Franklin Fueling Systems DC404-4 User Manual

DC400 Dispensing Cutoff System

404-4 Controller

Installation Instructions

Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA

Tel: [phone] • 800 225 9787 • Fax: [phone] • www.franklinfueling.com

Important Safety Messages

Franklin Fueling Systems (FFS) equipment is designed to be installed in association with volatile hydrocarbon liquids such
as gasoline and diesel fuel. Installing or working on this equipment means working in an environment in which these highly
ammable liquids may be present. Working in such a hazardous environment presents a risk of severe injury or death
if these instructions and standard industry practices are not followed. Read and follow all instructions thoroughly before
installing or working on this, or any other related, equipment.

As you read this guide, please be aware of the following symbols and their meanings:

Warning

This symbol identies a warning. A warning sign will appear in the text of this document when a potentially
hazardous situation may arise if the instructions that follow are not adhered to closely. A potentially hazardous
situation may involve the possibility of severe bodily harm or even death.

Caution

Warning

Warning

Warning

Warning

This is a caution symbol. A caution sign will appear in the text of this document when a potentially hazardous
environmental situation may arise if the instructions that follow are not adhered to closely. A potentially
hazardous environmental situation may involve the leakage of fuel from equipment that could severely harm
the environment.

Follow all applicable codes governing the installation and servicing of this product and the
entire system. Always lock out and tag electrical circuit breakers while installing or servicing this
equipment and any related equipment. A potentially lethal electrical shock hazard and the possibility

of an explosion or re from a spark can result if the electrical circuit breakers are accidentally

turned on during installation or servicing. Please refer to the Installation and Owner’s Manual for
this equipment, and the appropriate documentation for any other related equipment, for complete
installation and safety information.

Follow all federal, state and local laws governing the installation of this product and its associated
systems. When no other regulations apply, follow NFPA codes 30A and 70 from the National Fire
Protection Association. Failure to follow these codes could result in severe injury, death, serious
property damage and/or environmental contamination.

Always secure the work area from moving vehicles. The equipment in this manual is usually mounted
underground, so reduced visibility puts service personnel working on this equipment in danger from
moving vehicles entering the work area. To help eliminate these unsafe conditions, secure the area
by using a service truck to block access to the work environment, or by using any other reasonable
means available to ensure the safety of service personnel.

Use circuit breakers for multiple disconnect to turn off power and prevent feedback from other dispensers.

List of Parts

Description Part Number

QTY QuickON Wire connectors 210-0083

Controller 404-4

List of Tools

• Industry-standard, non-sparking tools

• Allen wrench, 19mm

• Conduit and ttings as required, must be UL
listed for use in Class I, Div 1 locations

Junction Box internal volume requirements per conductor:

Size of Conductor (AWG) Free space required for

each conductor (in3)

18 1.5

16 1.75

14 2.0

12 2.25

10 2.5

Determine volume of Junction box. This information may be on the
junction box itself usually expressed in cubic inches. If not, measure the
inside length, width, and depth of the box and multiply these numbers
together. This gives you the free volume of the junction box.

If the junction box is round measure the inside diameter and multiply this
number by itself. Multiply this number by 0.78 and record this answer.
Then measure the depth of the junction box and multiply it by the sum of
your rst answer. This gives the free volume of a cylindrical junction box.

Using the table above, subtract the cubic inches per each conductor
which originates outside the junction box and terminates or is spliced
within the junction box. Each conductor that passes through the junction
box without splice or termination shall be counted once. Refer to
National Electric Code 2011, article 314.16 (B).

2

Product Description

The DC400 system uses a sump sensor to detect the
presence of liquid in the STP (Submersible Turbine Pump)
or dispenser sump. If liquid is detected, the system will
shut down power to the STP or dispenser.

The DC400 system consists of the 404-4 Controller and
either a 2-Wire or 3-Wire sensor. Follow these instructions
for installation of the 404-4 Controller. Franklin Fueling
Systems sensors approved for use with the DC400 system
come with their own installation instructions.

Specications:

Input line voltage: 90 – 250VAC 50/60 Hz

404-4 power consumption: 2W

Relay switch conguration: SPST

Relay switch contact rating: 12A continuous, 250VAC

maximum

Operating temperature: -20 to 60 degrees C

Hazardous location

Class I, Div 1, Group D

category:

Refer to Franklin Fueling Systems control drawing 000-1737

Installation for Dispenser Cutoff

Notice! Only qualied service

Warning

Warning

Note: Install this kit ONLY in a UL listed dispenser.

Note: If the is no junction box or open port on the junction

box, you cannot install this kit.

1. Shut off all power to the dispenser. Lock out and
tag the corresponding dispenser circuit breaker.

2. Open / remove the dispenser lower panel for
access to the dispenser hazardous area. Inspect
the hazardous area to locate the dispenser
explosion proof power entry junction box. The 404­4 controller will be wired into the dispenser via a
spare conduit hub located on the dispenser power
entry junction box.

3. Determine where to best locate the 404-4
controller and how best to plumb conduit from
the dispenser spare conduit hub to the 404-4
controller. The 404-4 controller must be located
so that regular servicing of the dispenser (such as
changing of fuel lters) will not be impeded. The
404-4 controller can be located in the dispenser
hazardous area or suspended down below the
dispenser in the dispenser sump as room dictates.
Refer to gure 1.

technicians experienced with petroleum
dispensing and pumping systems
should install the DC400 system.

Notice! Do NOT exceed the 12A
(continuous), 250VAC relay contact
rating of this controller. Relay contacts
are not fused.

Dispenser

404-4

Controller

Cable Connection

2-Wire or

3-Wire sensor

Figure 1: Typical System Installation in a Dispenser Sump

Note:

Because each dispenser installation is unique it is

Junction Box

EYS

Dispenser
Base

Dispenser
Sump

EYS

impossible to provide a “one size ts all” conduit
tting kit. Necessary explosion-proof conduit and
conduit ttings must be determined and supplied by
the installer. The 404-4 controller conduit size is 3/4”
NPT. Simple ttings such as elbows, sweeps, unions,
and nipples should be used and must be UL listed and
suitable for use in Class I, Div 1, Group D locations.

4. Open the dispenser power entry junction box
cover and retain hardware for later use. Remove
spare junction box plug and plumb explosion-proof
conduit from the spare conduit entry hub to the
404-4 controller power port (the port with 6 wires
protruding). Thread the 6 wires coming out of the
power port of the 404-4 controller through the
conduit to the dispenser power entry junction box.

Important! Be sure installation of conduit, ttings and

wiring is in accordance with local, State and
National electrical codes. A conduit seal must be
installed between the dispenser J-box and the
controller. The conduit seal must be within 18" of
the dispenser J-box and the 404-4 controller. Refer
to NEC NFPA 70, article 501.15 (A) (3), 2011. Make
sure the dispenser power entry junction box has
enough spare room to accommodate the additional
404-4 controller wires (see the table on page 2).
Important! When tightening the conduit to the 404-4
controller, use a wrench on the conduit ttings and
not the 404-4 controller body.

5. Wire the 404-4 power wiring per the schematic
that matches your dispenser listed in Figures
7 - 14. Contact your dispenser manufacturer for a
wiring diagram if you are unsure of the dispenser
input power wiring.

Make sure to connect both ground

Warning

wires and verify they are connected
to earth ground. Failure to do so may

result in a re or explosion hazard in

case of a fault condition.

3

404-4

Controller

To Sensor
Connection

Explosion Proof Union

STP Junction Box Cover
NOTE: Use reducer to connect ¾" conduit
to ½" cover opening.

EYS

6. Connect the sensor wire cable coming from the 404-4 controller to the appropriate Franklin Fueling Systems
sensor. Refer to the sensor’s installation instructions for installation, wiring and testing of the sensor.

The sensor must be installed in accordance with the sensor’s control drawing and with Franklin Fueling System’s control
drawing 000-1737.

7. Double check all dispenser & controller power wiring to be sure it is correct then replace the dispenser power
entry junction box cover. Secure the cover with all of the bolts previously retained.

8. Turn the dispenser power back on. The dispenser should operate normally.

9. Replace and secure lower dispenser door(s).

10. Test the DC400 dispenser cutoff by submerging the sensor in water. The dispenser should shut off and remain off
as long as the sensor is submerged.

BLK

ORG/BLK

ORG

WHT

Dispenser

Breaker

404-4 Controller

12A, 240VAC

GRN

To Dispenser
Inputs

Sensor

GG

GRN/YEL

To Dispenser Earth Ground terminal

Installation for Submersible Pump Cutoff

Notice! Only qualied service technicians experienced

with petroleum dispensing and pumping systems
should install the DC400 system.

Warning

Notice! Do not exceed the 12 A (continuous), 250 VAC relay

contact rating of this controller. Relay contacts are not
fused. This controller is suitable for most submersible
pumps rated up to 2 hp @ 250 VAC and 1½ hp @
120 VAC. provided the maximum pump motor
service factor amperage is 12A or less. Contact the
submersible pump manufacturer if in doubt.

Warning

1. Shut off power to the STP. Lock out and tag the

2. In pump cutoff installations the 404-4 controller

4

Refer to MFG
wiring schematic
for terminal block /
wire connections

Dispenser Main Junction Box

Figure 2: Power Wiring Schematic for Controller Dispenser Connection

This controller is NOT for use with
3-phase pumps or Variable Frequency
Drive pump installations.

Remove power to avoid possible
electrocution or ignition of explosive
gasoline vapors.

corresponding STP circuit breaker.

will be connected directly to the integral electrical
junction box on the STP via rigid explosion proof
conduit. Since STP sump installations can vary,
the installer will need to determine where best to
place the controller in the sump and then procure

the necessary conduit and ttings.
A typical means of connecting the controller to
an STP via an explosion proof union is shown in
Figure 3. All ttings must be UL listed and suitable
for use in a Class I, Div 1, Group D environment.

If the STP junction box does not have a removable plug or
opening, installation adapters are available as listed below.

Installed STP Installation Adapter

FE Petro TS-FE

Red Jacket TS-RJ

Red Jacket Quantum TS-RJQ

Figure 3: Typical Connection to STP