Franklin Fueling Systems TS 550 User Manual

TS-550 evo

®

Fuel Management System

Installation Guide

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 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

Danger

Warning

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.

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 identies 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. A potentially 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 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 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.

Warning

Warning

Warning

Warning

Warning

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 Fuel Management System system is used to monitor tanks containing gasoline or other

ammable substances, you may create an explosion hazard if you do not follow the requirements in

this manual carefully.

All wiring must enter the 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 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. TS-550 evos 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 TS-550 evo console or attached components should only be performed by a qualied,

factory-trained technician.

2

Notice

Franklin Fueling Systems reserves the right to change this document and specications at any time without notice. 
Franklin Fueling Systems makes no expressed or implied warranty with regard to the contents of this manual. Franklin 
Fueling Systems assumes no liability for errors or omissions, or for any damages, direct or consequential, that may result 
from the use of this document or the equipment that it describes.

Trademarks

INCON®, TS-5 Series®, TS-550 evo® Series
are registered trademarks of Intelligent Controls. All brand and product names are trademarks or registered trademarks of 
their respective companies.

®, 

System Sentinel®, SCALD®, Brite®, BriteBox®, BriteBus®, and BriteSensors®

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.

Return Shipping Charges

Franklin Fueling Systems will not accept shipments of returned products without a Return Material Authorization (RMA) 
number. RMAs are obtained by contacting Franklin Fueling Systems’s Technical Service Division — NO RMAs will be 
given without the unit’s serial number(s). Returned material remains the property of the buyer until replaced or repaired.

Under Warranty

Franklin Fueling Systems will pay all freight and insurance charges for all “Under-Warranty” RMAs. 

Non-Warranty

It is the buyer’s responsibility to prepay all freight and insurance charges for “Non-Warranty” RMAs.

Refer to the Warranty section at the end of this manual for all warranty issues.

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: [phone] E-mail: [e-mail]
Fax: [phone] [e-mail]
Tel: US & Canada 1 800 225 9787
Tel: México 001 800 738 7610
Tel: Europa [phone]

Ofce Hours: 8am to 5pm CST - Monday through Friday

Please visit our web site at www.franklinfueling.com

Copyright ©2011 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.

3

Contents

Important Safety Messages ...................................................................................................... 2

Notice ........................................................................................................................................3

Trademarks ...............................................................................................................................3

Inspection of Materials .............................................................................................................. 3

Return Shipping Charges. ............................................................................................................... 3

Contacting Franklin Fueling Systems (FFS).................................................................................... 3

Introduction ............................................................................................................................... 5

Certied Installer/Service Person . .................................................................................................. 5

Station Owner/Operator . ................................................................................................................ 5

Abbreviations & Acronyms. ............................................................................................................. 5

Related Documentation. .................................................................................................................. 5

Product Description ..................................................................................................................5

Standard Installation Materials .................................................................................................6

Console Installation ..................................................................................................................7

Console Location............................................................................................................................. 7

Mounting the Console. .................................................................................................................... 7

TS-550 evo Dimensions and Operating Parameters .................................................................8

Communication Ports ...............................................................................................................9

RS-232 Communication Connectors. .............................................................................................. 9

Wiring the Console & Modules .................................................................................................10

Non-Intrinsically Safe Module Wiring ........................................................................................ 10

Controller Module (CM). .................................................................................................................. 11

Power Supply Module (PS). ............................................................................................................ 11

Relay Output Wiring (optional). ....................................................................................................... 13

Emergency Generator Applications (optional). ................................................................................ 13

Relay Module (RLY). ....................................................................................................................... 15

AC Input Module (ACI). ................................................................................................................... 16

4-20mA EXP Analog Input Module (420EXP). ................................................................................ 16

Input/Output Module (IO)................................................................................................................. 17

10 Amp Relay Module (10ARLY). .................................................................................................... 18

Intrinsically Safe Module Wiring ................................................................................................ 19

Probe Module (PRB). ...................................................................................................................... 20

2-Wire Sensor Module (2WSNS). ................................................................................................... 21   

3-Wire Sensor Module (3WSNS). ................................................................................................... 22

4-20mA Analog Input Module (420IB). ............................................................................................ 23

Control Drawing ........................................................................................................................ 24

Warranty ...................................................................................................................................26

Warranty Registration. ..................................................................................................................... 26

Specications ............................................................................................................................ 27

4

Introduction

This manual contains installation and site preparation 
instructions for Franklin Fueling Systems’s TS-550evo 
console. Overall safety issues, troubleshooting information, 
warranty, service, and return policies, as dened in this 
manual, must be followed.

Please read this entire manual carefully. Failure to 
follow the instructions in this manual may result in faulty 
operation, equipment damage, injury or death. This 
equipment should only be serviced by an Franklin Fueling 
Systems-certied installer.

Certied Installer/Service Person

Only an Franklin Fueling Systems certied installer or 
service person is allowed to access both the user interface 
keypad and areas internal to the TS-550evo console.

Station Owner/Operator

The station owner or operator of the TS-550evo console is 
only allowed to access the user interface keypad. Access 
to areas internal to the console is strictly prohibited.

Abbreviations & Acronyms

10ARLY - 10 Amp Relay Module
2WSMS - 2-Wire Sensor Module (Intrinsically Safe)
3WSMS - 3-Wire Sensor Module (Intrinsically Safe)
420EXP - 4-20 mA EXP module
ACI - AC Input Module
420IB - 4-20mA Analog Input Module (Intrinsically Safe)
AST - Aboveground Storage Tank
ATG - Automatic Tank Gauge
CM - Controller Module
DIM - Dispenser Interface Module
FMS - Fuel Management Systems
IO - Input / Output module
IS - Intrinsically Safe
LIM - LonWorks Interface Module
PC - Personal Computer
PRB - Probe Module (Intrinsically Safe)
PS - Power Supply Module
RLY - Relay Module

SCM - Secondary Containment Monitoring
TPI - Turbine Pump Interface

TS-EXPC - TS-5 Series - Expansion Console
UST - Underground Storage Tank

Related Documentation

The system operation and programming instructions, 
troubleshooting guide and console maintenance manual 
are provided for your use in separate documents. Detailed 
installation and testing instructions for each type of leak 
detection sensor are present in the relevant manual, and, 
likewise, the installation, testing, and programming of 
various upgrade kits and optional accessories are also 
contained in separate manuals, addenda or in one of this 
document’s appendixes.

Product Description

The TS-550 evo is a modular, automatic, continuous 
monitoring system that uses plug-in modules to perform 
a wide variety of functions.  From fuel management, 
monitoring, and/or control functions the TS-550 with its 
plug-in modules allows you to customize the system to 
meet your needs.  Purchase only those functions that 
you require, and expand your system later for greater 
capabilities.

The TS-550 evo’s enhanced processor and additional 
memory on the CM (Controller Module) along with 
the exibility of the modular design allows for peak 
performance while monitoring multiple systems.  The TS­550 can easily monitor all of your tanks, lines, sumps, and 
secondary containments.

The TS-550evo console comes standard with a Controller 
Module (CM), Power Supply Module (PS), and a color LCD 
display and these features:

•   Generates reports automatically in response to 
preset / programmed conditions and alarm

•   Provides audio-visual annunciation when an alar or 
warning condition exists

•   Performs inventory monitoring

•   Is able to print reports on a compatible external Hewlett­Packard Printer

•   Can communicate via Ethernet, RS-232, RS-485, or an 
optional internal fax/modem.

The TS-550 evo console optionally:

•   Has six (6) open slot for additional module that can be 
used to expand its capabilities

•   Can support a combination of up to:

•  36 Probes (or three Probe Modules)

•   36 2-wire sensors (or three 2-Wire Sensor Modules)

•   24 3-wire or 2-wire sensors (or three 3-wire Sensor 
Modules)

•   24 relay outputs (or three Relay Modules) 

•   24 4-20mA inputs  (or three 4-20ma Input Modules)

•   36 AC inputs (or three AC Input Modules)

•   12 4-20mA outputs & 24 AC/DC Inputs (or three 
Input & Output Modules)

Example Station:  If your station has 8 Submersible 

Pumps, 12 Tanks, 8 Lines and 24 
Sensors, you could control all of it with 
your FFS TS-550evo and six plug-in 
modules: a Relay Module, a Probe 
Module, an Analog Input Module, an AC 
Input Module and two Sensor Modules.

5

Standard Installation Materials

Recommended standard materials should be selected and 
installed per all applicable local, state and federal codes 
governing the installation of this product and its associated 
systems. Please see the corresponding console / module 
wiring section or the associated devices section of this 
manual for complete installation details.

Cables Required for Liquid Level Probes, and 4-20 mA
Sensors

Use cables and wires compliant with national and local 
codes. Franklin Fueling Systems recommends using the 
types of cable shown below up to a recommended length of:

•   Belden No. 87760 87760 (0.15" or 3.048 mm OD) to 260 
feet (80 m)

•   Belden No. 87761* (0.12" or 3.048 mm OD) to 400 feet 
(120 m)

•   Belden No. 88761 88761 (0.12" or 3.048 mm OD) to 400 
feet (120 m)

•   Belden No. 89182* (0.31" or 7.874 mm OD) to 1500 feet 
(450 m)

Note: An asterisk (*) denotes a cable that may be ordered 
from Franklin Fueling Systems.

Note:  Conductors of different intrinsically safe (IS) circuits 

may be run together within the same conduit, and, 
when they do, they should have at least .01 inches 
(.25 mm) of insulation.

Cable or Wire for 2-Wire or 3-Wire Sensors

2-wire or 3-wire sensor wire (type THHN, TFFN, or THWN, 
gas and oil resistant, 18 AWG minimum, 1500 feet max. 
wire run length) can be used when enclosed within rigid 
metal conduit  from the sensor to the console.

Leak detection sensor cable is required when NOT 
run through rigid metal conduit. Refer to the Direct Burial
Cable – Installation Manual (P/N 000-1041) for further 
information. See below for cable types and descriptions:

Alpha 58411 (Franklin Fueling Systems P/N

600-0062)

Two conductor cable for standard, 2 conductor leak 

detection sensors  (0.114 inch (2.9 mm) O.D.)

Wire required for the TS-550 evo Console

 • 3 conductors:  Power – 14 GA to 12 GA Max. – Black, 

White, and Green

 • 1 conductors:  Safety Ground – 12 AWG Green (2 may 

be required in some locations)

 • As required conductors:  Accessories – Type THHN, 

TFFN, or THWN, 18 AWG minimum

Circuit Breaker

20 Amp — providing power only for the TS-550evo 
console, one required per console

Weatherproof Junction Boxes

Minimum 16 cubic inch (406.4 cubic mm) weatherproof 
junction box, cover, and cover gasket for the manholes 
of: liquid level probes and leak detection sensors. See 
our sales literature for part numbers for ½ and ¾ inch 
(12.7 mm and 19.05 mm) conduit junction boxes and 
recommended manufacturers. Also use ¾ to ½ inch (12.7 
mm to 19.05 mm) bushings for probe/sensor compression 
ttings.

Use a weatherproof metal pull box for combining several 
circuits that will run into the TS-5 Series console through 
one or more conduits. Use a separate weatherproof metal 
pull box to combine intrinsically safe (IS) liquid level probe 
and leak detection sensor wiring. Do not run other non-
intrinsically safe wiring within the IS pull box. Run ½ or ¾ 
inch (12.7 mm or 19.05 mm) IS probe or sensor conduit 
from the manholes to the IS pull box, and then run up to 
four ½ or ¾ inch (12.7 mm or 19.05 mm) conduits to the 
console’s IS conduit knockouts.

Conduit

Rigid metal conduit (RMC) - male NPT threaded: use ½ 
or ¾ inch (12.7 mm or 19.05 mm) for IS probe and sensor 
wiring to the console (from the manholes, use ½ or ¾ inch 
conduit), and use ½ or ¾ inch (12.7 mm or 19.05 mm) for 
non-intrinsically safe accessories and power wiring.

Use conduit hardware that is appropriate for the installation 
and meets local, state and federal requirements.

Splice Connector Kits Must Be Used — Warranty
Requirement

Use the Franklin Fueling Systems-approved, moisture­resistant, no-strip splice connectors for liquid level probe 
and leak detection sensor wires. You may order the TSP­KW30, which contains 30 of the Franklin Fueling Systems­approved, moisture-resistant connectors.

Using moisture resistant splice connectors will:

•   Reduce/eliminate corrosion of the wire connections from 
repeated exposure to water condensation, which causes 
eventual signal loss and system failure.

•   Reduce/eliminate equipment damage from water 
ooding around the connectors, which causes short­circuit damage.

Thread Sealant (UL Classied)

Use a non-hardening, “stay-soft,” thread sealant, or 
equivalent, to seal and waterproof all tank riser pipe 
threads. In addition, the thread sealant (or “pipe dope” 
as it is commonly known) should also be chemically 
non-reactive to the product in the tank(s). Apply thread 
sealant to seal/waterproof all outdoor electrical conduit 
tting threads including the hole plugs at the weatherproof 
junction boxes.

Riser Pipes

ANSI Schedule 40  (or chemically non-reactive) – 4 inch 
(101.6 mm) (8 NPT) riser pipes for liquid level probes. 
See the appropriate leak detection sensor manual for 
information on required riser pipes and riser cap adapters.

6

Probe Installation Kit(s)

See the TSP-LL2’s installation instructions that came 
with the probe for the items included with the TSP-K4A 
standard probe installation kit. For chemical applications, 
see the TSP-LL2C’s installation instructions for the 
TSP -K4AS stainless steel riser cap adapter kit and the 
TSP-SSP stainless steel product oat.

TSP-LL2 Probe Floats

•   Floats for 4 inch (101.6 mm) riser pipes, order: TSP­IGF4 for gasoline applications or TSP-IDF4 for diesel 
and fuel oil

•   Floats for 3 inch (76.2 mm) riser pipes, order: TSP-IGF3 
for gasoline applications or TSP-IDF3 for diesel and fuel

oil

•   Floats for 2 inch (50.8 mm) riser pipes, order: TSP-IGF2 
for gasoline, TSP-IDF2 for diesel and fuel oils, or TSP­SSP stainless steel oat for chemical products

Manufacturer’s Tank Chart for Each Tank

The manufacturer’s Tank Chart and other documentation 
will be used for installation and programming, and possibly 
for future reference. Keep this information — do not
discard it.

Console Installation

Console Location

The location that you select to install the console must be 
indoors in an area classied as non-hazardous (see the 
console specications table at the beginning of the Wiring 
the Console & Modules chapter for further information). 
To get the maximum benet from this system, install the 
console where personnel can easily make use of it; mount 
it at eye level for operator convenience. Mount the console 
level on a vertical surface between 2 feet (0.6 m) and 
6 feet (1.9 m) high using the appropriate fasteners. For 
European applications, the console must be located in a 
pollution degree 2 environment per IEC60664.

Mounting the Console

The TS-550 evo consoles must be

Warning

Warning

mounted in a location where explosive

or ammable vapors are not present,

otherwise an explosion hazard will be
created which can result in severe injury,
death, serious property damage and/or
environmental contamination.

Leave a minimum of two inches (5.1 cm)
of space around the console open to
allow for ventilation, communication port
connections, conduit and wiring. If the
ventilation louvers located on the sides
of the TS-550 evo are obstructed, the unit
may overheat and stop functioning as
intended.

Four mounting tabs are available on the outside corners 
of the console. Select fasteners that have sufcient load 
carrying capacity and which are appropriate for wall 
construction – a fully equipped TS-550evo console can 
weigh as much as 40 pounds (18 kg), so make sure that 
your fasteners (and mounting surface) can adequately 
support that much weight. In addition, plan ahead to 
make sure that there is enough room around the console 
for: conduit coming into the unit, communication port 
connections, possible incoming probe or sensor wiring, 
and for the console door to fully open for easy access.

Note:  For questions concerning standard installation 

materials to be used for the TS-550 evo console, 
please refer to the Standard Installation Materials 
section of this manual.

7

TS-550 evo Dimensions and Operating Parameters

The TS-550 evo has conduit knockouts and communication ports located on the bottom of the unit. Use the diagram below 
to help you mount the console appropriately.

10.25" (260.4 mm)

8.25" (210 mm)

12" (305 mm)

9.00" (229 mm)

Figure 1: TS-550 evo Dimensions

Console Operating Parameters

Line Voltage: 115/230 V~ +15%, -10%

Frequency & Power: 50/60 Hz, 150 W maximum

Storage Temp.: -20° to 60° C (-4° to 140° F)

Operating Temp.: 0° to 40° C (32° to 104° F)

Operating Humidity: 0 to 95%, non-condensing

Cleaning: Cloth or sponge slightly dampened in mild 

Splash Resistance: Not to be exposed to direct spray, splash or drips

Location: Indoors in an ofce or in a non-hazardous 

detergent

pollution degree 2 environment per IEC60664

8

Communication Ports

COMM 2BUS EXT

CAN H

CAN L

GND

TPI RS-485

COMM 1USBETHERNETHORN

FAX/MODEM

NON-INTRINSICALLY SAFE WIRING ONLY!

FOR USE ONLY WITH EQUIPMENT SPECIFIED

IN THE INSTALLATION INSTRUCTIONS

A

B

GND

+

—

The TS-550 evo console has several communication ports that can be used to communicate with various devices. The 
communication ports can be used for a wide variety of applications: to connect the console to a computer network, to print 
reports on an external printer or to fax reports via the optional internal fax/modem. Please refer to the table below for a 
more complete listing of the ports and their associated devices.

Port Connector Type Devices Module

RS-232 Comm 1 DB9 Female Local PC (preferred in Comm 1) Controller

RS-232 Comm 2 DB9 Male

Ethernet RJ-45 Local Network Controller

USB 1 Type A External Hewlett-Packard Printer Controller

USB 2 Type A External Hewlett-Packard Printer Controller

Fax/Modem RJ-11

RS-485/TPI

Bus Extension

(CAN)

RS-422/232 & Current Loop DB9 Male Dispenser Distribution Box (Dbox)

LON

4 Pin Pluggable Terminal Block, 0.2" 
(5.08 mm) LS

3 Pin Pluggable Terminal Block, 

0.15" (3.81 mm) LS

2 Pin Pluggable Terminal Block, 0.2" 
(5.08 mm) LS

POS Terminal, External Modem, External 
ATG to TS-EMS or Local PC with a null­modem cable

Phone Line (requires an optional fax/
modem)

TS-DIM (external) Power Supply

TS-EXPC Power Supply

IFSF Network LON Interface

Power Supply

Controller

Dispenser 
Interface

Peripheral equipment connected

Caution

to the T5 series console’s
communication port must:

1. Be listed by UL or another third­party Nationally Recognized
test laboratory when required
by the authority having
jurisdiction, and:

2. Not be installed over a
hazardous location (unless so
rated)

Figure 2: View of Communication Ports

Note:

The onboard TS-DIMIB (Dispenser Interface Module) and the TS-LON (IFSF protocol Interface Module) are optional 
daughterboards that attach to the Power Supply Module. Only one daughterboard can be used in a system.

Note:  Either the Current Loop or RS-422/232 connector will be used to connect to a dispenser distribution box (Dbox) 

depending on the manufacturer’s settings.

RS-232 Communication Connectors

Two connectors for RS-232 interfaces are provided on the bottom of the TS-550 evo console. The pin designations for the 
RS-232 connectors are as follows:

Console RS-232 Comm Port 1

DB9 Connector, Female, DCE

Pin No. Function Input/Output Pin No. Function Input/Output

O

2 TXA

3 RXA

5 Signal GND 3 TXA

7 4 DTR

8 CTS

→

I

←

O

→

Console RS-232 Comm Port 2

DB9 Connector, Male, DTE

1 DCD

2 RXA

5 Signal GND

O →

I ←

I

←

O →

Note: Follow the communications setup instructions in the TS-550evo Programming Guide.

9