1.1 Read the operating instructions before use

Please read through these instructions carefully before installing or operating. Following the installation, pass the instructions on to the operator. This unit must be installed and commissioned in accordance with the regulations and standards in force. These instructions can also be found at www.docuthek.com.

1.2 Explanation of symbols

 1 ,  2 ,  3 ,  a ,  b ,  c  = Action

= Instruction

1.3 Liability

We will not be held liable for damage resulting from non-observance of the instructions and non-compliant use.

1.4 Safety instructions

Information that is relevant for safety is indicated in the instructions as follows:

All interventions may only be carried out by qualified gas technicians. Electrical interventions may only be carried out by qualified electricians.

1.5 Conversion, spare parts

All technical changes are prohibited. Only use OEM spare parts.

2.1 Type code TC 1V

2.2 Type code TC 1C, TC 2, TC 3

TC..N only for 120 and 24 V

Gas type, measurement time, installation position, mains voltage, mains frequency, power consumption, ambient temperature, enclosure, max. switch-on current and max. inlet pressure – see type label.

TC 1V

1. TC 1V
2. Connectors
3. 5 x M16 cable glands
4. 2 x O-rings

TC 1C

1. TC 1C for combination controls CG
2. 1 x adapter
   2 x O-rings
   2 x retaining screws
3. Connectors
4. 5 x M16 cable glands
5. 2 x O-rings

TC 2

1. TC 2 for solenoid valves
2. 1 x adapter
   2 x O-rings
   2 x retaining screws
3. Connectors
4. 5 x M16 cable glands
5. 2 x O-rings

TC 3

1. TC 3
2. Auxiliary valves
3. Valve block
4. 5 x M16 cable glands
5. 1 x screw plug

3.1 Mounting TC 1V to valVario controls

1 Disconnect the system from the electrical power supply.

2 Close the gas supply.

3

4

5

The O-rings must be inserted in the connectors of the TC.

The solenoid actuator cannot be rotated on solenoid valves with proof of closure switch VCx..S or VCx..G.

Connect the TC to the inlet pressure connection p_u and the interspace pressure connection p_z of the inlet valve. Ensure that connections p_u and p_z on the TC and the gas solenoid valve are not reversed.

TC and bypass/pilot gas valve cannot be fitted together on the same side of the double block valve.

In the case of a VCx combination, it is recommended to always install the bypass/pilot gas valve on the rear of the second valve and the tightness control on the viewing side of the first valve, together with the connection box.

The TC is secured using two captive, self-tapping combination Torx screws T20 (M4) inside the housing. Do not undo any other screws!

VAS 1–3, VCx 1–3

a

b

c

Tighten the screws with max. 250 Ncm.

VAS 6–9, VCx 6–9

a

b

c

Tighten the screws with max. 250 Ncm.

3.2 Mounting TC 1C to combination control CG

1 Disconnect the system from the electrical power supply.

2 Close the gas supply.

3

4

5

The O-rings must be inserted in the connectors of the TC.

Use the adapter plate supplied to mount the TC 1C to combination control CG.

Connect the TC to the inlet pressure connection p_u and the interspace pressure connection p_z of the inlet valve. Ensure that connections p_u and p_z on the CG are not reversed.

6

7

8

9

10

11

Tighten the screws with max. 250 Ncm.

3.3 Mounting TC 2

1 Disconnect the system from the electrical power supply.

2 Close the gas supply.

3

4

5

The O-rings must be inserted in the connectors of the TC.

Connect the TC to the inlet pressure connection p_u and the interspace pressure connection p_z of the inlet valve.

Use the adapter plate supplied for installation.

We recommend using Ermeto screw couplings to attach the adapter plate to the gas solenoid valve. It may be necessary to compensate the distance to the valve housing.

Only use approved sealing material to seal the pipe connections.

6

7

8

9 Connect the interspace pressure connection p_z on the adapter plate to the space between the valves using a 12 x 1.5 or 8 x 1 pipe.

Ensure that connections p_u and p_z on the TC and adapter plate are not reversed.

10

11

12

3.4 Mounting TC 3

Connect the TC to the inlet pressure connection p_u, the interspace pressure connection p_z and the outlet pressure connection p_d of the inlet valve. Ensure that connections p_u, p_z and p_d on the TC are not reversed.

Use a 12 x 1.5 or 8 x 1 pipe for the pipe connections.

7.1 Determining the measurement time

If a leakage rate is specified, find the measurement time t_M from the following:
Q_max. = max. flow rate [m³/h]
Q_L = Q_max. [m³/h] x 0.1% = leakage rate [l/h]
p_u = inlet pressure [mbar]
V_P = test volume [l]

For all CG versions, measurement time t_M must be set to 5 s on TC 1C.

7.2 Determining the test volume

Test volume V_P is calculated from the valve volume V_V, added to the volume of the pipe V_R for each additional metre in length L.

7.3 Determining the leakage rate

If no leakage rate Q_L is specified, we recommend the max. possible test period/measurement time is set.

It is possible to check a specific leakage rate Q_L using the TC. Within the European Union, the maximum leakage rate Q_L is 0.1% of the maximum flow rate Q_{(n) max.} [m³/h].

If a low leakage rate Q_L is to be detected, a long test period/measurement time must be set.

7.4 Calculation of the measurement time

A web app for calculating the measurement time t_M is available at www.adlatus.org.

Calculation example:
Q_max. = 100 m³/h
p_u = 100 mbar
V_P = V_V + L x V_R = 7 l
Q_L = (100 m³/h x 1000)/1000 = 100,000 l/h /1000 = 100 l/h

(2.5 x 100 x 7)/100 = 17.5 s
Set the next highest value (in this example 20 s).

7.5 Setting the measurement time on the device

To set the calculated measurement time, the jumper in the device must be reconnected as described below.

1 Disconnect the system from the electrical power supply.

2 Unscrew the housing cover.

3 Set the jumper to the position for the required measurement time (calculation example = 20 s).

4 Position the housing cover and screw tight.

5 Mark the set measurement time t_M on the type label with a waterproof pen.

6 Switch on the power supply.

The operating signal LED flashes yellow (0.2 s on/off). After 10 s, the TC accepts the new setting and the LED is yellow or green, see table, Indicators and operating controls.

7.6 Calculating the entire test period

The entire test period t_P is made up of the measurement times t_M of both valves and the fixed opening time t_L of both valves together.

8.1 Indicators and operating controls

LED	Meaning
Power	Power supply
	Operating signal
	Valve 1
	Valve 2
	Reset button

The LEDs can display messages using three colours (green, yellow, red) and permanent or flashing light :

LED			Message/Operating status
Power		Green	Power supply OK
		Yellow	TC is ready for operation; safety interlock* input signal interrupted
		Green	TC is ready for operation; active safety interlock* input signal
		Green	V1 is tight
		Yellow	V1 is untested
		Yellow	Tightness test is running on V1
		Red	V1 is leaking
		Green	V2 is tight
		Yellow	V2 is untested
		Yellow	Tightness test is running on V2
		Red	V2 is leaking
All		Yellow	Initialization

* Safety interlock = linking of all the relevant safety-related control and switching equipment for the use of the application. The burner start enable signal is issued via the safety interlock output (terminal 6).

For other messages, see TC 1–3 operating instructions, Assistance in the event of malfunction.

8.2 Switching on the mains voltage

All the LEDs will be lit in yellow for 1 s when the mains voltage has been switched on. The TC is in the initialization phase.

The test starts according to the test instant (Mode) which has been set.

8.3 During the test

Mode 1 or Mode 3, test before burner start-up:
Voltage at terminal 10 (thermostat/start-up signal ).
Or
Mode 2, test after burner run:
The TC shows the last operating status. In the case of untested valves, the and LEDs are yellow. There is mains voltage at terminal 1 and renewed test after switching off the voltage to terminal 10 (thermostat/start-up signal ).

During the test, the and LEDs will flash yellow.

8.4 After the test

The and LEDs are green:
Both valves are tight.
Mode 1 or Mode 3: the enable signal is issued via terminal 6 when voltage is applied to terminal 5.
Or
Mode 2: the enable signal is issued via terminal 6 when voltage is applied to terminals 10 and 5.

The or LED is red:
A valve is leaking.
Voltage at terminal 12. A fault signal is output.

8.5 Power failure

If the power fails briefly during the test or during operation, the tightness test will restart in accordance with the test procedure described.

If there is a fault message, the fault is displayed again after a power failure.

9.1 Power LED is permanently red.

! There is over-/undervoltage. The TC performs a safety shut-down.

• Check the mains voltage. As soon as there is no longer over-/undervoltage, the TC returns to normal operating mode and the Power LED is green. It is not necessary to reset the device.

9.2 Operating signal LED is permanently yellow.

! Safety interlock input signal is interrupted, no voltage at terminal 5. The tightness test is still being carried out. No enable signal is issued to the automatic burner control unit.

• Check safety interlocks.

! Fuse F2 defective.

• Replace F2, see Replacing the fuse.

9.3 LED flashes yellow.

! Permanent remote reset. The remote reset signal has been active for more than 10 s.

• The warning signal is cancelled once the remote reset signal to terminal 11 has been removed.

9.4 Operating signal LED is permanently red.

! Incorrect jumper/DIP switch setting.

• Correct jumper and DIP switch setting, see Setting the measurement time and Setting the test instant. Then press the reset button.

! Internal error.

• Remove the unit and return it to the manufacturer for inspection.

9.5 Operating signal LED flashes red.

! Too frequent burner start commands. The TC performs a fault lock-out. The start commands are limited to 5 x in 15 minutes.

As long as this limit is not exceeded, another start-up attempt is possible after three further minutes. If a tightness test is completed, the counter which limits the number of start commands is reset.

• Then press the reset button.

! Too many remote resets. More than 5 resets have been conducted within the last 15 minutes, either automatically or manually.

! Consecutive fault caused by a previous fault whose actual cause has not been remedied.

• Pay attention to previous fault messages.

• Remedy cause. Then press the reset button.

9.6 or LED is permanently red.

! The valve is leaking. The TC performs a fault lock-out.

• Replace the valve.

! Wiring of the TC to the valves is faulty.

• Start the program and observe the interspace pressure p_z. The pressure must change during the TEST phase. Check the wiring.

! Inlet pressure p_u < 10 mbar.

• Provide the min. inlet pressure of 10 mbar.

! Interspace pressure p_z cannot be reduced.

! The volume downstream of the valve on the burner side must be 5 times higher than the volume between the valves and atmospheric pressure must prevail.

! The measurement time t_M is too long.

! Adjust t_M, see Setting the measurement time.

9.7 and LEDs are permanently red.

! During the tightness test, the TC has determined that inlet valve 1 and outlet valve 2 have been reversed (fault lock-out).

• Check the wiring. Then press the reset button.

9.8 No LED lit even though mains voltage applied.

! Fuse F1 defective.

• Replace F1, see Replacing the fuse.

11.1 Ambient conditions

Icing, condensation and dew in and on the unit are not permitted.

Avoid direct sunlight or radiation from red-hot surfaces on the unit. Note the maximum medium and ambient temperatures!

Avoid corrosive influences, e.g. salty ambient air or SO₂.

The unit may only be stored/installed in enclosed rooms/buildings.

The unit is suitable for a maximum installation height of 2000 m AMSL.

Ambient temperature: -20 to +60°C (-4 to +140°F), no condensation permitted.
Long-term use in the upper ambient temperature range accelerates the ageing of the elastomer materials and reduces the service life (please contact manufacturer).

Storage temperature = transport temperature: -20 to +40°C (-4 to +104°F).

Enclosure: IP 65.

This unit is not suitable for cleaning with a high-pressure cleaner and/or cleaning products.

Gas types: natural gas, LPG (gaseous), biogas (max. 0.1 %-by-vol. H₂S) or clean air. The gas must be clean and dry in all temperature conditions and must not contain condensate.

Medium temperature = ambient temperature.

Inlet pressure p_u: 10 to 500 mbar (3.9 to 195 "WC).

Measurement time t_M: 5 to 30 s, adjustable. Set at the factory to 30 s.

Valve opening time: 3 s.

Housing made of impact-resistant plastic.

Connectors: aluminium.

Weight:
TC 1V: 215 g (0.47 lbs),
TC 2 with adapter: 260 g (0.57 lbs),
TC 3: 420 g (0.92 lbs).

Mains voltage and control voltage:
120 V AC, -15/+10%, 50/60 Hz,
230 V AC, -15/+10%, 50/60 Hz,
24 V DC, ±20%.

Power consumption (all LEDs green):
5.5 W at 120 V AC and 230 V AC,
2 W at 24 V DC,
TC 3: plus 8 VA for an auxiliary valve.

Fine-wire fuse:
5 A, slow-acting, H, 250 V, pursuant to IEC 60127-2/5,
F1: protection of valve outputs (terminals 15 and 16), fault signal (terminal 12) and supply of the control inputs (terminals 2, 7 and 8).
F2: protection of safety interlock/controller enable signal (terminal 6).

The input current at terminal 1 must not exceed 5 A.

Max. load current (terminal 6) for safety interlock/controller enable and valve outputs (terminals 15 and 16):
at 230/120 V AC mains voltage, max. 3 A resistive load;
at 24 V DC mains voltage, max. 5 A resistive load.

Fault signal (terminal 12):
Fault output at 120 V AC/230 V AC/24 V DC mains and control voltage:
max. 5 A.

TC switching cycles:
250,000 pursuant to EN 13611.

Reset: using a button on the device or by remote reset.

Length of connection cable:
at 230 V AC/120 V AC: any, at 24 V DC (supply connected to PE): max. 10 m permitted,
at 24 V DC (supply not connected to PE): any.

5 cable glands:
M16 x 1.5.

Electrical connection:
Cable cross-section: min. 0.75 mm² (AWG 19), max. 2.5 mm² (AWG 14).

14.1 Certificate download

Certificates – see www.docuthek.com

14.2 Declaration of conformity

We, the manufacturer, hereby declare that the product TC 1–3 with product ID No. CE-0063DN1848 complies with the requirements of the listed Directives and Standards.

Directives:

• 2014/35/EU – LVD
• 2014/30/EU – EMC
• 2011/65/EU – RoHS II
• 2015/863/EU – RoHS III

Regulation:

• (EU) 2016/426 – GAR

Standards:

• EN 1643:2014
• EN 60730-2-5:2015
• EN 61508:2010, Parts 1–7
• SIL 3 according to EN 61508

The relevant product corresponds to the tested type sample.

The production is subject to the surveillance procedure pursuant to Regulation (EU) 2016/426 Annex III paragraph 3.

Elster GmbH

14.3 SIL

Safety-specific characteristic values, see Safety manual/Technical Information TC (D, GB, F) – www.docuthek.com.

14.4 AGA approved

Australian Gas Association, Approval No.: 8618.

14.5 Eurasian Customs Union

The products TC 1, TC 2, TC 3 meet the technical specifications of the Eurasian Customs Union.

14.6 REACH Regulation

The device contains substances of very high concern which are listed in the Candidate List of the European REACH Regulation No. 1907/2006. See Reach list HTS at www.docuthek.com.

14.7 China RoHS

Directive on the restriction of the use of hazardous substances (RoHS) in China. Scan of the Disclosure Table China RoHS2, see certificates at www.docuthek.com.