DC400 Dispensing Cutoff System
DC404 and DC406
Installation Instructions
Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA
Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
Important Safety Messages
Franklin Fueling Systems (FFS)/Healy 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
Caution
Warning
Warning
Warning
This symbol identies 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.
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.
Warning
Use circuit breakers for multiple disconnect to turn off power and prevent feedback from other
dispensers.
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Product Description
Orange / Black
Orange
The DC400 system uses a sump sensor (latching oat
sensor or non-latching optical 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.
Installation in a Dispenser
Unpack unit and check for shipping damage. The system
consists of two components, the controller and the sensor.
1. Shut off the power to the dispenser:
Warning
2. Remove the cover from the junction box and
locate a spare threaded hub.
3. Remove the plug from the hub and if needed
install a reducing bushing so that you have a ½”
threaded opening.
4. The controller has 7 wires extending from the
end of a ½" nipple. Feed the 7 wires through this
opening and thread the ½" nipple into a hub.
5. Tighten the nipple using a wrench on the nipple
and not the body of the controller.
6. Connect the wires as shown in Figure 1.
7. Plug the sensor into the 4 - wire female plug on
the end of the controller. Wrap the plugs with the
electrical tape.
CAUTION:
8. Place the sensor into the bottom of the sump at
the level to cause dispenser shutdown (Figure 2).
Remember that the unit will shut down when the
sensor detects liquid.
Remove power to avoid possible
electrocution or ignition of explosive
gasoline vapors.
Never plug or unplug the sensor unless
the controller is de-energized. Doing so
will damage the unit.
9. Loop and secure the excess cable with a tie-wrap
so that the sensor is suspended at the appropriate
position. The S404 oat sensor must be installed
in a vertical orientation for proper operation!
10. Replace the junction box cover.
11. Turn the dispenser power back on. The dispenser
should operate normally.
12. If the oat sensor causes the dispenser to shut
down,
the sensor must be reset by pushing the
oat back down with the provided reset tool
through the vent hole in the sensor top to restore
power to the dispenser. The optical sensor does
not need to be reset.
Note:
Use only the provided reset tool to push the oat down.
404-4
Controller
S406 or
S404 sensor
Figure 2: System Installed in Dispenser Sump
Dispenser
Junction Box
Dispenser
Sump
EYS
L1
110 VAC
Neutral
Red
Black
Relay
Yellow
Blue
404-4 Controller
Figure 1: 110 VAC Wiring Schematic for Controller Dispenser Connection
N.C.
Green
Dispenser
Dispenser
110 VAC Input
Dispenser
Neutral
3
Installation in Submersible Pump Sump
404 - 4 Controller
Orange / Black
NOTICE
1. Shut off the power to the STP.
Warning
2. Remove the plug from the STP electrical junction
box cover and save the plug.
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
Determine what ttings you will need to position the
controller. A typical means of connecting the controller to
an STP is shown on Figure #3. Assemble the ttings onto
the controller and tighten.
This controller is not for use with
3-phase pumps or Variable Frequency
pump installations.
Remove power to avoid possible
electrocution or ignition of explosive
gasoline vapors.
4. Disconnect the union (Figure 3) and carefully
position the connected wires into the electrical
box. Thread the reducing bushing into the
threaded opening, being careful not to scrape or
twist the wires. Reconnect and tighten the union.
5. Plug the sensor into the 4 - wire female plug on
the end of the controller. Wrap the plugs with the
electrical tape.
STP Electrical
STP Sump
S406 or
S404 Sensor
404 Controller
Junction Box
½" Explosion Proof Union
STP Junction
Box Cover
Figure 3: Connection to STP
3. Connect the 7 wires as shown on Figure #4.
Sensor
Connection
L1
From pump
control relay
or contactor
(220 VAC)
Red
Black
Yellow
Blue
Relay
Figure 5: STP Sump Installation
6. Place the sensor into the bottom of the sump at
the level to cause pump shutdown. Remember
that the unit will shut down when the sensor
detects liquid.
CAUTION:
Be sure to plug the sensor into the
controller before turning the power
back on to prevent damage to the
controller.
Orange
STP
N.C.
Green
404-4 Controller
L2
Figure 4: 220 VAC Wiring Schematic for STP Connection
4
Black
7. Turn the circuit breaker back on and test for
proper operation by authorizing a dispenser of
that product and feeling the top of the pump for
vibration.
8. Test the sensor as described in the Testing
section.
Alarm Wiring
The relay contacts (Orange / Black and Orange) are
normally closed dry contacts that will open when liquid is
detected. This enables the 404-4 controller to be wired into
other congurations.
Note: You must not exceed the relay contact rating of
250 VAC, 12 A.
Figure 6 shows an example of alarm wiring for applications
that do not require a positive shutdown.
404-4 Controller
Contacts
120 VAC
N.C.
Orange / Black
120 VAC
Neutral
Figure 6: Wiring Example for Non-Positive Shutdown
In the example above, the alarm light illuminates when the
404-4 controller senses liquid. Other possibilities exist for
connecting to an external monitoring device, such as an
INCON T5 Tank Gauge.
Orange
External
120 VAC
Relay Coil
120 VAC
Alarm Pilot Light
N.C.
Neutral
Testing
Test the function of the system according to applicable
codes, and at least annually to verify proper system
operation.
To Test The Float Sensor Cutoff
1. Insert the sensor in a vessel of water. The dispenser
should shut down (remove power from the orange
wire) when the sensor oat rises in water about ½"
and makes contact with the top of sensor.
2. Remove the sensor from the water and reset the
sensor by pushing the oat back down with the
provided reset tool to restore power to the pump or
dispenser.
To Test the Optical Sensor
Note: This sensor is affected by ambient light and should
be shielded from direct light.
Always disconnect power before
Warning
checking the optical sensor. Opening
up the sensor sump location to light
may cause the sensor to change state.
1. Insert the sensor in a vessel of water. The pump or
dispenser should shut down (by removing power
from the orange wire) when the water level rises in
water a little less than 1”.
2. The sensor should reset after it is removed from the
water.
Troubleshooting
If the controller relay repeatedly cycles or oscillates
when the sensor is tripped, it is likely that the controller is
switching its own power. Check the wiring diagram and
conrm that the controller is wired properly. Make sure that
the orange / black, red and black wires are tied to power
from the breaker and the orange wire feeds the dispenser.
If problems continue, please contact FFS Technical
Support at 800-984-6266.
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©2010 000-0312 Rev A
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