Installation Manual TCS900041 Rev. 10

TCS 3000
Catalog Title
ELECTRONIC REGISTER
Catalog Subtitle
Installation Manual
Total Control Systems www.tcsmeters.com

TCS 3000 Installation
Table of Contents
Table of Contents 2 1-Stage Security Valve Installation 20
Receipt & Inspection 3 2-Stage Preset Valve Installation 21
Notice 3 Temperature Probe Installation 22
Introduction 4 Temperature Probe Installation Kits 23
System Specifications 4 Daisy Chain Communication 24
Dimensions 5 Printer Installation 25
682 Piston Meter Installation 6 Printer Installation Kits 26
700 Rotary Meter Installation 7 Printer Installation Kits (Continued) 27
Remote Meter Installation 8 Printer Installation Kits (Continued) 28
Remote Meter Mounting Dimensions 9 Power Off Time Relay installation 29
Grounding Strap Installation 10 Radio Modem Installation 30
Power On Time Relay Installation 11 Sierra Cellular Modem Installation 31
Direct Mount Pulser Installation 12 Maestro Cellular Modem Installation 32
Test Pulser Installation 13 Remote Display Installation 33
Pump Control Installation 14 1-Channel Communication Board Installation 34
Pump Speed Control Installation 14 1-Channel Differential Pressure (DP) Installation 35
Additive Injection Pump Installation 15 1-Channel Tank Level Monitor Installation 36
Electronic Air Eliminator — Float 16 8-Channel Tank Level & DP Installation 37
Electronic Air Eliminator — Vibronic 17 Typical Wiring Diagram 38
LPG 1-Stage Security Valve Installation 18 Software Version Upgrade Instructions 39
LPG 2-Stage Preset Valve Installation 19 Replacement Front Cover Computer Instructions 40
Parts Schematic 41
Warning Symbols Warranty 42
CAUTION EYE PROTECTION

Follow the warning instructions within Pressurized systems may cause hazardous leaks
the following information to avoid and spray that may be dangerous for your eyes.
equipment failure, personal injury or Always wear eye protection around pressurized
death. systems and its hazardous liquids.
TURN POWER OFF INJURY

Before performing any maintenance, Wear gloves for protection from hazardous liq-
be sure to turn system power off to uids that may cause irritation or burns.
avoid any potential electric spark
READ
FLAMMABLE Read and understand all related manuals thor-
Flammable liquids and their vapors oughly. The Engineering and OIM manuals will
may cause a fire or explosion if ignited. provide the knowledge for all systems, mainte-
nance and operation procedures. If you have
any questions, please consult the factory.
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 UL/cUL
CLASS 1, DIVISION 2, GROUPS C AND D HAZARDOUS LOCATIONS.
Total Control Systems 2 www.tcsmeters.com

Receipt & Inspection
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. Notify the delivery company about possible damage and refuse receipt of the ship-
ment.
Registers are individually boxed and are protected with static resistant packing material. Each package is identified
with the register assembly part number, description and serial number. Verify the register model is the correct model,
size, and configuration as ordered. Contact your distributor if there is any discrepancy or question.
Register assemblies should be handled with appropriate methods for the size and weight involved. Appropriate cloth-
ing and shoes need to be utilized. Transport the register package to the installation site with appropriate transporta-
tion 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 potentially cause
injury.
If foam has been used to protect register, carefully remove top foam layer before attempting to remove register as-
sembly from box. Foam packaging maybe formed around the register assembly making it difficult to remove. Do not
lift 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 to these warnings may
cause serious injury to you and/or the register.
Appropriate precautions should be taken regarding any personal, environmental and material compatibility with the
end use system.
Notice
Total Control Systems (TCS) shall not be liable for technical or editorial errors in this manual or omissions from this
manual. TCS makes no warranties, express or implied, including the implied warranties of merchantability and fitness
for a particular purpose with respect to this manual and, in no event, shall TCS be liable for special or consequential
damages including, but not limited to, loss of production, loss of profits, etc.
The contents of this publication are presented for informational purposes only, and while every effort has been made
to ensure their accuracy, they are not to be construed as warranties 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 specifications of such products at any time.
TCS does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper se-
lection, 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 first receiving the written permission of Total Control Systems, Fort Wayne, Indiana
USA.

Introduction
The TCS 3000 register is a fully integrated custody transfer flow computer that will control all vehicle delivery opera-
tions. The Open Software Architecture provides the option of a simple “Pump & Print” delivery or a custom measure-
ment solution. The TCS 3000 features a 4.5”x 3.5” full color VGA display screen, multiple delivery screens and a backlit
alpha-numeric keypad for the user interface. Available in flexible mounting configurations of 75 or 90 degree displays
for meter mounting, and a remote mounting.
As an flow computer with open software architecture, there will always be a need to add features to the register as the
industry applications evolve. Therefore please be reminded to contact the factory for periodic updates.
The TCS 3000 electronic register is a fully integrated flow computer that will control all delivery operations. The modu-
lar design and open software 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. Software features offer complete flexibility of delivery screen information with preset, price/tax,
customizable ticket format and password protection.
Optional 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 operation costs. Many additional features are available (multiple product
delivery, additive injection, density/temperature correction, multiple valve & pump control, etc.) to enhance your
measurement solution.
This manual will help guide you with the setup confirmation and calibration of the register. Additional information will
be provided for wiring instruction and auxiliary devices to integrate into the register.
System Specifications
ELECTRICAL
Power 12 — 24 VDC INPUT
Current 1.4 Amps
Solid State Relays 12/24 Vdc; Passive Solid State
INTERNAL PULSER
Pulse Ratio 100:1 PPR; Quadrature
Power 5 Vdc
Hertz 0 — 5000 Hz
EXTERNAL PULSE INPUT

Type Single or Dual Channel (Quadrature)
Power 5 Vdc—Option for 12-24 VDC
ENCLOSURE
Aluminum die cast with epoxy powder coat
Ratings UL/cUL Class 1, Division 2, Group C + D Hazardous Locations
IP 66 / NEMA 4
Temperature Range - 40 F to 158 F (-40 C to 70 C)
Connection Ports: Ten (10) 1/2” NPT UL/cUL threaded connection ports
Optional ten (10) M20 ATEX threaded connection ports
Calibration Seal Optical switch, password and mechanical seal

The USB0 and USB1 ports are for maintenance only. To access these connectors, power to the unit must be
disconnected and the area known to be free of ignitable gas or equivalent.
COMMUNICATION
Three (3) RS 485 output, 2-wire half duplex, custom protocol; 9600 baud, 8 bit, no parity, 1 stop bit
Two (2) RS 232 output, 9600 baud; 8 bit, no parity, 1 stop bit
DIMENSIONS — INCHES (MILLIMETERS)

Installation Procedure — TCS 682 Series Meter
Before beginning the installation of the TCS 3000 register, unpack the entire contents of the packaging in a safe loca-
tion where you will not misplace any of the parts. Lay out the parts as they would be installed. This will ensure that
you have all the correct parts for the installation. Verifying all the necessary parts were included in the shipment in
advance will reduce downtime and avoid any wasted preparation work.
Item Qty TCS 300871 TCS 300971

Metric NPT
Phillips Pan 6 TCS300137 TCS300137
Cotter Pin
Spring Washer 6 TCS300138 TCS300138
682 Drive Coupling
Terminal Cover 1 TCS300164 TCS300164

7.5 AMP Fuse 1 TCS300192 TCS300192
Fuse Holder 1 TCS300193 TCS300193
Cable Gland 4 TCS300249 TCS300133
Resistor 1K OHM 2 TCS300753 TCS300753
1/4—28 X 3/4 Zinc Bolt 2 TCS68004 TCS68004
1/4—28 X 3/4 Drilled Bolt 2 TCS68004D TCS68004D
Drive Coupling, 682 1 TCS600420 TCS600420
3/64 X 1 Cotter Pin 1 TCS790091 TCS790091
Installation Procedure:
1. Remove and put aside the four mounting bolts and any mounting adaptor. Remove the existing mechanical regis-
ter or electronic register, if applicable. Use a box or container to set old equipment and parts in.
2. Using the shaft specific to your installation, slide the Drive Shaft Coupling on the Pulser Shaft and align the holes.
Once the holes are aligned insert the Cotter Pin and bend the pin ends back around the Drive Coupling.
3. Slide the Drive Coupling onto the Meter Drive Shaft.
4. Rotate the TCS 3000 register until the display is facing in the desired direction and check to see that the meter
holes align with the holes at the base of the TCS 3000 register.
5. Secure the bolts.

Installation Procedure — TCS 700 Series Meter
tion 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 installation. Verifying all the necessary parts were included in the
shipment in advance will reduce the truck downtime and avoid any wasted truck preparation work.

Metric NPT

7.5 AMP Fuse 1 TCS300192 TCS300192
700 Drive Coupling Cotter Pin Cable Gland 4 TCS300244 TCS300133
O-Ring, Cable Gland 4 TCS300245 TCS300245
700 Drive Shaft 1/4—28X1 Zinc Bolt 2 TCS68013 TCS68013

1/4-28X1 Drilled Bolt 2 TCS68013D TCS68013D
3/64 X 1 Cotter Pin 1 TCS790091 TCS790091
700 Meter Drive Coupling 1 TCS790092 TCS790092
1. Remove and put aside the four mounting bolts and any mounting adaptor. Remove the existing 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 existing adjuster. Set adjuster dust cover
aside in a box or container where it will not be misplaced. Screw the screws back into meter unit. Notice the type
of vertical drive shaft in the meter.
3. Using the shaft specific to your installation, slide the Drive Coupling on the Pulser and align the holes. Once the
holes are aligned insert the Cotter Pin and bend the pin ends back around the Drive Coupling.
4. Slide the Drive Coupling onto the Meter Drive Shaft.
5. Rotate the TCS 3000 register until the display is facing in the desired direction and check to see that the meter
holes align with the holes at the base of the TCS 3000 register.
6. Secure the bolts.

Installation Procedure — 3000 Remote Mount
tion where you will not misplace any of the parts. Lay out the parts as they would be installed. This will ensure that
you have all the correct parts for the installation. Verifying all the necessary parts were included in the shipment in
advance will reduce downtime and avoid any wasted preparation work.
TCS 300877 TCS 300977

Item Qty
Metric NPT
7.5 AMP Fuse 1 TCS300192 TCS300192
Cable Gland 4 TCS300249 TCS300133
O-Ring, Cable Gland 4 TCS300245 TCS300245
Fuse
Fuse Holder
Resistors
Cable Glands
1. Use the Remove Mount Kit to mount the TCS3000 register in your desired location.
2. Follow the directions in the Direct Mount Pulser Manual (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 register.
4. Insert the pulser wiring through the cable gland. Wire the pulser into the correct pulser location on the terminal
board. Leave a small amount of slack on the wiring. Be careful not to leave any bare exposed wiring.
5. Compress the cable gland on the TCS3000 register until it is snug on the pulser wire.

Installation Procedure — 3000 Remote Mount
Dimensions—Inches (Millimeters)

Installation Procedure — Grounding Strap
#8 Grounding Strap
Zip Ties
1/4” Hardware
TCS 300597, Grounding Strap Kit
GROUNDING A TRUCK SEAT:
Mount ground strap using sup-
1. Identify any adjustable, shock absorbing seat in the truck cab. plied hardware or an existing
These seats will typically have pivot points, hinges, or other me- bolt. Do not use this ground
point if the seat cushion has a
chanical design features that make seat adjustments possible.
front pivot.
2. Find an existing screw or hole near the back of the seat frame,
close to the cab floor. If a hole or screw does not already exist,
drill a 3/8” hole in the seat frame. Mount ground strap using sup-
plied hardware or an existing
3. Attach one end of the ground strap to the seat frame bracket bolt.
using the lock washer, flat washer and nut provided.
4. Find and existing hole in the part of the seat frame attached to Bundle excess ground wire using
the seat cushion above any pivots and adjustments. If a hole or a wire tie.
screw does not already exist, drill a 3/8” hole in the seat frame. Checking for good ground connection along the ground strap:
Make sure that there are no interfering pivots, guides, or adjust-
1. Turn OFF all accessories, including the dome light, to prevent
ment mechanisms that could interfere with the ground path
other currents from distorting the reading.
between the seat cushion and the ground strap. If the seat cush-
ion has a wooden base, attach the strap lug to an existing screw 2. Take a multimeter and measure the resistance between the
from the metal bracket directly attached to the wood seat where brackets the ground strap bolts are fastened to.
the seat fabric is attached to the wood. There must be good
3. If the resistance is less than 3Ω, the system is grounded ade-
contact between the seat fabric and the ground strap lug.
quately. If the resistance is still greater than 3Ω, check for
5. Use the wire ties provided with the kit and tie off the strap so proper metal to metal contact on both ends of the grounding
that it doesn't interfere with the movement of the seat and is strap. Clean any paint, dirt, or oxidation that may block the
clear of traffic areas in the cab. grounding point. If the resistance remains above 3Ω, attach
the ground strap to a different point and repeat the process
6. Check the strap for a good ground connection. (see right)
until resistance is below 3Ω.

Installation Procedure — Time On Relay
Power On Timing Relay

When installing the TCS 3000 register on delivery tank trucks, it is recommended to use a timing relay for safe startup of the TCS
3000 registration. Install the TCS 300289 Power On Time Relay from the Accessory Ignition (ACC) to the TCS 3000 register for a
selectable time (Seconds) open of power. This will allow the clean power to the TCS 3000 register during its boot up cycle and limit
exposure to any significant current draw from charging glow plugs or a low power battery startup.
TIME ADJUSTMENT
1) Wire GND to the Negative side of the Battery. NOTE: a minimum of a 18 gauge wire should be used.
2) Wire ACC (+) and (C) ACC Positive (on the relay), then jumper ACC Positive to the truck ACC (Ignition).
3) Wire N.O. to the (Positive) side of the Terminal Board in the TCS 3000 register.
4) Adjust the Time interval with a small Philips screw driver. Recommended minimum value is 45 seconds.
NOTE: If your wiring a Printer, it should be wired to the N.O. also. This will allow the printer to power up at the same time.

Installation Procedure — Direct Mount Pulser

Installation Procedure — Test Pulser
Prior to putting the liquid handling system into service, the distributor can utilize the TCS 3000 register TEST PULSER to verify that
all Inputs/Outputs are working correctly. The Test Pulser will simulate an actual product delivery without having to pump product
through the meter. Utilize the Test Pulser to check pump and additive injection pump outputs, air eliminator and exhaust valve
operation, preset solenoid actuation, daisy chain communication for the modem and printers. In order for the Test Pulser to work
properly you will need to make sure the Pulser Switch is in the OFF position.
TST1K — TAHA1
TST2K — TAHB1

Installation Procedure — Pump & Throttle
The Pump Control is utilized as a positive output signal for the entire delivery pro-
cess. Providing security pump authorization and more accurate deliveries. Some-
times required to be used with onboard computer systems or programmable logic RED
BLACK
controllers (PLC).
PUMP CONTROL
1. Locate the Pump Control (PMP. CTRL) position on the terminal
board.
2. Screw the cable gland into the back of the TCS 3000 register and
tighten into the housing.
3. Run the Pump Control to the onboard computer or programma-

ble logic controller (PLC) wiring through the cable gland. Wire the
air eliminator float into the correct location on the terminal
board. Leave a small amount of slack on the wiring.
4. Compress the cable gland on the TCS3000 register until it is snug

on the air eliminator float wiring.
1. THROTTLE 1: Locate the Pump Starter (INJ Pump) port on
terminal for Throttle 1 positive output signal based on Flow Rate.
WARNING: Throttle 1 product selection will override the Additive
Injection parameter if selected.
2. THROTTLE 2: Locate the Auxiliary 1 (AUX 1) port on terminal for

Throttle 2 positive output signal based on Flow Rate.
3. For both Throttle outputs, wire signal wire to (+) and ground to
(GND).

Installation Procedure — Additive Injection Pump
There are two selections for managing Additive Injection Pumps; External and Piston.
EXTERNAL: The External function for Additive Injection is to

provide an positive output signal during the entire delivery BLACK
RED
process to manage an external additive injection pump. The
source power voltage is what you will receive from the terminal
named INJ PUMP.
NOTE: If using Throttle Control 1, this will deactivate the External additive injection
pump.
GND — GND
Additive Meter: A single or dual channel additive flow meter +5V — VIN
can be wired into the ADD. INJ. PULSER terminal to inde-
TAHA2 — CHA
pendently measure additive volume during a flow rate. Cali-
TAHB2 — CHB
brate Additive Meter within following PISTON additive selec-
tion, then switch back to External.
PISTON: The Piston function for Additive

Injection is to provide calibrated positive output
signals during the entire delivery process to actuate
an external additive injection pump. The source
power voltage is what you will receive from the
terminal named AUX 3.
BLACK
RED
Additive Meter: A single or dual channel additive
flow meter can be wired into the ADD. INJ. PULSER
terminal to independently measure additive volume
GND — GND during a flow rate.
+5V — VIN
TAHA2 — CHA
TAHB2 — CHB
NOTE: Additive Injection Pump and Valve terminals will not operate in Weights & Measures mode. Calibration for the PISTON
additive injection pump and flow meter are required to be performed outside W&M Settings, then changed within W&M

Installation Procedure — Float Electronic Air Eliminator
Air Eliminator Float Wiring
Air Eliminator Solenoid
1/4” NPT Exhaust Vent
1. Locate the air eliminator float wiring on the metering system.
2. Install the cable gland into the back of the TCS 3000 register
and tighten into the housing.
3. Run the air eliminator float wiring through the cable gland.
Wire the air eliminator float into the Air Eliminator (AIR
ELIMINAT.) terminal on the board. Leave a small amount of
slack on the wiring.
4. Compress the cable gland on the TCS3000 register until it is

snug on the air eliminator float wiring. 1
5. Locate the air eliminator solenoid wiring on the metering
system.
BLACK
6. Install the cable gland into the back of the TCS 3000 register RED
and tighten into the housing.
7. Run the air eliminator solenoid wiring through the cable

gland. Wire the air eliminator solenoid into the Auxiliary
Relay 2 (AUX 2) on the terminal board. Leave a small amount
of slack on the wiring.
8. Compress the cable gland on the TCS 3000 register until it is

snug on the air eliminator solenoid wiring.
NOTE: Do not run multiple cables through a single cable

Installation Procedure — Vibronic Electronic Air Eliminator
1. Connect Independent +24VDC to Terminal Block L1 in the Vibronic Sensor
2. Connect Terminal Block 7 to “GND” and Terminal Block 8 to “Air Elim.” under Air Eliminator Section of the TCS
3000 register.
3. Set the Dip Switch on the Vibronic Sensor to the MIN Position.
4. Wire Air Eliminator Solenoid as normal.

Installation Procedure — LPG 1-Stage Security Valve
S2 – Fast Flow
Solenoid Valve
GREEN
BLACK
BLACK
1. Using the bolts and gasket provided, install the 757 LPG valve on the outlet (downstream) side of the meter.
2. Follow the instructions provided with the valve for wiring the solenoid.
3. Mount the 3 Way Valve and threaded fitting directly to the TCS 3000 register and follow the instructions 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 18 gauge shielded cable
into the back of the TCS 3000 register. The 3 Way valve will be wired into Solenoid 2 on the terminal board.
5. TCS 3000 register product programming for Valve Type should be set to Single Stage.

Installation Procedure — LPG 2-Stage Preset Valve
S1 – Fast Flow
Solenoid Valve
GREEN
BLACK
BLACK
S2 -Slow Flow Shut

Off Solenoid Valve
1. Using the bolts and gasket provided, install the 757 LPG valve on the outlet (downstream) side of the meter.
2. Follow the instructions provided with the valve for wiring the solenoid.
3. Mount the 3 Way Valve directly to the TCS3000 register and follow the instructions 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 18 gauge shielded cable
into the back of the TCS 3000 register. The 3-Way Valve will be wired into Solenoid 1 (S1) on the terminal board
and the Slow Flow Bypass Valve will be wired into Solenoid 2 (S2).
5. Insert the solenoid wiring into the cable gland. Wire the solenoid into the correct solenoid location on the termi-
nal board. Leave a small amount of slack on the wiring.
6. Compress the cable gland on the TCS 3000 register until it is snug on the solenoid wire.
7. TCS 3000 register product programming for Valve Type should be set to Dual Stage.
*When Calibrating the Unit Set Up Valve Type as 1001*

Installation Procedure — 1-Stage Security Valve
S2
S2
S2
655-21 Diaphragm 2” Valve 755-21 Piston 2” Valve 755-31 Diaphragm 3” Valve
1. Using the bolts and gasket provided, install the 655 Diaphragm or
755 Piston Valve on the outlet (downstream) side of the meter.
2. Wire the solenoid valve to Solenoid 2 (S2) for a Single Stage oper-
ation
3. Once the solenoid is wired, run the corresponding wire as pic-
tured using a minimum of 18 gauge shielded cable into the back
of the TCS 3000 register.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid
into the correct solenoid location on the terminal board. Leave a
small amount of slack on the wiring.
on the solenoid wire.

Installation Procedure — 2-Stage Preset Valve
S1
S2
S1
S1
S2 S2
655-20 Diaphragm 2” Valve 755-20 Piston 2” Valve 755-30 Diaphragm 3” Valve
1. Using the bolts and gasket provided, install the 655 Diaphragm or
755 Piston Valve on the outlet (downstream) side of the meter.
2. Wire the Fast Flow valve to Solenoid 1 (S1) and the Slow Flow
Shut Off valve to Solenoid 2 (S2) for a 2-stage preset operation.
3. Once the solenoids are wired, run the corresponding wire as pic-
tured using a minimum of 18 gauge shielded cable into the back
of the TCS 3000 register.
4. Insert the solenoid wiring into the cable gland. Wire the solenoid
into the correct solenoid location on the terminal board. Leave a
small amount of slack on the wiring.
on the solenoid wire.
*When Calibrating the Unit Set Up Valve Type as 1101*

Installation Procedure — Temperature Probe
RED
RED
WHITE
WHITE
3/8” Reference Port

Anti-Sieze
Temperature Probe
Spacer Lock
Drilled Washer
Thermowell Jacket
Seal Wire Cable Gland
1. Locate the thermowell in the metering system.
2. Slide the temperature probe jacket over the temperature probe wire until it covers the entire wire.
3. Screw the cable gland into the thermowell and tighten. Squeeze the Copper Anti-Seize on the metal tip of the
temperature probe.
4. Slide the temperature probe into the thermowell. Compress the cable gland down onto the temperature probe.
5. Screw the cable gland into the back of the TCS3000 register and tighten.
6. Insert the temperature probe wiring into the cable gland. Wire the Temp. Probe into the Temp Probe location on
the terminal board. Leave a small amount of slack on the wiring.
7. Compress the cable gland on the TCS3000 register until it is snug on the temperature probe wire.
8. Run the temperature probe wiring to the back of the TCS 3000 register. Insert the wiring into the third cable gland
from the top of the register as in the illustration above.
9. Leave slack in the temperature probe wiring and tighten the cable gland down on the temperature probe. If
needed the probe wire may be trimmed of excess wire before tightening down the cable gland.
10. Wire the probe into the TCS 3000 register as pictured.

Installation Procedure — Temperature Probe Kit
TCS 3000 RTD Probe/Aluminum Thermowell Kit
Item Qty TCS 300811

NPT
Cable Gland, 1/2 NPT UL 1 TCS 300133
O-Ring, 1/2 NPT Gland 1 TCS 300255
4 Wire 100 Ω Temperature Probe 1 TCS 300701
Temperature Probe Jacket 1 TCS 300702
Capplug T6X 1 TCS 300719
Copper Antiseize 2 Gram 1 TCS 300749
Thermowell 1/2” NPT Aluminum 1 TCS 740300
Thermowell 3/8” NPT Aluminum 1 TCS 740305
Nylon Spacer Lock 1 TCS 740302
Drilled 3/8’ SS Washer 1 TCS 740303
TCS 3000 RTD Probe/SS Thermowell Kit
Item Qty TCS 300815

NPT
Cable Gland, 1/2 NPT UL 1 TCS 300133
O-Ring, 1/2 NPT Gland 1 TCS 300255
4 Wire 100 Ω Temperature Probe 1 TCS 300701
Temperature Probe Jacket 1 TCS 300702
Capplug T6X 1 TCS 300719
Copper Antiseize 2 Gram 1 TCS 300749
Thermowell 1/2” Stainless Steel 1 TCS 740400
Thermowell 3/8” Stainless Steel 1 TCS 740405
Nylon Spacer Lock 1 TCS 740302
Drilled 3/8’ SS Washer 1 TCS 740303

Installation Procedure — Daisy Chain Communication
Daisy Chain:
Daisy Chain is used for linking multiple registers together to use one printer or modem to link multiple registers to the
database.
To Daisy Chain the Registers use a two wire 22 gauge shielded cable. Nominate one Register to be the Host.
Once you’ve chosen which Register will be the Host the other Registers will be considered the clients. Run the 22
guage wire from slot A and B of DAISY CHAIN on the Host Unit to slot A and B of DAISY CHAIN on the Client Unit.
To tie the Client to the next Client unit on the Daisy Chain, run the 22 gauge wire from slot A and B of DAISY CHAIN to
slot A and B of the next client’s DAISY CHAIN.
B B B B
A A A A
Host Client 2 Client 3 Client 4
The Host will have 2 wires. Client 2 will have 4 wires. Client 3 will have 4 wires. The Last Client will have 2 wires.
B B B B
A A A A
Continue to Daisy Chain until you have tied the chain together, alternating slots on the Daisy Chain until you’ve
reached the end of the chain. The Host and the last Client on the chain will be the only two registers on the chain to
have a two wire connection.

Installation Procedure — Printer
1. Find a suitable location for the printer appropriate to your application.
2. Secure the printer in place with the Velcro strip provided.
3. Wire the power and communication cables into the back of the printer.
4. Run the communication cable to the back of the TCS3000.
5. Screw the cable gland into the back of the TCS3000 and tighten.
6. Insert the printer communication cable into the cable gland and wire into the correct location on the terminal
board.
7. Compress the cable gland on the TCS3000 until it is snug on the printer communication cable.
Epson Slip Printer The DIP Switch on Pole Epson Roll Printer
3 must be set to ON.
The DIP Switch on Pole
3 must be set to ON.
DETAIL A DETAIL B
NOTE: Once DIP Switch 3 has been moved to position ON; You must cycle power for the Parameter to retain.

TCS 3000 Epson Slip 12 VDC Kit

Metric NPT
Cable Gland 1 TCS 300244 TCS 300254
O-Ring, Gland 1 TCS 300245 TCS 300255
12VDC Epson Printer Power 1 TCS 300712 TCS 300712
3 Wire Printer Comm Cable 1 TCS 300714 TCS 300714
Velcro 4” X 5” 1 TCS 300721 TCS 300721
Epson Printer 1 TEL TMU295-011 TEL TMU295-011
Wehof Order Form 1 TCS WEHOF TCS WEHOF
TCS 3000 Epson Slip 24 VDC Print Kit

Metric NPT
Velcro 4” X 5” 1 TCS 300721 TCS 300721
24 VDC Epson Printer Power 1 TCS 300772 TCS 300772
TCS 3000 Epson Slip Print 110V Kit

Metric NPT
3 Wire Printer Comm. Cable 1 TCS 300714 TCS 300714
Velcro 4” X 5” 1 TCS 300721 TCS 300721
AC Power Supply w Cord 1 TEL TPS-180 TEL TPS-180

TCS 3000 Epson Roll 12 VDC Kit

Metric NPT

3 Wire Printer Comm. Cable 1 TCS 300714 TCS 300714
Velcro 4” X 5” 1 TCS 300721 TCS 300721

Roll Printer 1 TEL TMU220A103 TEL TMU220A103
TCS 3000 Epson Roll 24 VDC Print Kit

Metric NPT
Velcro 4” X 5” 1 TCS 300721 TCS 300721
TCS 3000 Epson Roll Print 110V Kit

Metric NPT
Velcro 4” X 5” 1 TCS 300721 TCS 300721
110VAC Epson Printer Power 1 TCS 300773 TCS 300773

TCS 3000 Printek Bluetooth Kit

Metric NPT
Printek Printer 1 TCS 300706 TCS 300706
Velcro 4” X 5” 1 TCS 300721 TCS 300721
Bluetooth Modem 1 TCS 300722 TCS 300722
Printek Charger 1 TCS 300727 TCS 300727
Printek Blue Tooth Docking 1 TCS 300728 TCS 300728
TCS 3000 Citizen Bluetooth Kit

Metric NPT
*
Velcro 4” X 5” 1 TCS 300721 TCS 300721
Bluetooth Modem 1 TCS 300722 TCS 300722
Ciztizen Bluetooth Print 1 TCS 300723 TCS 300723
DC Truck Adapter/Citize 1 TCS 300724 TCS 300724
*Bluetooth Modem will not pair with other devices, unless TCS Programs the device at the Factory*

Installation Procedure — Time Off Relay
Power Off Timing Relay

When installing the TCS 3000 registration on delivery tank trucks with Cellular Modems, it is recommended to provide a timing re-
lay for the power off of the modem and register to completely transmit all delivery records. Install the Power Off Time Relay from
the Accessory Switch (ACC) to the TCS 3000 register for a selectable time (Seconds) open of power.
Item TCS Part No.

Time-Off Relay; 12VDC TCS 300785
Time-Off Relay; 24VDC TCS300786

Installation Procedure — 900MHz Radio Transmitter
Installation Procedure
BROWN
BLUE
1. Wire the 9DB Pin Communication Cable to the Computer (COMP.) port BLACK
of the TCS 3000 register terminal board.
RED
2. Radio modems can be powered within the TCS 3000 register, via the
Power Input.
3. Antenna must be connected to cellular modem for there to be any

activity.
To make sure proper power and communication is achieved with your cel-
lular modem, the DIP Switch Settings and LED operation will be illustrated
as below:

Installation Procedure — Sierra Cellular Modem
1. Wire the 9DB Pin Communication Cable to the Computer (COMP.) port of BROWN
BLUE
the TCS 3000 register terminal board. BLACK
2. Cellular modems come with their own Power Cable & Plug. The Red &
White wire must be wired to the External Power Source (accessory switch)
together. Ground to Battery ground.
3. Antenna must be connected to cellular modem for there to be any activity.
4. Cellular modems will be required to have proper programming prior to

use.
BLACK
RED
WHITE
To make sure proper power and communication is achieved with your cel-
lular modem, the LED operation will be illustrated as below:
EXTERNAL POWER SOURCE
4-Pin Power Connector
WHITE ( + )
BLACK ( - ) RED ( + )

Installation Procedure — Maestro Cellular Modem
BROWN
BLUE
1. Wire the 15DB Pin Communication Cable to the Computer (COMP.) port of BLACK
the TCS 3000 register terminal board.
2. Cellular modems come with a Power Cable & Plug. The Green wire must
be wired to the External Power Source (accessory switch) together. The
White wire must be wired to Battery ground.
3. Antenna must be connected to cellular modem for there to be any activity.
4. Cellular modems will be required to have proper programming prior to

use.
WHITE (Ground)
GREEN (Positive)
EXTERNAL POWER SOURCE
Status Indicator 4-Pin Power Connector

The LED will indicate different status of the modem:
GREEN ( + ) WHITE ( - )
• OFF: modem is switched off
• ON: modem has no network and GPS doesn’t have a fix
• ON, and OF pulse every 10 seconds: modem has no network and GPS has a fix
• Flashing slowly: modem is registered on the network and GPS doesn’t have a fix
• Flashing rapidly: modem is registered on the network and GPS has a fix

Installation Procedure — Remote Display
External Power Source
See Red Lion, Omega or Tekinno serial slave display manuals for RS-485 programming and wiring Instructions.
WARNING: The external remote display requires an External Power Source, do not pull power from the TCS 3000
register.

Installation Procedure — 1 Channel Communication Installation
COMMUNICATION BOARD
M4 X 11 STANDOFF M4 X 14 STANDOFF
SCREWS
WIRING SHIELD
1. Remove the six Screws holding the Wiring Shield to the M8 x 27 Standoffs.
2. Remove the two top M8 x 27 MM Standoffs and replace with two M4 x 14 Standoffs
3. With two M4 x 14 Standoffs, mount the Single Channel Communication Board over the two top (short) M4 x 11
Standoffs.
4. Install the Wiring Shield with six Screws.
5. Replace USB cable adapter into wiring shield for safe keeping.

Installation Procedure — Density Sensor
Wiring Instructions:
1) Install the single channel communication board as described on page 34.
2) The Red 4-20 mA power will be terminated on the +USUP terminal (regulated to +18Vdc).
3) The signal wire will be the RX terminal.
4) Black ground wire will be GND.

Installation Procedure — Differential Pressure (Voltage)
GTP 7534 Differential

Pressure Piston Gauge with Rotary
Encoder
2) The GTP 7534 differential pressure gauge with rotary encoder requires 5Vdc. Run the Red wire to the +5Vdc power
on the center terminal block.
3) The GTP 7534 Blue signal wire will be run to the RX terminal.

Installation Procedure — Differential Pressure (Current)
Analog Differential Pressure Sensor
2) Wire according to diagram above or as detailed in the pressure gauge manual.

Installation Procedure — 1 Tank Level Monitor
Madison U3M Shown
TO: 4-20mA Input

from Tank Monitor

Installation Procedure — Water Defense Sensor—Faudi
TO: 4-20mA Input

from Water Sensor

Installation Procedure — Water Defense Sensor—Parker
TO: 4-20mA Input

from Water Sensor

COMMUNICATION BOARD 3 CH
M4 X 11 STANDOFF M4 X 14 STANDOFF
SCREWS
WIRING SHIELD
1. Remove the six Screws holding the Wiring Shield to the M8 x 27 Standoffs.
2. Remove the two top M8 x 27 MM Standoffs and replace with two M4 x 14 Standoffs
3. With two M4 x 14 Standoffs, mount the Single Channel Communication Board over the two top (short) M4 x 11
Standoffs.
4. Install the Wiring Shield with six Screws.
5. Replace USB cable adapter into wiring shield for safe keeping.

1) Wire Power and Ground for 3 Channel Board in with the Main Power and Ground for the
TCS 3000
2) Wire RS485 Input from 3 Channel Communication board to Periph 485 on Terminal Board
as shown above.

Installation Procedure — Density Sensor
1) Install the three channel communication board as described on page 41.
2) The Red 4-20 mA power will be terminated on the VS1(2)(3) terminal (regulated to +18Vdc).
4) Black ground wire will be GND.

Installation Procedure — Differential Pressure (Voltage)
**NOTE**
When using the Gammon Gauge You MUST Flip
Switch to 5VDC
1) Install the 3 channel communication board as described on page 41.
2) The GTP 7534 differential pressure gauge with rotary encoder requires 5Vdc. Run the Red wire to the VS1 (2)(3)
black after moving the switch as noted above..
3) The GTP 7534 Blue signal wire will be run to the RX terminal.
4) THE GTP 7534 Black wire will be run to GND.

Installation Procedure — Differential Pressure (Current)
1) Install the 3 channel communication board as described on page 41.
2) The Red Wire will be run from Vin on the Dwyer to the VS1(2)(3) on the 3 Channel Board
3) The Blue Wire will be run from the Vo on the Dwyer Gauge to the RX on the 3 Channel Board
4) Black wire will be run from Com on the Dwyer Gauge to the RX on the 3 Channel Board.

Installation Procedure — 1 Tank Level Monitor
Wiring for Madison U3M Shown
1) Install the three channel communication board as described on page 41.
2) The Red 4-20 mA power will be terminated on the VS1(2)(3) terminal (regulated to +18Vdc).

Installation Procedure — Water Defense Sensor—Faudi
TO: 4-20mA Input
2) The Red 4-20 mA power will be terminated on the VS1 (2)(3) terminal (regulated to +18Vdc).
3) RX on the 3 Channel Board to the –UB on the Faudi AFGuard Sensor

Installation Procedure — Water Defense Sensor—Parker
TO: 4-20mA Input

from Water Sensor
2) The Brown Wire will be run from +VDC on the Parker Sensor to the VS1(2)(3) on the 3 Channel Board
3) The White Wire will be run from the 4-20mA Out on the Parker Sensor to the RX on the 3 Channel Board
4) The Blue wire will be run from 4-20mA Return on the Parker Sensor to the GND on the 3 Channel Board.
5) The Black Wire will run from the GND on the Parker Sensor to the GND on the 3 Channel Board.

Installation Procedure — 8 Channel Communication

Installation Procedure — 8 Channel Communication—Densitometer

Installation Procedure — 8 Channel Communication—DP—Gammon

Installation Procedure — 8 Channel Communication—DP—Dwyer
COM

Installation Procedure — 8 Channel Communication—Tank Level—Madison

Installation Procedure — 8 Channel Communication—Water - Faudi

Installation Procedure — 8 Channel Communication—Water - Parker

Generation 1 Installation Procedure — Software Update
FIGURE 1
Mini USB Port
Male Mini USB to

Female USB
USB Thumb Drive with
communication LED
Item Qty TCS P/N
USB FEM/Mini Male Cable 1 TCS 300787
TCS 3000 USB 1 TCS 300795
TCS 3000 Software Update Kit (TCS 300882)
1. Load new software upgrade to a USB thumb drive (Minimum 8G, Formatted FAT 32).
NOTE: The new software upgrade should be the ONLY file on the drive.
2. Open the TCS 3000 register. On the front cover of the register, there are 2 mini-USB connections. Using a factory
supplied USB cable, attach the thumb drive to the USB port closest to the inside of the register. This port is the
highest on the circuit board of the two. See Figure 1.
3. Plug the USB cable into the USB port, and then insert the USB thumb drive into the mating cable (see Figure 1).
4. Under Advanced Functions, locate System Update and press ENTER.
5. The screen will display System Update, press MODE to continue with the update.
6. If the thumb drive is not recognized or there is a faulty cable, the display will respond with NO UPDATE DATA error
message.
7. Once the file is recognized, you will be prompted to remove the media. Remove the USB and the register will re-
boot and begin the update process. This should take approximately 3 minutes.

Generation 2 Installation Procedure — Software Update
FIGURE 2
USB Thumb Drive with

communication LED
Item Qty TCS P/N
TCS 3000 USB 1 TCS 300795
1. Load new software upgrade to a USB thumb drive (Minimum 8G, Formatted FAT 32).
NOTE: The new software upgrade should be the ONLY file on the drive.
2. Open the TCS 3000 register. On the front cover of the register, is a USB connection. Using a factory supplied USB,
attach the thumb drive to the USB port to the inside of the register. See Figure 2.
3. Under Advanced Functions, locate System Update and press ENTER.
4. The screen will display System Update, press MODE to continue with the update.
5. If the thumb drive is not recognized or there is a faulty cable, the display will respond with NO UPDATE DATA error
message.
6. Once the file is recognized, you will be prompted to remove the media. Remove the USB and the register will
reboot and begin the update process. This should take approximately 3 minutes.

Generation 1 Terminal Board vs. Generation 2 Terminal Board Differences
Generation 1 Image Generation 2 Image
Generation 2 Front Cover Differences

LED I/O Indicators
Indicator Lights Advise

When There is Power to
the Terminal Strip
Ability to Power
12-24VDC Pulser
Generation 2 Terminal Board Differences

Generation 1 & 2 Interchangeability
Figure A Figure B
INCOMPATIBLE COMPATIBLE
Flip switch down to use

Generation 2 Front Cover with
Generation 1 Terminal Board.
For Generation 2 system (both

boards are yellow) flip switch
down.
Figure C
Before Completing an Upgrade or Exchange

Generation 2 Front Covers (Cover with Yellow Board) are compatible with Generation 1 Rear Covers (Rear with Green
Board) as pictured in Figure B.
To Use a Generation 2 Front Cover with a Generation 1 Rear Cover you must flip the Access Switch as shown
in Figure C.
Generation 1 Front Covers are NOT compatible with Generation 2 Rear Covers as pictured in Figure A.
Software
The highest level software update to be used on a Generation 1 unit is 999. The highest level firmware to be used is
v10.18.18.
Generation 2 units begin with software version 1001 and firmware version V30.03
Generation 1 Software is NOT compatible with Generation 2 units.

Installation Procedure — Replacement Register Front Cover
HINGE PIN ALLEN SCREW FRONT COVER REPLACEMENT
SET SCREW
SOCKET SCREW
50 PIN RIBBON
REQUIRED TOOLS:
POWER RIBBON • 2 mm Allen Wrench

• 3 mm Allen Wrench
• 5 mm Allen Wrench
• Philips Screw Driver
GROUND CABLE
HINGE PIN ALLEN SCREW
1. Unlatch the 50 Pin Communication and the Power ribbon cables from the front cover assembly.
2. Remove the grounding strap from the front cover assembly using a Philips screw driver.
3. Remove two Set Screws from the rear housing of the register hinges using a 3 mm Allen Wrench.
4. Remove the two Hinge Pin Allen Screws from the top and bottom of the front cover assembly. Use a 2 mm Allen
Wrench for removal.
5. Once the replacement front cover computer is received, carefully remove the unit from the anti-static plastic bag
and do not dispose of the original packaging materials.
6. Reassemble the replacement front cover computer assembly to the rear housing with the Hinge Pin Allen Screws
and Set Screws.
7. Insert the 50 Pin Communication and Power ribbon cables and fastening the grounding cable.
8. Insert the front cover assembly in the anti-static bag and carefully place back into the original box packaging.
NOTE: Packing instructions are within the original box.

9. Before shipping back to Total Control Systems, be sure to have a Returns Goods Authorization enclosed within the
packaging.


NOTES
TCS 3000 Warranty
WARRANTY
New 3000 electronic registers, equipment or components manufactured by Total Control Systems, a division
of Murray Equipment, Inc. (TCS) with which this warranty is enclosed, are warranted by TCS to the original
purchaser only for a period of TWELVE (12) months from installation or eighteen (18) months from the date of
shipment, to be free, under normal use and service, from defects in material and workmanship.
Defects occurring within the stated warranty period, TCS will repair or replace, at TCS’s option; provided that
part or parts are returned to TCS transportation charges prepaid, and TCS’s examination discloses the parts
or workmanship to have been defective upon delivery to the purchaser.
EXCLUSIONS
Warranty does not cover any parts and equipment not manufactured by TCS, but these items may be covered
by separate warranties of their respective manufacturers. This warranty does not extend to any equipment
that has been subjected to misuse, negligence or accident or if operated in any manner other than in accord-
ance with TCS’s operating instructions and specifications.
CLAIM PROCEDURES
In order to obtain performance by TCS of its obligations under this warranty, the original purchaser must ob-
tain a Return Goods Authorization (RGA) number from TCS’s customer service department within 30 days of
discovery of a purported breach of warranty, but not later than the expiration of the warranty period. Once
authorization is received, return the defective meter, piece of equipment, or component covered by this war-
ranty, with transportation charges prepaid, to TCS at the address shown below together with a written state-
ment setting forth the nature of the defect and RGA number.
LIMITATIONS
THERE ARE NO OTHER WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED. TCS SPECIFICALLY DIS-
CLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE.
TCS will determine if all parts or meter defect falls within the warranty guidelines and will repair or replace
within a reasonable time span. TCS is not responsible for any in or out bound freight. TCS's sole obligation
that shall represent the buyer's sole and exclusive remedy shall be to repair or at TCS's option to replace any
product or part determined to be defective. In no event shall TCS be liable for any special, direct, indirect, inci-
dent, consequential or other damages of similar nature, including without limitation, loss of profits, products,
production time, or loss of expenses of any nature incurred by the buyer or any third party. TCS has not au-
thorized on its behalf any representation or warranties to be made, nor any liability to be assumed except as
expressly provided herein; there is no other express or implied warranty.
DESIGN AND EQUIPMENT CHANGES
Any changes in design or improvements added shall not create any obligation to install same on equipment
previously sold or ordered.
NOTES
TCS900041 REV. 10
2515 Charleston Place

Fort Wayne, IN 46808
Toll Free: (800) 348-4753

Phone: (260) 484-0382
Fax: (260) 484-9230
Email: sales@tcsmeters.com
Website: www.tcsmeters.com
Total Control Systems www.tcsmeters.com

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TCS 3000

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Warning Symbols Warranty 42

CAUTION EYE PROTECTION

TURN POWER OFF INJURY

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EXTERNAL PULSE INPUT

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DIMENSIONS — INCHES (MILLIMETERS)

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Item Qty TCS 300871 TCS 300971

Terminal Cover 1 TCS300164 TCS300164

3. Slide the Drive Coupling onto the Meter Drive Shaft.

5. Secure the bolts.

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Item Qty TCS 300870 TCS 300970

Phillips Pan 6 TCS300137 TCS300137

700 Drive Shaft 1/4—28X1 Zinc Bolt 2 TCS68013 TCS68013

4. Slide the Drive Coupling onto the Meter Drive Shaft.

6. Secure the bolts.

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TCS 300877 TCS 300977

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TCS 300597, Grounding Strap Kit

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Power On Timing Relay

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3. Run the Pump Control to the onboard computer or programma-

4. Compress the cable gland on the TCS3000 register until it is snug

2. THROTTLE 2: Locate the Auxiliary 1 (AUX 1) port on terminal for

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EXTERNAL: The External function for Additive Injection is to

PISTON: The Piston function for Additive

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Air Eliminator Float Wiring

Air Eliminator Solenoid

1/4” NPT Exhaust Vent

4. Compress the cable gland on the TCS3000 register until it is

and tighten into the housing.

7. Run the air eliminator solenoid wiring through the cable

8. Compress the cable gland on the TCS 3000 register until it is

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S2 -Slow Flow Shut

*When Calibrating the Unit Set Up Valve Type as 1001*

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655-21 Diaphragm 2” Valve 755-21 Piston 2” Valve 755-31 Diaphragm 3” Valve

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655-20 Diaphragm 2” Valve 755-20 Piston 2” Valve 755-30 Diaphragm 3” Valve

*When Calibrating the Unit Set Up Valve Type as 1101*

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3/8” Reference Port

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TCS 3000 RTD Probe/Aluminum Thermowell Kit

Item Qty TCS 300811

When Calibrating the Unit Set Up Valve Type as 1001

When Calibrating the Unit Set Up Valve Type as 1101