Safety

Translation from the German © 2021 Elster GmbH · Edition 04.21 34429500
D GB F NL I E DK S N P GR Please read and keep in a safe place
TR CZ PL RUS H ➔ www.docuthek.com
Please read through these instructions
Operating instructions carefully before installing or operating. Following the
Tightness control TC 410 installation, pass the instructions on to the opera-
tor. 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.
Explanation of symbols
• ,  ,  ,  ... = Action
▷ = Instruction

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Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
DANGER
Contents Indicates potentially fatal situations.
Tightness control TC 410 . . . . . . . . . . . . . . . . . 1 WARNING
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Indicates possible danger to life and limb.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Checking the usage . . . . . . . . . . . . . . . . . . . . 2 CAUTION
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Indicates possible material damage.
Part designations . . . . . . . . . . . . . . . . . . . . . . . . 2
All interventions may only be carried out by qualified
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 gas technicians. Electrical interventions may only be
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 carried out by qualified electricians.
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conversion, spare parts
Setting the test instant . . . . . . . . . . . . . . . . . . 3 All technical changes are prohibited. Only use OEM
Setting the test period tP . . . . . . . . . . . . . . . . 3 spare parts.
Values for valve and pipe volume . . . . . . . . . . . . 3
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assistance in the event of malfunction . . . . . . 4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 5
Designed lifetime . . . . . . . . . . . . . . . . . . . . . . . . . 5
Logistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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 Checking the usage Installation
TC 410 for tightness test before every controlled start-
up or after every controlled shut-down in systems CAUTION
with 2 safety valves. Tightness control TC 410 can Please observe the following to ensure that the TC
be used for individual valves, quick opening or slow is not damaged during installation:
opening with start gas rate. The valves are controlled – Avoid condensation.
directly for testing by the TC 410. A pressure switch – Gas type and inlet pressure pu: dependent on
for gas must be mounted on the interspace between external pressure switch.
the valves to be monitored for the tightness test. ▷▷ Any installation position.
This function is only guaranteed when used within the ▷▷ The device must not be in contact with masonry.
specified limits – see page 5 (Technical data). Any Minimum clearance 20 mm (0.78").
other use is considered as non-compliant. ▷▷ In the case of very large test volumes VP, an
Type code installed relief line should be of nominal size 40
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to allow for the discharge of the test volume VP.

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Code Description
TC Tightness control 1 Disconnect the system from the electrical power
4 In control cabinet supply.
1 Testing before or after burner run 2 Shut off the gas supply.
0 External pressure switch required
T T-product 3 4 5
-1 Test period: 10 to 60 s
-10 Test period: 100 to 600 s
K Mains voltage: 24 V DC 3 4
TEST
OK
1
2

5
N 110/120 V AC, 50/60 Hz
T 220/240 V AC, 50/60 Hz
Part designations ▷6▷ Snap the lower6section onto6a") 35 mm U-shaped
.7
2

70 (2the lower section with

1
OK
TEST

mounting rail or2screw 3") on

1 1 (0.8
two screws Ø 5 mm.
37,5 (1.48")

6 6 ø 5 (ø 0.2")
2 .76")
1 70 (2
2 .83")
1 21 (0
37,5 (1.48")

2
1

ø 5 (ø 0.2")
OK
TEST

2
7 Mount the pressure switch on the interspace
of the valves to be monitored – see operating
1 Upper housing section instructions for pressure switch.
2 Lower housing section
Type label
▷▷ Test period and gas type, mains voltage, power
consumption, ambient temperature, enclosure,
1 2
switching current
TEST and
OK maximum inlet pressure –
see type label.
pu pz pd
D-49018 Osnabrück, Germany
TC 410 ▷▷ On VG 15 – 40/32, the test point is connected
Imax 5A to the valve inlet.
IP40
V1 V2

pu pz

8 Set the pressure switch to half the inlet pres-

sure pu/2.

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 V1 V2 ϑ max
L1(+)
▷▷ The switching differential of the pressure switch N N(-)
may not exceed ±10% of the set value.
Example: : "TEST " :" TEST"
inlet pressure pu = 100 mbar, 1 2 1 2

set switching pressure pu/2 = 50 mbar,

max. switching differential 50 mbar x 10% =
5 mbar.
The switch-on and switch-off pressure must be
between 45 mbar and 55 mbar.
Setting the test period tP
Wiring
▷▷ The test period tP is set at the works to 10 s
CAUTION (100 s) on TC 410-1 (TC 410-10) and can be
changed with a jumper in increments of 10 s

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Electric shocks can be fatal!

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(100 s) to a max. of 60 s (600 s).
– Before working on possible live components,
▷▷ Without jumper = 60 s (600 s).
ensure the unit is disconnected from the power
▷▷ The longer the test period tP, the smaller the leak-
supply.
age rate at which a safety shut-down is triggered.
Please observe the following to ensure that the TC
▷▷ If no leakage rate is specified, we recommend
is not damaged during installation:
the max. test period is set.
– Incorrect wiring may result in unsafe states and
▷▷ If a leakage rate is specified, find the test pe-
the destruction of the tightness control, the au-
riod tP from the following:
tomatic burner control unit or the valves.
Qmax. = max. flow rate [m3/h]
– Do not reverse L1 (+) and N (–).
QL = Qmax. [m3/h] x 0.1% = leakage rate [l/h]
1 Disconnect the system from the electrical power pu = inlet pressure [mbar]
supply. VP = test volume [l], see page  3 (Values for
2 Shut off the gas supply. valve and pipe volume)
3 Open the housing cover of the TC. ▷▷ The tightness control TC requires a minimum
▷▷ Electrical connection: 2.5 mm2 terminals. start rate in order to carry out tightness tests
▷▷ The data on the type label must comply with the on slow opening valves:
mains voltage. up to 5 l (1.3 gal) test volume VP = 5% of maxi-
4 Prepare knock-out holes at the appropriate cable mum flow rate Qmax.,
glands. up to 12 l (3.12 gal) test volume VP = 10% of
▷▷ Use the NO contacts 3 COM and 2 NO on the maximum flow rate Qmax..
pressure switch (pe/2 = pu/2). 1 Determine test period tP.
5 Electrically wire TC 410.

1 2 3 4 5 6 7 8 9 10 11 12 13
tP [s] = 4 x ( pu [mbar] x VP [l]
QL [l/h]
+1s )
max. 1 A, L1(+)V1 Values for valve and pipe volume
OK pe/2 264 V L1(+)V2
ϑ V1 V2 ϑ max VP V2
L1(+)
N N(-)
V1

Setting the test instant

▷▷ The test instant (MODE) can be set inside the L VP = VV + L x VR
housing using a jumper. Valve Nominal Pipe
▷▷ Mode 1: test before burner start-up with incom- Valves volume size volume
ing ϑ signal (factory setting). VV [l] DN VR [l/m]
▷▷ Mode 2: test after burner run with outgoing ϑ sig- VG 10 0.01 10 0.1
nal and also after switching on the mains voltage. VG 15 0.07 15 0.2
▷▷ Without jumper = test before burner start-up. VG 20 0.12 20 0.3
1 Disconnect the unit from the electrical power VG 25 0.2 25 0.5
supply. VG 40/VK 40 0.7 40 1.3
VG 50/VK 50 1.2 50 2
2 Unscrew the housing cover. VG 65/VK 65 2 65 3.3
3 Set the test instant with a jumper, MODE 1 or 2. VG 80/VK 80 4 80 5
VG 100/VK 100 8.3 100 7.9

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 Valve Nominal Pipe Commissioning
Valves volume size volume
VV [l] DN VR [l/m] ▷▷ Indicators and operating controls:
VK 125 13.6 125 12.3
VK 150 20 150 17.7
VK 200 42 200 31.4
1 2
VK 250 66 250 49 TEST OK
VAS 1 0.08
VAS 2 0.32 TEST = TEST phase (yellow)
VAS 3 0.68 OK = operating signal (green)
VAS 6 1.37 1 = fault valve 1 (red)
VAS 7 2.04 2 = fault valve 2 (red)
VAS 8 3.34 = reset button
VAS 9 5.41 1 Main switch on.
VCS 1 0.05
2 Apply mains voltage to terminal 1.
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VCS 2 0.18
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VCS 3 0.39 ▷▷ If one or both fault lamps (red) are lit, wait ap-
VCS 6 1.11 prox. 5 s then press the reset button. The fault
VCS 7 1.40 signal goes out.
VCS 8 2.82 3 Start the tightness test.
VCS 9 4.34 ▷▷ Mode 1, test before burner start-up.
Calculation example: 4 Voltage at terminal 3.
Qmax. = 100 m3/h Or
pu = 100 mbar ▷▷ Mode 2, test after burner run.
VP = VV + L x VR = 7 l 5 Mains voltage at terminal 1 and renewed test
QL = 100 m3/h x 0.1% = 100 l/h after switching off the voltage to terminal 3.

4x (
100
100 x 7
 
+ 1 s = 32 s )
Set the next highest value (in this example 40 s)
The test begins:
▷▷ LED TEST is lit.
After test, if the valves are tight:
▷▷ LED OK is lit.
with the jumper.
MODE 1: voltage at terminal 4.
Or
2 Disconnect the unit from the electrical power
MODE 2: voltage at terminal 4 does not arrive
supply.
until voltage is applied to terminal 3.
3 Unscrew the housing cover.
After test, if the valves are leaking: voltage at termi-
4 Connect the jumper to the pin for the required
nals 8 and 9.
test period tP between 10 ϑand 60 s (100 and
V1 V2 max ▷▷ LED 1 is lit.
600 s). L1(+) Or
N N(-) ▷▷ LED 2 is lit.
: "TEST " :" TEST" Power failure
1 2 1 2 ▷▷ If the power fails briefly during the test or during
operation, the tightness test will restart auto-
D-49018 Osnabrück, Germany
matically.
▷▷ After a power failure during a fault, both red fault
TC lamps will be lit.
5 Position the housing cover and screw tight.
CE-0085AP0020
6 Mark the set test period tP on the type label with
Assistance in the event of
a waterproof pen.
malfunction

tp(s) 10 20 30 40 50 60 CAUTION
Electric shocks can be fatal!
– Before working on possible live components, en-
sure the unit is disconnected from the power supply.
– Fault-clearance must only be undertaken by
authorized trained personnel.
– (Remote) resets may only be conducted by
authorized personnel.
▷▷ Faults may be cleared only using the measures
described below.

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▷▷ Press the reset button, see page  4 (Com- Maintenance
missioning).
▷▷ If the tightness control will not start even though Tightness controls TC require little servicing. We rec-
all faults have been remedied, remove the unit ommend a function check once a year.
and send it to the manufacturer for inspection.
Technical data
? Fault
Mains voltage:
! Cause
110/120 V AC, -15/+10%, 50/60 Hz,
• Remedy
220/240 V AC, -15/+10%, 50/60 Hz,
24 V DC, ±20%.
? No LED is lit although mains voltage and
Power consumption:
ϑ signal are applied?
10 VA for 110/120 V AC and 220/240 V AC,
! Fuse defective.
1.2 W for 24 V DC.
• Replace 5 A slow-acting fine-wire fuse – after

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Ambient temperature: -15 to +60°C (5 to 140°F),

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replacing the fuse, start the tightness test several
no condensation permitted.
times and check the program sequence and the
Storage temperature: -15 to +40°C (5 to 104°F).
outputs of the tightness control.
Screw terminals 2.5 mm2.
• If it does not operate correctly, return the unit to
Fusing: fine-wire fuse 5 A, slow-acting, H pursuant
the manufacturer.
to IEC 127, also protects the valve outputs and
! Mode 1: test before burner start-up is set; L1
external operating signal.
and N are reversed on terminals 1 and 2.
Switching current for valves/enable output:
• Connect L1 to terminal 1 and N to terminal 2.
max. 5 A.
! For 24 V DC: polarity of mains voltage on termi-
External operating signal: with mains voltage,
nals 1 and 2 reversed.
max. 5 A resistive load (UL listed: 5 A for 120 V),
• Connect + to terminal 1 and – to terminal 2.
max. 2 A at cos ϕ = 0.35 (pilot duty).
! Mains voltage too low.
Fault output: dry contact (not internally fused),
• Compare to details on the type label. Tolerance:
max. 1 A for 220/240 V, max. 2 A for 120 V.
-15/+10% for 110/120 V AC and 220/240 V AC,
Reset: using a button on the device.
±20% for 24 V DC.
Remote reset: by applying mains voltage
? TC repeatedly signals a fault?
­(terminal 5).
! A valve is leaking.
Housing made of impact-resistant plastic.
• Replace the valve.
Gas type and inlet pressure: dependent on exter-
! Pressure switch incorrectly set.
nal pressure switch.
• Set the pressure switch to half the inlet pressure.
Test period tP: TC 410-1: 10 to 60 s, adjustable.
! Wiring to the valves reversed.
Set at the factory to 10 s.
• Start the program and observe the interspace
TC 410-10: 100 to 600 s, adjustable. Set at the
pressure pz. The pressure must change during
factory to 100 s.
the TEST phase. Check the wiring.
Enclosure: IP 40.
! Inlet pressure pu < 10 mbar.
5 knock-out holes for M16 plastic cable glands.
• Provide the min. inlet pressure of 10 mbar.
Weight: approx. 400 g (0.88 lbs).
! Interspace pressure pz cannot be reduced.
• The volume downstream of the valve on the Designed lifetime
burner side must be 5 times higher than the Max. service life under operating conditions: 10 years
volume between the valves and atmospheric after date of production or 250,000 operating cycles
pressure must prevail. pursuant to EN 1643.
! The test period tP is too long.
• Adjust tP, see page  3 (Setting the test pe-
riod tP).
? The downstream automatic burner control
unit does not start?
! On the tightness control, L1 (+) and N (–) on
terminals 1 and 2 are reversed.
• Connect L1 (+) to terminal 1 and N (–) to termi-
nal 2.
? TEST phase running (yellow LED indicator is
lit) although no ϑ signal has been applied?
! Mode 2 set.
• Set jumper to Mode 1, see page  3 (Setting
the test instant).
GB-5
 Logistics Approval for Australia

Transport
Protect the unit from external forces (blows, shocks,
vibration). On receipt of the product, check that the
delivery is complete, see page  2 (Part designa- AGA
tions). Report any transport damage immediately. Australian Gas Association, Approval No.: 4581
Storage Eurasian Customs Union
Store the product in a dry and clean place.
Storage temperature: see page 5 (Technical data).
Storage time: 6 months in the original packaging
before using for the first time. If stored for longer than The products TC meet the technical specifications
this, the overall service life will be reduced by the of the Eurasian Customs Union.
corresponding amount of extra storage time.
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Directive on the restriction of the use of

hazardous substances (RoHS) in China
Certification Scan of the Disclosure Table China RoHS2 – see
Declaration of conformity certificates at www.docuthek.com
We, the manufacturer, hereby declare that the prod-
ucts TC comply with the requirements set out in Disposal
section 5.2.2.3.4 of EN 746-2. They achieve a safety Devices with electronic components:
level equivalent to EN 1643:2000. WEEE Directive 2012/19/EU – Waste Electrical
Elster GmbH and Electronic Equipment Directive
Scan of the Declaration of conformity (D, GB) – see At the end of the product life (number of operat-
www.docuthek.com ing cycles reached), dispose of the packaging and
product in a corresponding recycling centre. Do not
FM approved dispose of the unit with the usual domestic refuse. Do
not burn the product. On request, old units may be
returned carriage paid to the manufacturer in accord-
ance with the relevant waste legislation requirements.

Factory Mutual Research Class: 7400 and 7411

Safety overpressure slam shut valves. Designed for
applications pursuant to NFPA 85 and NFPA 86.
UL listed for 120 V

Underwriters Laboratories – UL 353 Limit control

Canadian Standards Association: CSA – C22.2 No. 24

Contact

If you have any technical questions, please contact

your local branch office/agent. The addresses are Elster GmbH
available on the Internet or from Elster GmbH. Strotheweg 1, D-49504 Lotte (Büren)
Tel. +49 541 1214-0
We reserve the right to make technical modifications Fax +49 541 1214-370
in the interests of progress. hts.lotte@honeywell.com, www.kromschroeder.com
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