TS-550 evo®
Fuel Management System
Installation Guide
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 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 |
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hazardous situation may arise if the instructions that follow are not adhered to closely.Apotentially hazardous |
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situation may involve the possibility of severe bodily harm or even death. |
Caution
Danger
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.
Warning |
Follow all federal, state and local laws governing the installation of this product and its associated |
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systems. When no other regulations apply, follow NFPA codes 30, 30A and 70 from the National Fire |
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Protection Association. Failure to follow these codes could result in severe injury, death, serious |
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property damage and/or environmental contamination. |
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Warning |
Always secure the work area from moving vehicles. The equipment in this manual is usually |
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mounted underground, so reduced visibility puts service personnel working on this equipment in |
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danger from moving vehicles entering the work area. To help eliminate these unsafe conditions, |
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secure the area by using a service truck to block access to the work environment, or by using any |
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other reasonable means available to ensure the safety of service personnel. |
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Warning |
When the Fuel Management System system is used to monitor tanks containing gasoline or other |
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flammable substances, you may create an explosion hazard if you do not follow the requirements in |
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this manual carefully. |
Warning
Warning
Warning
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 qualified, factory-trained technician.
2
Notice
Franklin Fueling Systems reserves the right to change this document and specifications 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®, System Sentinel®, SCALD®, Brite®, BriteBox®, BriteBus®, and BriteSensors® 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.
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: |
1 608 838 8786 |
E-mail: sales@franklinfueling.com |
Fax: |
1 608 838 6433 |
techserve@franklinfueling.com |
Tel: |
US & Canada 1 800 225 9787 |
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Tel: |
México 001 800 738 7610 |
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Tel: |
Europa +49 6571 105 380 |
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Office 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 |
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Important Safety Messages....................................................................................................... |
2 |
Notice........................................................................................................................................ |
3 |
Trademarks............................................................................................................................... |
3 |
Inspection of Materials............................................................................................................... |
3 |
Return Shipping Charges................................................................................................................. |
3 |
Contacting Franklin Fueling Systems (FFS).................................................................................... |
3 |
Introduction................................................................................................................................ |
5 |
Certified 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............................................................................................................................. |
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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)................................................................................. |
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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 |
4-20mAAnalog Input Module (420IB).............................................................................................. |
23 |
Control Drawing......................................................................................................................... |
24 |
Warranty.................................................................................................................................... |
26 |
Warranty Registration...................................................................................................................... |
26 |
Specifications............................................................................................................................ |
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 defined 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-certified installer.
Certified Installer/Service Person
Only an Franklin Fueling Systems certified 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 - 4-20mAAnalog 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 flexibility 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 fittings.
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 nonintrinsically 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 flooding around the connectors, which causes shortcircuit damage.
Thread Sealant (UL Classified)
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 fitting 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 TSPK4AS stainless steel riser cap adapter kit and the TSP-SSP stainless steel product float.
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 float 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 classified as non-hazardous (see the console specifications table at the beginning of the Wiring the Console & Modules chapter for further information). To get the maximum benefit 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 mounted in a location where explosive
or flammable 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) Warning 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 sufficient 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) |
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9.00" (229 mm) |
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12" (305 mm)
Figure 1: TS-550 evo Dimensions
Console Operating Parameters
Line Voltage: |
115/230 V~ +15%, -10% |
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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) |
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Operating Humidity: |
0 to 95%, non-condensing |
Cleaning: |
Cloth or sponge slightly dampened in mild |
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detergent |
Splash Resistance: |
Not to be exposed to direct spray, splash or drips |
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Location: |
Indoors in an office or in a non-hazardous |
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pollution degree 2 environment per IEC60664 |
8
Communication Ports
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 |
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RS-232 Comm 1 |
DB9 Female |
Local PC (preferred in Comm 1) |
Controller |
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POS Terminal, External Modem, External |
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RS-232 Comm 2 |
DB9 Male |
ATG to TS-EMS or Local PC with a null- |
Power Supply |
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modem cable |
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Ethernet |
RJ-45 |
Local Network |
Controller |
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USB 1 |
Type A |
External Hewlett-Packard Printer |
Controller |
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USB 2 |
Type A |
External Hewlett-Packard Printer |
Controller |
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Fax/Modem |
RJ-11 |
Phone Line (requires an optional fax/ |
Controller |
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modem) |
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RS-485/TPI |
4 Pin Pluggable Terminal Block, 0.2" |
TS-DIM (external) |
Power Supply |
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Bus Extension |
3 Pin Pluggable Terminal Block, |
TS-EXPC |
Power Supply |
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(CAN) |
0.15" (3.81 mm) LS |
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RS-422/232 & Current Loop |
DB9 Male |
Dispenser Distribution Box (Dbox) |
Dispenser |
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Interface |
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LON |
2 Pin Pluggable Terminal Block, 0.2" |
IFSF Network |
LON Interface |
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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)
SPECIFIE EQUIPMENTD WITH ON USE FOR LY INSTRUCTIONS INSTALLATION THE IN
LY! ON WIRING SAFEINTRINSICALLY-NON
FAX/MODEM HORN ETHERNET USB |
COMM 1 |
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BUS EXT |
COMM 2 |
TPI RS-485 |
D |
H L |
D |
GN |
CAN CAN |
A B GN + — |
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 |
2 |
TXA |
O → |
3 |
RXA |
I ← |
5 |
Signal GND |
|
7 |
|
|
8 |
CTS |
O → |
Console RS-232 Comm Port 2
DB9 Connector, Male, DTE
Pin No. |
Function |
Input/Output |
1 |
DCD |
O → |
2 |
RXA |
I ← |
3TXA
4 |
DTR |
I ← |
5 |
Signal GND |
O → |
Note: Follow the communications setup instructions in the TS-550evo Programming Guide.
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