST-5.08 by
PHOENIX CONTACT)
LIQUID TIGHT CABLE GLANDS: suit cables 2.9 - 6.4mm OD (Part # 3207 by HEYCO)
24VDC - Power Supply input (Internal fuse: 20 x 5mm 2Amp antisurge)
IP1 - Pressure switch or Cycle switch input (N/O volts-free)
IP2 - Low Level or Remote Test switch input (N/O volts-free)
FAULT - Fault Alarm Relay output (jumper selectable: N/O volts-free contact,
switched 24VDC or 0VDC. Resettable fuse rating: 0.5Amp)
OP1 - Pump SSR output (switched 24VDC, 30Watts)
OP2 - Valve Solenoid SSR output (switched 24VDC, 20Watts)
SSR = Solid State Relay (short circuit protected)
NOTES FOR SETTING TIMERS & OPTIONS (V6.0)
WARNING - Power supply should be switched off and remain off during setup!
(1) Setting DELAY TIME (DSW1) and PUMP ON TIME (DSW2)
Circuit board printed overlay shows location of 8-way DIP switches DSW1 and DSW2.
In the following tables: '1' = switch ON (UP),'0' = switch OFF (DOWN).
Switches 6, 7 & 8 are used to select TIME INCREMENT/Pulsed as follows:
Switch 6 7 8 TIME INCREMENT
DSW1 DELAY TIME 0 0 0 2 seconds
DSW1 0 1 0 1 minute
DSW1 1 0 0 10 minutes
DSW1 1 1 0 1 hour
DSW2 PUMP ON TIME 1 0 0 1 second
DSW2 0 1 0 10 seconds
DSW2 0 0 1 1 minute
DSW2 1 1 1 1 second on 1 second off
DSW2 0 1 1 1 second on 1 second off
X 30 (Total 1 minute)
Setting DELAY TIME (DSW1) and PUMP ON TIME (DSW2) continued.

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Switches 1 - 5 are used to select the time increment MULTIPLIER as follows (same function
for both DSW1 & DSW2):
Switch 1 2 3 4 5 MULTIPLIER
1 0 0 0 0 1
0 1 0 0 0 2
1 1 0 0 0 3
0 0 1 0 0 4
1 0 1 0 0 5
0 1 1 0 0 6
1 1 1 0 0 7
0 0 0 1 0 8
1 0 0 1 0 9
0 1 0 1 0 10
1 1 0 1 0 11
0 0 1 1 0 12
1 0 1 1 0 13
0 1 1 1 0 14
1 1 1 1 0 15
0 0 0 0 1 16
1 0 0 0 1 17
0 1 0 0 1 18
1 1 0 0 1 19
0 0 1 0 1 20
1 0 1 0 1 21
0 1 1 0 1 22
1 1 1 0 1 23
0 0 0 1 1 24
1 0 0 1 1 25
0 1 0 1 1 26
1 1 0 1 1 27
0 0 1 1 1 28
1 0 1 1 1 29
0 1 1 1 1 30
Example : DELAY TIME = 20 seconds, PUMP ON TIME = 10 seconds
Switch 1 2 3 4 5 6 7 8 Time Setting
DSW1 0 1 0 1 0 0 0 0 10 x 2 sec
DSW2 1 0 0 0 0 0 1 0 1 x 10 sec
NOTE: DSW1 & DSW2 must be set prior to power-on. Changes to the switch settings
whist the Controller is powered will not be recognised.
If an invalid setting has been made eg. out of range multiplier, the error will be signalled
by a flashing ' 0' on the CYCLES display.

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(2) Setting OPTIONS (DSW3 & JP1)
Circuit board printed overlay shows location of 8-way DIP switch DSW3 (labelled OPTIONS)
and 3-way jumper JP1 (labelled FAULT).
Switches 1 - 4 are used to enable the DOSAGES feature, where multiple activations (1 - 15)
of the Pressure / Cycle switch input IP1 are required during the Pump On Time period. If the
Pump On Time period expires before the preset number of activations have occurred, a FAULT
will be indicated. Switches 1 - 4 all set to OFF disables the DOSAGES feature.
With the DOSAGES feature enabled, during the Pump On Time period, the CYCLES display
changes its role to track / display the number of IP1 activations that have occurred since the
start of that Pump On Time period. Once the cycle is completed, the CYCLES display then
reverts to displaying cycles.
See OPTION 0 (OP1 pulse interval) below for alternate use of switches 1 - 4.
Switch 1 2 3 4 IP1 activations or
OP1 pulse interval (seconds)
1 0 0 0 1
0 1 0 0 2
1 1 0 0 3
0 0 1 0 4
1 0 1 0 5
0 1 1 0 6
1 1 1 0 7
0 0 0 1 8
1 0 0 1 9
0 1 0 1 10
1 1 0 1 11
0 0 1 1 12
1 0 1 1 13
0 1 1 1 14
1 1 1 1 15
Switch 5 is used to select OPTION 0 OP1 pulse interval (seconds) set by switches 1 - 4
ON (UP), OFF (DOWN) above - DOSAGES feature disabled.
Switch 6 is used to select OPTION 1 Termination of Pump On Time when IP1 (pressure ON
(UP), OFF (DOWN) switch or cycle switch) closes or when preset number
of IP1 activations are reached.
Switch 7 is used to select OPTION 2 IP2 functions as remote test input (same operation
ON (UP), OFF (DOWN) as TEST switch on front panel).
Switch 8 is used to select OPTION 3 Disable FAULT detection (ignore IP1).
ON (UP), OFF (DOWN)
Selecting OPTION 0 with switches 1 - 4 all OFF is invalid.
Selecting OPTION 1 & 3 together is invalid.
See SOFTWARE OPERATION for a detailed description of the PROGRAM and OPTIONS.
NOTE : DSW3 must be set prior to power-on. Changes to the switch settings whist the
Controller is powered will not be recognised.

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Jumper JP1 is used to select the FAULT ALARM output type, normally open volts-free
contact (2-way shunt fitted to centre pin of JP1 only), switched 24VDC (2-way shunt connecting
centre pin & ' + ' pin) or switched 0VDC (2-way shunt connecting centre pin & ' - ' pin). When
volts-free contact option selected, both the ' COM ' and ' O/P ' screw terminal connections are
used, ' COM ' being the relay common and ' O/P ' being the normally open volts-free contact
that closes to common when FAULT is activated. When switch 24VDC or 0VDC option is
selected, only the ' O/P ' screw terminal connection is used in conjunction with supply negative
or supply positive as required.
SOFTWARE OPERATION
There are three 8-way DIP switches labelled DSW1 (DELAY TIME), DSW2 (PUMP ON TIME)
and DSW3 (OPTIONS) that are preset by the user. DSW3 selects the program with various
options (OPTION 0, 1, 2 and/or 3) as described below. The DIP switches are read only during
the power-on initialisation sequence.
At power-on the FAULT + LOW LEVEL indicators (and FAULT relay output) are flashed on for
1 second as a 'lamp test' to verify that they are operational. At the same time, the software
version number will be displayed on the CYCLES display eg. '50' = V5.0, 51' = V5.1 etc.. At
the end of the 1 second 'lamp test', the CYCLES display will display ' 0'.
If an invalid DIP switch setting has been made, the controller will not operate. Instead it will
indicate that there is a problem by flashing ' 0' on the 2-digit display.
The first Delay Time period following power-on is either fixed at 10 sec (DSW1 switch 8 ON) or
as per DSW1 setting (DSW1 switch 8 OFF). Subsequent Delay Time periods will be as per
DSW1 setting.
Controllers fitted with an audible FAULT alarm device (piezo beeper) will emit a pulsing beep
(1 sec ON, 1 sec OFF) when FAULT is indicated. To silence the beeper, press and hold the
TEST switch for more than 5 sec (note this will not cancel the FAULT lamp or relay output).
To cancel all FAULT indications, press and release the TEST switch in less than 5 seconds ie.
normal press ... the indication will be cancelled upon release.
SYSTEM PROGRAM
Delay Time period set by DSW1 commences. Upon expiration of the delay period, output OP1
is energised for the Pump On Time period set by DSW2. During the Pump On Time period, the
switch input IP1 must close otherwise FAULT will be indicated. If IP1 is closed at the beginning
of the Pump On cycle, it must open and then close again to avoid FAULT indication.
OP2 is energised at the same time as OP1, but remains active for a further 5 sec. after OP1
deactivates. The CYCLES display is incremented by one (0, 1, 2, 3 ... 98, 99, 0, 1 ... ) when
OP2 deactivates. Delay Time period recommences. A repeat cycle is now in progress.
When a FAULT is indicated, all outputs are deactivated until the controller is reset by either
interrupting power or by pressing the TEST switch on the front panel. Pressing TEST resets the
Delay Time period to zero and energises output OP1 immediately.

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APPLICATION: Single Line Progressive
OP1 - Pump
IP1 - Cycle switch
IP2 - Low Level or Remote Test switch
Single Line Injector with automatic vent valve
OP1 - Pump
IP1 - Pressure switch
IP2 - Low Level or Remote Test switch
Dual Line with automatic reversing valve
OP1 - Pump
IP1 - Cycle switch
IP2 - Low Level or Remote Test switch
Single Line Injector with electric vent valve
OP1 - Pump
OP2 - Electric vent valve
IP1 - Pressure switch
IP2 - Low Level or Remote Test switch
OPTION 0 - (DSW3 switch 5 ON)
This option modifies the base program to allow OP1 pulse interval (pulsing option selected via
DSW2) to be set between 1 - 15 sec using switches 1 - 4. Selecting OPTION 0 disables the
DOSAGES feature.
OPTION 1 - (DSW3 switch 6 ON)
This option modifies the base program so that the Pump On Time will terminate on IP1
activation or when the number of IP1 activations (doses) = the number preset on DSW3 (n = 1-
15).
OPTION 2 - (DSW3 switch 7 ON)
This option modifies the base program to use a Remote Test switch input in place of the Low
Level switch input. The Remote Test switch connected to IP2 mimics the TEST switch on the
front panel.
OPTION 3 - (DSW3 switch 8 ON)
This option modifies the base program to cancel the FAULT alarm function ie. Ignore IP1.

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Figure 1. TC100D2 Controller Printed Circuit Board