Data Flow Systems TCU800 Manual de usuario
Installation and
Operation Manual
TCU800
Data Flow Systems, Inc.
Preliminary
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Data Flow Systems, Inc. assumes no responsibility for any errors that may appear in this
document, nor does it make any commitment to update the information contained herein.
However, questions regarding the information contained in this document are welcomed.
Data Flow Systems also reserves the right to make changes to the specications of the
TCU800 and to the information contained in this document at any time without notice.
This document contains information related to special features and functions that are
only available when the TCU is utilized in a DFS TAC II SCADA System. These special
features and functions may not be available when the TCU800 is utilized in a 3rd party
SCADA System. If you are unsure about the availability of a feature or function, please
contact DFS for clarication.
© Data Flow Systems, Inc.
605 N. John Rodes Blvd., Melbourne, FL 32934
Phone 321-259-5009
Fax 321-259-4006
www.dataowsys.com
DFS-00540-011-01
This document was last updated November 17, 2020.
Notice
Data Flow Systems, Inc.
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TCU800 User Manual
Preface iii
Purpose of this Manual.....................................................................................................................................................................................................iii
Document Conventions....................................................................................................................................................................................................iii
Abbreviations Used in this Manual..................................................................................................................................................................................iii
1. Safety Precautions 1
General Precautions..........................................................................................................................................................................................................1
Connecting/Disconnecting the TCU.................................................................................................................................................................................1
Protecting against Electrostatic Discharge........................................................................................................................................................................1
2. Product Overview 2
Description.......................................................................................................................................................................................................................2
Features............................................................................................................................................................................................................................3
Compatibility....................................................................................................................................................................................................................4
PIN Names/Wiring Denitions........................................................................................................................................................................................5
3. Unit Overview 9
User Interaction................................................................................................................................................................................................................9
Hand-Off-Auto (HOA) Switches.....................................................................................................................................................................................10
Soft Touch Button............................................................................................................................................................................................................10
USB Ports........................................................................................................................................................................................................................11
Touchscreen.....................................................................................................................................................................................................................11
Monitoring and Control...................................................................................................................................................................................................12
Digital Output Control.....................................................................................................................................................................................................13
Analog Input Monitoring.................................................................................................................................................................................................13
Serial Connectivity...........................................................................................................................................................................................................14
Phase Voltage Monitoring................................................................................................................................................................................................14
Internal Monitoring..........................................................................................................................................................................................................15
Automatic/Manual Control..............................................................................................................................................................................................15
Level Sensing Transducers..............................................................................................................................................................................................16
Internal Phase Monitor....................................................................................................................................................................................................17
Outputs.............................................................................................................................................................................................................................17
Touchscreen.....................................................................................................................................................................................................................18
Electrical Protection........................................................................................................................................................................................................18
Battery Backup (Optional)..............................................................................................................................................................................................18
Principles of Operation...................................................................................................................................................................................................19
Discrete System (Contact Closure Devices)...................................................................................................................................................................19
Analog System (Pressure Transducer)............................................................................................................................................................................21
4. Setup 27
Mounting Instructions.....................................................................................................................................................................................................27
Electrical Installation and Wiring Diagrams....................................................................................................................................................................28
Bias Voltage Source Options............................................................................................................................................................................................33
Installed in RTU...............................................................................................................................................................................................................44
5. User Interface 45
6. Operating Procedures 49
Conguring the Pump Control Process............................................................................................................................................................................49
Main Settings....................................................................................................................................................................................................................50
Alarm Outputs..................................................................................................................................................................................................................51
Floats................................................................................................................................................................................................................................51
Radio................................................................................................................................................................................................................................52
Auxiliary...........................................................................................................................................................................................................................54
Analog..............................................................................................................................................................................................................................55
Pump Monitoring..............................................................................................................................................................................................................57
Phase Monitoring.............................................................................................................................................................................................................57
Contents
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MODBUS.........................................................................................................................................................................................................................58
Derived Flow....................................................................................................................................................................................................................59
TCU Settings....................................................................................................................................................................................................................59
Radio Test Mode...............................................................................................................................................................................................................60
Reset Pump Stats..............................................................................................................................................................................................................61
Time..................................................................................................................................................................................................................................61
Auto Conguration...........................................................................................................................................................................................................61
Device Manager................................................................................................................................................................................................................62
Calibrate PMA..................................................................................................................................................................................................................62
Factory Reset....................................................................................................................................................................................................................62
Telemetry Conguration...................................................................................................................................................................................................64
7. Viewing and Troubleshooting Alarms 69
AC Power Fault................................................................................................................................................................................................................69
Auxiliary Input Alarm......................................................................................................................................................................................................70
DC Bias Fault...................................................................................................................................................................................................................70
Float Sequence Fault........................................................................................................................................................................................................71
High Well Alarm...............................................................................................................................................................................................................71
Phase Sequence Fault........................................................................................................................................................................................................71
Phase Voltage Fault...........................................................................................................................................................................................................72
Motor Starter Fault............................................................................................................................................................................................................72
Motor Stop Fault...............................................................................................................................................................................................................73
Transducer Fault................................................................................................................................................................................................................74
Leaving the Alarms Screen...............................................................................................................................................................................................75
8. Modbus Support 76
Appendix
A. Technical Specications 83
B. Checkout Procedure for Pump Controller 84
Step 1: Electrical Termination Review.............................................................................................................................................................................84
Step 2: Operations Testing................................................................................................................................................................................................85
C. Maintenance and Troubleshooting 87
Blown Fuse.......................................................................................................................................................................................................................87
TCU Replacement............................................................................................................................................................................................................88
D. Parts List 89
E. Mounting Instructions 96
F. Well Volume Calculations 101
G. Adding a RIO to the TCU 102
TCU Replacement............................................................................................................................................................................................................102
Congure RIO for Learn Mode........................................................................................................................................................................................103
Mount RIO and Wire AC Power and I/O.........................................................................................................................................................................104
Connect RIO to TCU........................................................................................................................................................................................................104
Place the RIO in Learn Mode...........................................................................................................................................................................................105
Conguring the TCU to Poll the RIO...............................................................................................................................................................................105
Verify Communication Between TCU and RIO...............................................................................................................................................................106
Add and Congure the RIO’s I/O in HT4 or Third-Party HMI........................................................................................................................................106
H. CT Module 108
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I. TCU Transducer Conguration Examples 114
4-20 mA or 0-5 VDC Transducer with High Float (Pump Down Mode).........................................................................................................................114
4-20 mA or 0-5 VDC Transducer with Floats Backup (Pump Down Mode)...................................................................................................................116
4-20 mA or 0-5 VDC Transducer with Analog Input 2 as Backup (Pump Down Mode).................................................................................................119
Discrete System (Pump Down Mode)...............................................................................................................................................................................121
J. Polling the TCU - DFS Point and Modbus Registers 124
Pump Control Application by Module Letter and Point...................................................................................................................................................124
Pump Control Application by Modbus Register...............................................................................................................................................................130
K. Support, Service, and Warranty 143
Support and Service..........................................................................................................................................................................................................143
Technical Product Assistance............................................................................................................................................................................................143
Return Authorization (RA) Procedure..............................................................................................................................................................................143
Notice................................................................................................................................................................................................................................144
Warranty............................................................................................................................................................................................................................144
Questions or Comments on this Manual...........................................................................................................................................................................145
Glossary 146
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Purpose of this Manual
This manual is a reference guide for installing and operating the TCU800 (Telemetry Control Unit). It contains information
meant to guide and assist in the installation and conguration procedure. This includes mounting and wiring instructions,
product features and specications, I/O listings, instructions for integrating with telemetry, information on Modbus
compatibility, and instructions for conguring and using the TCU’s pump control process. Refer to this manual when
designing, installing, conguring, or troubleshooting systems that use Data Flow Systems’ TCU. For information on
customizing the TCU’s operations, contact DFS.
Document Conventions
The following conventions are used throughout this manual:
• Bulleted lists provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchal information.
• Bold italic type is used for emphasis.
• All CAPITALIZED ITALIC type is used for terminal names.
Abbreviations Used in this Manual
H-O-A – Hand-Off-Auto
I/O – Input/Output
PCU – Pump Control Unit
PLC – Programmable Logic Controller
RTU – Remote Terminal Unit
SCU – Supervisory & Control Unit
TCU – Telemetry Control Unit
BEM – Bus Extender Module
STAT – Status
SSH – Secure Shell
RX – Receive
TX – Transmit
VA C – Voltage Alternating Current
VDC – Voltage Direct Current
Preface
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