Franklin Fueling Systems LS500 User Manual

LS500 Auto Learn

Line Leak Detection

Installation & User’s Guide

Manual #	Revision	date	Changes from Previous Revision
000-2145	E	August 2012	Updated to Incude TS-550evo

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

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

Notice

Franklin Fueling Systems (FFS) strives to produce the finest manual possible and to ensure that the information that it contains is complete and accurate. However, FFS reserves the rights to change this document and specifications at any time without notice. FFS makes no expressed or implied warranty with regard to the contents of this manual. FFS

assumes no liability for errors, omissions or for any damages, direct or consequential, that may result from the use of this document or the equipment that it describes.

This manual is for use expressly with the TS-550, TS-550evo and TS-5000 at their approved specifications.

For further information, installation and programming instructions, please refer to the T5 Series Installation Guide (p/n 000-2150), T5 Series Programming Guide (p/n 000-2142) or the TS-550evo FMS Programming Guide (p/n 000-2173).

Trademarks

INCON®, Tank Sentinel®,System Sentinel®, System Sentinel AnyWare® and Tank Sentinel AnyWare® are registered trademarks of Intelligent Controls. All brand and product names are trademarks or registered trademarks of their respective companies.

Inspection of Materials

Visually inspect all components for defects or damage prior to installation. If any defect or damage is found, do not use the product and contact Franklin Fueling Systems for further assistance.

Warranty Information

Please refer to the FFS Fuel Management Systems & Product Warranty Policy for all warranty information.

Contacting Franklin Fueling Systems (FFS)

Please feel free to contact us by mail at:

Franklin Fueling Systems

3760 Marsh Rd.

Madison, WI 53718 USA

Or contact us by phone, fax or e-mail:

Tel: +1	800 225 9787	E-mail: [e-mail]
Fax: +1	608 838 6433	[e-mail]

Office and Sales Hours: 8 a.m. to 5 p.m. CST - Monday through Friday

Technical Support Hours: 7 a.m. to 7 p.m. CST - Monday through Friday

Please visit our website at www.franklinfueling.com

Copyright ©2008 by Franklin Fueling Systems (FFS). No part of this publication may be reproduced in any form without the prior written consent of FFS.

All rights reserved.

2

Contents
Notice................................................................................................................................	2
Important Safety Messages.............................................................................................	4
Overview...........................................................................................................................	5
Site Requirements...................................................................................................................	5
Transducer Installation............................................................................................................	6
Definitions and Acronyms........................................................................................................	6
Intrinsically Safe LS500 Installation...............................................................................	7
Explosion Proof LS500E Installation..............................................................................	8
LS-500 Setup (Console Programming)..........................................................................	9
4-20mA Input Module............................................................................................................	10
Relay Module.........................................................................................................................	11
Turbine Pump Interface (TPI) Applications............................................................................	12
Fuel Management Systems (FMS) Line Application Set-Up.................................................	13
Line Status and Control Screens..................................................................................	14
Control Indicator Table...........................................................................................................	15
Learn Indicator Table.............................................................................................................	15
Pre-Operational LS500 Testing.....................................................................................	16
Required Equipment..............................................................................................................	16
Line Stability Test...................................................................................................................	16
Learn Process................................................................................................................	17
When to Learn / Re-Learn......................................................................................................	17
Procedure..............................................................................................................................	17
Learn Messages....................................................................................................................	18
LS-500 Reports...............................................................................................................	19
LS-500 Line Leak Reports.....................................................................................................	19
Alarms.............................................................................................................................	19
LS-500 Alarms and Warnings................................................................................................	20
Clearing Alarms.....................................................................................................................	22
LS-500 Functional Testing.............................................................................................	23
Enabling / Disabling Lines.............................................................................................	23

3

Important Safety Messages

INCON 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 flammable 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 identifies 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.Apotentially hazardous
		situation may involve the possibility of severe bodily harm or even death.

Caution

Danger

Warning

Warning

Warning

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.

This symbol identifies an electrical danger. An electrical danger sign will appear in the text of this document when a potentially hazardous situation involving large amounts of electricity may arise if the instructions that follow are not adhered to closely.Apotentially hazardous situation may involve the possibility of electrocution, severe bodily harm, or even death.

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 fire 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 30, 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.

When the Tank Sentinel system is used to monitor tanks containing gasoline or other flammable substances, you may create an explosion hazard if you do not follow the requirements in this manual carefully.

All wiring must enter the Tank Sentinel console’s enclosure through the designated knockouts. An explosion hazard may result if other openings are used.

All wiring from probes or sensors to the Tank Sentinel console must be run in conduit separate from all other wiring. Failure to do so will create an explosion hazard.

Substituting components could impair intrinsic safety. The Tank Sentinel 5 (T5) series consoles are intrinsically safe for sensors installed in – Class I, Division 1, Group D – hazardous locations. Substitution of components could make the energy limiting circuitry in the system ineffective and could cause an explosion hazard. Repairs to a T5 Series console or attached components should only be performed by a qualified, factory-trained technician.

4

Overview

The TS-LS500 is a continuous product line leak detection system that monitors the primary pipe. This product is an available option of Franklin Fueling Systems’ TS-550 and TS-5000 FMS consoles.

The TS-LS500 system includes the FMS application running on a T5 series console and a transducer. One transducer is required per product line, which measures the line pressure. Line Pressure is created by the pump and static seating pressure is metered by a pressure relief valve. Transducers (TS-LSU500) use the AutoLearn technology to continuously evaluate the line conditions.

Note: The TS-LS500 requires pressure for leak tests and should only be installed in systems that are designed to obtain and hold this minimum static pressure. The system will report “learned with errors” if tests are run at less than optimum pressure.

Applications

The following diagram illustrates a typical installation of the LS500 equipment inside of a STP sump.

FE Petro	Wire Splices
Submersible
Pump	TS-LSU500
	Black
	Red
	White (capped)
	Shield (Not connected)

Intrinsically safe wiring or explosion-proof conduit, depending upon application

Figure 1: LS500 Install Overview

To maintain optimal line pressure, Franklin Fueling makes the following recommendations for submersible pumps:

•For FE Petro Submersible Pumps, use a Standard Check Valve (part # 400988931).

•For Red Jacket Submersible Pumps, use an adjustable functional element, adjusting the pump OFF pressure to be at least 2 psi below the pump ON pressure.

Newer style Red Jacket Submersible Pumps do not have an adjustable functional element as an option. These submersible pumps have a check valve that meets the LS500 pressure requirements.

Site Requirements

Item

Value

Minimum Static Pressure

18 PSI for precision testing

15 PSI for gross leak testing

20 PSI for learning lines

Maximum line volume for rigid pipe

312.2 gallons

Maximum line volume for flexible pipe

95.4 gallons

Minimum volume for rigid or flexible pipe

2.5 gallons

Table 1: Capacity Table

Pipe Diameter I.D.

1"

1 ½"

1 ¾"

2"

2 ½"

3"

4"

5"

Flex

Length

61'

27'

20'

15'

10'

7'

4'

2'

Rigid

Length

61'

27'

20'

15'

10'

7'

4'

2'

Table 2: Pipe Length Required for Holding Minimum Line Volume

Pipe Diameter I.D.

1"

1 ½"

1 ¾"

2"

2 ½"

3"

4"

5"

Flex

Length

2339'

1040'

764'

585'

374'

260'

146'

94'

Rigid

Length

7656'

3403'

2500'

1914'

1225'

851'

479'

306'

Table 3: Pipe Length Required for Holding Maximum Line Volume

5

3/4" NPT

2-3/8" (70mm) across flats

6.25" (159 mm)

5.13" (130 mm)

2" NPT

Figure 2: TS-LSU500 Dimensions

Transducer Installation

1.Apply UL Classified Gasoline / Oil resistant pipe dope thread sealant to the threads of the LSU500 Transducer and use a 2 3/8” open-end wrench to install it in the Leak Detector Port of the STP housing

(see Figure 1).

2.Install Couplings, threaded Rigid Metal Conduit (RMC), and Explosion / Weather Proof Junction Boxes (J-Boxes) in the STP sumps. For intrinsically safe wiring, run the transducer lead to the junction box. For explosion-proof installations, run conduit to the top of the transducer.

3.Install threaded RMC and EYS fittings along with Transducer Cables (Belden #9365) from LS500 console to the Explosion / Weather Proof J-Boxes. A licensed electrician should splice the cables together. If this wiring is Intrinsically Safe it MUST NOT be run with any Explosion-Proof wiring or other non-Intrinsically safe wiring!

Alpha cable #58411 (INCON #600-0062) must be used if using nonmetallic (PVC) conduit as allowed by local code.

Definitions and Acronyms		PC	– Personal Computer
AIM	– 4-20mAAnalog Input Module (Intrinsically Safe)	PM	– Probe Module (Intrinsically Safe)
		RM	– Relay Module
FMS – Fuel Management Systems		SCM – Secondary Containment Monitoring
IS	– Intrinsically Safe	STP	– Submersible Turbine Pump
ISD	– In-Station Diagnostic	TPI	– Turbine Pump Interface
LCD	– Liquid Crystal Display	T5 – T5 Series FMS Consoles
LED	– Light Emitting Diode		(TS-5 / 608, TS-550 EMS, TS-5000 / EXPC
LLD	– Line Leak Detection		/ TS-550evo)

TS-EMS – Environmental Monitoring System

TSA – TankSentinel Anywhere

6

Intrinsically Safe LS500 Installation

Note: The Intrinsically Safe 4-20mA Input Module has a BLUE face.

	Warning	Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing
		any system wiring.
	Warning	DO NOT make transducer wiring connections with power connected to the console or any module.

Caution Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-IS) wiring in the same conduit. Caution Do not use explosion-proof transducers (TS-LS500E) with intrinsically safe LS500.

Note: LS500 must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other applicable national or local codes.

1.Pull the wiring through the intrinsically safe conduits that will be used for the TS-LSU500 transducers.

2.Mount the TS-LSU500 in the Leak Detector Port of the STP housing. (As outlined in the Transducer Installation Section above).

3.The TS-LSU500 wiring must enter the console in IS conduit through a knockout on the IS side of the barrier. Secure each pair of transducer wires to a single channel on the 4-20mA Input Module. Always start at the first available channel and do not skip channels. For example, if channels one through three are already being used for another application channel 4 must be used. Be sure to connect the wires to the correct polarity (+/-). If the transducer is wired backwards it will not function.

	4-20mA Input
	Module
	RUN	Non-Hazardous	Hazardous Location
(Blue)	ERR	Location	Class I, Division 1, Group
			D, Group IIA, Zone 0
	–
	+
	–
	+
	–
	+
	–
	+
	–
	+		LS-500
	–
	+		- (BLK)
	–
			+ (RED)
	+
	–	- (BLK)
	+	+ (RED)	Tank Pressure Sensor

Intrinsically Safe Conduit

Figure 3 – 4-20 mA Input Module Wiring

7

Explosion Proof LS500E Installation

Note: The Explosion Proof 4-20mA Input Module has a RED face.

	Warning	Lockout and tag circuit breakers, and disconnect console power wiring before installing or servicing
		any system wiring.
	Warning	DO NOT make transducer wiring connections with power connected to the console or any module.
	Caution	Do not run intrinsically safe (IS) wiring and non-intrinsically safe (non-IS) wiring in the same
		conduit.

Note: LS500E must be installed in accordance with the national electrical code, ANSI / NFPA 70, CEC or other applicable national or local codes.

Note: The explosion-proof transducer needs to have explosion-proof conduit to the head of the transducer.

1.Pull the wiring through the explosion proof conduit that will be used for the TS-LSU500 transducers.

2.Mount the TS-LSU500E in the pump manifold.

3.The TS-LSU500E wiring must enter the console in Explosion Proof conduit through a knockout on the Hazardous side of the barrier. Secure each pair of transducer wires to a single channel on the 4-20mA Input Module. Always start at the first available channel and do not skip channels. For example, if channels one through three are already being used for another application channel 4 must be used. Be sure to connect the wires to the correct polarity (+/-). If the transducer is wired backwards it will not function.

4 - 20mA EXP
INPUT MODULE
RUN	Non-Intrinsically	Hazardous Location
ERR	Safe Side of	Class I, Division 1, Group
	Console
(Red)		D, Group IIA, Zone 0
–
+
–
+
–
+
–
+
–		LS-500E
+
–
+
–
+		- (BLK)
–
		+ (RED)
+

Explosion-Proof Conduit

Figure 4 – 4-20 mA Input Module Wiring

8