Franklin Fueling Systems TS-LLD User Manual
TS-LLD
Electronic Line Leak Detector
Installation Guide
Part Number: 000-1359, Rev. H
Copyright
TS-LLD INSTALLATION GUIDE
©
March 2012
NOTICE
INCON has strived to produce the finest possible manual for you, and to ensure that the
information contained in it is complete and accurate. However, INCON makes no expressed or
implied warranty with regard to its contents. INCON assumes no liability for errors or omissions, or
for any damages, direct or consequential, that result from the use of this document or the
equipment which it describes.
This document contains proprietary information and is protected by copyright. All rights are
reserved. No part of this document may be reproduced in any form without the prior written
consent of INCON.
INCON reserves the right to change this document at any time without notice.
Need Help ? Contact INCON at:
INTELLIGENT CONTROLS, INC.
PO Box 638
SACO ME 04072
Office Hours: 8 a.m. to 5 p.m. EST Monday through Friday
Sales 24 hour Technical Service
Phone: (800) 872-3455 Phone: (800) 984-6266
Fax: (207) 283-0158 Fax: (207) 282-9002
E-mail: sales@intelcon.com E-mail: tech@intelcon.com
Visit our web site at: http://www.intelcon.com
INCON ® is a registered trademark of Intelligent Controls, Inc.
Tank Sentinel ® is a registered trademark of INCON
Red Jacket ® is a trademark of the Marley Pump Co.
FE Petro ® is a registered trademark of FE Petro, Inc.
The INCON TS-LLD is covered by United States Patent Number 5,918,268 (June 29, 1999)
Copyright 1995, 1996, 1997, 1998, 1999 Intelligent Controls, Inc. All rights reserved.
—
TS-LLD INSTALLATION GUIDE
❖
—
Table of Contents
Chapter . Section Page No.
P Preface ................................................................................................. P - i
Graphic Symbol Conventions ................................................................................... P - i
Page Numbering Convention – Example: ........................................................ P - i
Page Layout Convention – Example: ................................................................ P - i
Components Included with Each TS-LLD System ................................................. P - ii
Before you Begin .................................................................................................... P - ii
NOTES ..................................................................................................... P - ii
1 TS-LLD Electronic Line Leak Detector – Overview .......................... 1 - 1
Overview and Theory of Operation.......................................................................... 1 - 1
Leak Test Requirements and Length ................................................................. 1 - 2
The LSU (Leak Sensing Unit) ............................................................................ 1 - 2
Communications ................................................................................................ 1 - 2
The Control Unit (CU) ........................................................................................ 1 - 3
Operator Interface ........................................................................................... 1 - 3
Your Notes ............................................................................................................ 1 - 4
2.0 TS-LLD Materials & Tools Required ............................................ 2.0 - 1
Do a Site Survey Before Attempting the Installation ............................................ 2.0 - 1
Submersible Turbine Pumps
Electrical Supply ........................................................................................... 2.0 - 1
Materials Required ............................................................................................... 2.0 - 1
Tools Required ..................................................................................................... 2.0 - 2
2.1 TS-LLD SAFETY............................................................................ 2.1 - 1
Important Safety Notes and Warnings................................................................. 2.1 - 1
Safety Notes and Warnings (continued... ) ...................................................... 2.1 - 2
2.2 TS-LLD LSU Installation ............................................................... 2.2 - 1
LSU Installation Steps ......................................................................................... 2.2 - 1
NOTE..................................................................................................... 2.2 - 4
NOTE..................................................................................................... 2.2 - 6
2.3 TS-LLD CU Installation & Wiring ................................................. 2.3 - 1
Control Unit ( CU ) Installation Steps ................................................................... 2.3 - 1
NOTE..................................................................................................... 2.3 - 1
TABLE 2.3 - 1 Typical Single Phase Wire Connection List ................. 2.3 - 4
NOTE..................................................................................................... 2.3 - 4
TS-LLD Line Leak Detector — Mechanical Blender Interface ............................ 2.3 - 8
Final Installation Steps .................................................................................... 2.3 - 14
TABLE OF CONTENTS Page TOC - 1 TOC
Table of Contents
Chapter . Section Page No.
2.4OptionalTS-LLD – Tank Sentinel Console Interface............... 2.4 - 1
TS-1000 Tank Gauge Interface............................................................................ 2.4 - 1
Example TS-1000 & TS-2000 ATG Reports:.................................................... 2.4 - 2
TS-2000 Tank Gauge Interface............................................................................ 2.4 - 3
NOTE..................................................................................................... 2.4 - 3
Programming the TS-2000................................................................................ 2.4 - 4
Alarm Relays.................................................................................................. 2.4 - 4
Alarm Reports................................................................................................ 2.4 - 4
TS-1001 / TS-2001 LLDI Interface....................................................................... 2.4 - 4
Your Notes..........................................................................................................2.4 - 6
2.5TS-LLD After Installation Steps & Testing.................................. 2.5 - 1
After Installation Steps & Testing...................................................................... 2.5 - 1
Important — Warranty Registration..................................................................... 2.5 - 2
Important — Customer Documentation............................................................... 2.5 - 2
3TS-LLD System Operation & Testing................................................ 3 - 1
System Operation................................................................................................... 3 - 1
CU Component Location & Function................................................................... 3 - 2
Control Unit Display................................................................................................ 3 - 2
Normal Displays ( on steady / solid )................................................................... 3 - 2
Day Counts........................................................................................................ 3 - 2
Fault Displays ( Flashing on and off ).................................................................. 3 - 2
a. Line Leak Test Failure – Flashing Leak Alarm Codes.................................. 3 - 2
When a Leak Test Fails / Line Leak is Detected:.......................................... 3 - 3
b. Monthly-Compliance Warning – Flashing Day Codes.................................. 3 - 3
Indications:.................................................................................................... 3 - 3
Recommendation:......................................................................................... 3 - 3
c. Flashing Display Error Codes........................................................................ 3 - 3
Line Leak Test light................................................................................................. 3 - 4
Line Leak Detected light......................................................................................... 3 - 4
Display Functions, Codes & Concise Instructions.................................................. 3 - 4
Reset Test touch button — press to:....................................................................... 3 - 4
NOTE........................................................................................................ 3 - 4
Display Diagnostic Test Codes:......................................................................... 3 - 4
NOTE........................................................................................................ 3 - 4
TOC Page TOC-2 TS-LLD INSTALLATION GUIDE
Table of Contents
Chapter . Section Page No.
3 TS-LLD System Operation & Testing (continued... )
Starting a 0.1 gph Annual Precision Leak Test ................................................ 3 - 4
Requirements: ............................................................................................... 3 - 4
Definition: quiet-time ..................................................................................... 3 - 4
How to Start a Manual Test ........................................................................... 3 - 5
Normal Operation – Sequence of Events / Steps ............................................... 3 - 5
1.) Product Dispense – Begin
( dispense: nozzle out / lever up / switch on ) ............................................. 3 - 5
2.) Product Dispense – End
( dispense: nozzle in / lever down / switch off ) ........................................... 3 - 5
3.) The 3.0 gph Gross Hourly Test .................................................................... 3 - 5
4.) The 0.2 gph Monthly-Compliance Test ........................................................ 3 - 5
NOTE........................................................................................................ 3 - 5
A 0.2 gph Test Automatically Starts When: ................................................... 3 - 6
Out of Compliance ............................................................................................ 3 - 6
Frequently Asked Questions:
Why do Days Count Up ?............................................................................... 3 - 7
Why do Error Codes 29, 30, 31, or 32 Appear ? ........................................... 3 - 7
How do I Display the Last Alarm or Error Code ? .......................................... 3 - 7
How do I Reset Flashing Error Codes ? ...How do I Allow Dispensing ?
...How do I Clear Flashing Codes ? ............................................................... 3 - 7
Why can’t I Reset and Dispense ?................................................................. 3 - 7
How Do I Verify a Leak ? ................................................................................ 3 - 7
How do I Start a Manual Test ? ...................................................................... 3 - 8
How Often Should the Manual Test be Run ? ............................................... 3 - 8
What Should I Do:
When a 3 gph Leak Test Fails / Gross Leak is Detected ? ............................ 3 - 8
When a 0.2 gph Leak Test Fails / Leak is Detected ? ................................... 3 - 8
When a 0.1 gph Annual Precision Leak Test Fails / Leak is Detected ? ....... 3 - 8
4 TS-LLD Line Leak Detection .............................................................. 4 - 1
When a Line Leak is Detected................................................................................ 4 - 1
NOTE........................................................................................................ 4 - 1
Steps to take When a Line Leak is Detected: ..................................................... 4 - 1
NOTE........................................................................................................ 4 - 2
How Often Should a Manual ).1 gph Test be Run ? ................................................ 4 - 2
Need help ? ....................................................................................................... 4 - 2
TABLE OF CONTENTS Page TOC - 3 TOC
Table of Contents
Chapter . Section Page No.
5 TS-LLD Maintenance & Service ......................................................... 5 - 1
NOTE........................................................................................................ 5 - 1
Cleaning the Control Unit ........................................................................................ 5 - 1
Control Unit Replacement Parts ............................................................................. 5 - 1
Pump Relay Control Box Replacement Parts ......................................................... 5 - 1
Leak Sensing Unit (LSU) Adapters & Replacement Parts ..................................... 5 - 2
LSU Removal for Service / Inspection and Cleaning ........................................ 5 - 2
After Maintenance or Service DO – .................................................................. 5 - 2
6.0 Service & Factory Support .......................................................... 6.0 - 1
Where to Find Help .............................................................................................. 6.0 - 1
Service ................................................................................................................. 6.0 - 1
Need help ? Factory Support ............................................................................. 6.0 - 2
Phone and Pax members: ................................................................................ 6.0 - 2
Sales & Tech. Service numbers,
Technical Service & After Hours – Pager – ................................................ 6.0 - 2
INCON Office Hours ....................................................................................... 6.0 - 2
Before calling INCON ..................................................................................... 6.0 - 2
Return Shipments ................................................................................................ 6.0 - 2
Warranty Registration Form
Your Notes ......................................................................................................... 6.0 - 4
(copy, & Fax Reg. Form back to INCON) ....... 6.0 - 3
6.1 Test Fail Alarms, Warnings & Error Codes ................................ 6.1 - 1
Display Codes ..................................................................................................... 6.1 - 1
Normal Display Codes (on steady – not flashing)......................................... 6.1 - 1
Flashing Alarms, Warnings, and Errors Display Codes ............................... 6.1 - 1
Diagnostic Display Codes (on steady – not flashing) ................................... 6.1 - 1
Your Notes ......................................................................................................... 6.1 - 2
6.2 TS-LLD Troubleshooting Guide .................................................. 6.2 - 1
Display Codes ...................................................................................................... 6.2 - 1
Problem Description/Symptom
NOTE..................................................................................................... 6.2 - 2
Your Notes ......................................................................................................... 6.2 - 4
Probable Cause
(Action to take) ....... 6.2 - 1
6.3 TS-LLD Warranty & Terms ........................................................... 6.3 - 1
Warranty .............................................................................................................. 6.3 - 1
Warranty Disclaimer and Limitation of Liability ................................................... 6.3 - 1
For Further Information, Contact INCON ........................................................... 6.3 - 2
Your Notes ......................................................................................................... 6.3 - 2
TOC Page TOC - 4 TS-LLD INSTALLATION GUIDE
Table of Contents
Chapter . Section Page No.
Appendix A TS-LLD Technical Specifications ......................................... A - 1
Operating Specifications ......................................................................................... A - 1
Electrical Specifications .......................................................................................... A - 1
Allowable Pipe Type and Length ............................................................................. A - 1
Environmental Specifications .................................................................................. A - 2
Mechanical Specifications ...................................................................................... A - 2
Safety Approvals and Listings ................................................................................ A - 2
User Feedback Form .......................................................................................... U - 1
Table of Figures & Diagrams
Chapter . Section Page No.
Chapter 1
Figure 1.1 LSU Outline ...................................................................... 1 - 1
Figure 1.2 CU Outline Dimensions ...................................................... 1 - 1
Chapter 2 . Section 2
Figure 2.2-1 MI Cable Adapter Installation (before and after) ............ 2.2 - 1
Figure 2.2-2 Plug Location – RedJacket STP Housing ...................... 2.2 - 2
Figure 2.2-3 Plug Location – FE Petro STP Housing ......................... 2.2 - 3
Figure 2.2-4 TS-LLD Leak Sensing Unit – Thread Doping ................ 2.2 - 3
Figure 2.2-5 Line Leak Detector Installation – RedJacket Pump ....... 2.2 - 4
Figure 2.2-6 Line Leak Detector Installation – FE Petro Pump.......... 2.2 - 5
Figure 2.2-7 Line Leak Detector Wiring – RedJacket Pump .............. 2.2 - 6
Figure 2.2-8 Line Leak Detector Wiring – FE Petro Pump Housing... 2.2 - 7
Figure 2.2-9 MI Cable Adapter Installation – RedJacket Pump ......... 2.2 - 8
Figure 2.2-10 MI Cable Adapter Installation – FE Petro Pump ............ 2.2 - 9
Figure 2.2-11 Tightening MI Cable Adapter Fitting – RedJacket ....... 2.2 - 10
Figure 2.2-12 Tightening MI Cable Adapter Fitting – FE Petro .......... 2.2 - 11
Figure 2.2-13 Typical Installation TS-LLD Line Leak Detector ........... 2.2 - 12
Figure 2.2-14 INCON TS-LLD Installation @ Ext. Leak Det. Port ...... 2.2 - 13
Figure 2.2-15 INCON TS-LLD Installation at BigFlo
Diaphragm Valve ..................................... 2.2 -14 & 2.2 - 15
Figure 2.2-16 INCON TS-LLD Installation at FE Petro
STP or IST pumps (Single or Three Phase)............. 2.2 - 16
TABLE OF CONTENTS Page TOC - 5 TOC
Table of Figures & Diagrams
Chapter . Section Page No.
Chapter 2 . Section 3
Figure 2.3-1 CU Internal & Bottom Views, and Relay Box Top View .. 2.3 - 1
Figure 2.3-2 CU Component Location - Internal View........................ 2.3 - 2
Figure 2.3-3 TS-LLD CU Typical Mounting and Conduit Routing....... 2.3 - 3
TABLE 2.3 -1 Typical Single Phase Wire Connection List .............. 2.3 - 4
Figure 2.3-4 Typical Single Phase 240 VAC
Pump Relay Box & Control Unit Wiring Diagram ........ 2.3 - 5
Figure 2.3-5 Typical Single Phase 240 VAC
Pump & Control Unit Interface Schematic .................. 2.3 - 6
Figure 2.3-6 Single Phase 240 VAC Multiple Pump & Manifolded
Line w/ Single LSU & CU Interface Schematic .......... 2.3 - 7
Figure 2.3-7 Mechanical Blender Dispensers to
TS-LLD Control Unit Interface Schematic .................. 2.3 - 8
Figure 2.3-8 Three Phase 240 VAC Pump & Control Unit
Interface Schematic .................................................... 2.3 - 9
Figure 2.3-9 Three Phase 240 VAC Supply – Starter – Motor
Control Box – and BigFlo Pump (3 wire)
Interface Schematic to TS-LLD ................................ 2.3 - 10
Figure 2.3-10 Three Phase 240 VAC Supply – Starter – Motor
Control Box – and BigFlo Pump (5 wire)
Interface Schematic to TS-LLD ................................ 2.3 - 11
Figure 2.3-11 Three Phase 240 VAC Supply – Starter & Motor
Control Box – Standard (FE Petro STP)
Interface Schematic to TS-LLD ................................ 2.3 - 12
Figure 2.3-12 Three Phase 240 VAC Supply – FE Petro
Variable Frequency Controller (VFC),
Motor Control Box – and IST Pump
Interface Schematic to TS-LLD ................................. 2.3 - 13
Figure 2.3-13 Control Unit Final Assembly ......................................... 2.3 - 14
Chapter 2 . Section 4
Figure 2.4-1 TS-1000 & TS-TGI Layout .............................................. 2.4 - 1
Figure 2.4-2 TS-1000 & TS-TGI – TS-LLD Wiring Diagram ............... 2.4 - 2
Figure 2.4-3 TS-2000 – TS-LLD Line Leak Detector Interface .......... 2.4 - 3
Figure 2.4-4 TS-1001 / 2001 Typical Hardware Layout ...................... 2.4 - 4
Figure 2.4-5 TS-1001 / 2001 LLD
I
Wiring Diagram ........................... 2.4 - 5
Chapter 3
Figure 3-1: Control Unit Cover – Component Location ....................... 3 - 2
Chapter 5
LSU Bottom & Side Views ........................................................................ 5 - 2
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TOC Page TOC - 6 TS-LLD INSTALLATION GUIDE
❖
—
P PREFACE
Contents:
Graphic Symbol Conventions (used in this manual)
Page Numbering and Layout Conventions
Components Included with Each TS-LLD System
Before You Begin
Graphic Symbol Conventions
NOTE
Important information, tips, and hints are highlighted by the NOTE graphic.
☞
CAUTION
graphic and contain instructions that must be followed to avoid faulty equipment
operation, or an explosion or shock hazards. If ignored, severe injury or death
result !
DANGER
instructions that must be followed to avoid an explosion or electrical shock
hazard. If ignored, severe injury or death
— ❖ — End of Chapter symbol
Page Numbering Convention – Example:
Page 4 – 1 = Chapter 4 page 1 and Page 6.1 – 2 = Chapter 6 . Section 1 – Page 2
Page Layout Convention – Example:
or
WARNING
messages are highlighted by the WARNING
messages are highlighted by the DANGER graphic and contain
will
result !
may
Chapter Number &
Name (
FIRST
Chapter Contents
TOP LEFT
PA GE
)
Manual Name
(
EVEN NUMBERED
PAGES
)
Page Number
Chapter Number
Chapter Name
ODD NUMBERED
(
PAGES
)
Page Number
Chapter Number
PREFACE Page P - i P
Components Included with Each TS-LLD System
(TS-LLD Packing List)
(1) CU – Control Unit enclosure assembly (with stick-on CU Serial No. label)
(1) CU – Control Unit faceplate cover assembly
– (4) CU cover hold-down screws (4-40 x 1/4 inch)
*
(1) Bundle of different colored wire (Wire Bundle)
– (1) Spare 1/2 Micro Amp Fuse (F1)
*
– (1) Line Filter Capacitor, 1 µ Farad (for pump relay / motor control box)
*
(1) Sheet of (9) stick-on –
(1) LSU – Leak Sensing Unit (with stick-on LSU Serial No. label)
(1) Cable adapter (2 inch NPT) – (for Red Jacket Pumps)
– (1) Plug (1/4 inch NPT)
*
– (2) Wire Nuts (red) – (for connections at pump)
*
(1) Warranty Registration Card (write / stick-on CU & LSU Serial No. labels)
(1) TS-LLD Installation Guide Manual
(1) Read Me First – Installation Guide (Supplement Sheet)
(1) TS-LLD Quick Reference Guide (for the station owner / customer)
– Denotes parts in the supplied Hardware Kit (within plastic accessory bag)
*
DANGER
labels
Before you Begin
NOTES
☞
Refer to all applicable Local and State codes before beginning this installation. If a
conflict exists between the information presented in this manual, and the local
codes, then follow the local codes.
Maintenance, Service, and Installation of the TS-LLD system is to be performed by
Factory Trained and Certified personnel only.
Heed all
attempting any installation, maintenance, or service work.
This manual is your reference guide for the INCON TS-LLD line leak detector. It
includes typical installation details, which may vary depending on the actual
equipment at the site. Reference the Submerged Turbine Pump (STP) or
submersible pump, and pump relay (Motor Control) box — manufacturers’
documentation — for the installation details and requirements of this equipment.
CAUTIONS
and
WARNINGS
! See Chapter 2.1 about Safety, before
—
P Page P - ii TS-LLD INSTALLATION GUIDE
❖
—
1 TS-LLD Electronic
Line Leak Detector system –
Overview
Contents:
• Overview and theory of
Operation
• Leak Test Requirements
and Length
Overview and Theory of Operation
- JU N C T IO N
BOX SIDE
8 INCH
LEADS
M I CABLE
ADAPTER
• The LSU (Leak Sensing Unit)
• Communications
• The CU (Control Unit)
• Operator Interface
The INCON TS-LLD is an electronic line leak detector
system. It has two components: a Control Unit (or CU)
and a Leak Sensing Unit (or LSU). The CU is mounted in
the station near the pump control relay box, and the LSU is
installed in the line leak detector port at the submersible
pump housing. One system per pump is required to detect
leaks from a pressurized fuel line.
2 3 .5 IN CH E S
APPROX.
OVERALL
LENGT H
ASSEMBLED
M I CABLE
The TS-LLD detects leaks in the pipeline leading from the
submersible pump to the dispenser. To comply with
current EPA regulations, three types tests are provided.
These are: a 0.1 gph annual test, a 0.2 gph monthly test,
and a 3.0 gph hourly test, which run at full line pressure.
Note: All Dimensions are in inches, and are approximate
0.60
2.25
Line #:
Product:
4.35
TOP & BOTTOM VIEW - C ONTROL UNIT (CU )
3.35
Knoc kout f or
1/2 inch f itting
- Ty pic a l -
x x x x x x x x
TS-LL D C U S eri al Numb er
xxxxxxxx
- LINE LEAK
P O RT S ID E
2 INCH NPT
FR ON T VIEW
RIGHT SIDE VIEW
Figure 1.1 LSU Outline Figure 1.2 CU Outline Dimensions
Overview Page 1 - 1 1
Overview and Theory of Operation (Continued... )
The 0.1 gph annual test is started manually from the control unit (also known as a
manual test). On the other hand, the gross 3.0 gph hourly test and the
intermediate precision 0.2 gph monthly-compliance test both start and run
automatically.
and finish any line leak test.
Leak Test Requirements and Length
The 3.0 gph hourly test starts after every dispense and takes about 3 minutes
of
quiet-time
The 0.2 gph monthly-compliance test automatically starts after a 3.0 gph test
passes
hours. The monthly compliance test either runs, passes, and resets the day-count
to 00, or, advances a day if no test has passed after 24 hours. Depending on
conditions of the line and product, the 0.2 gph monthly-compliance test needs
13 minutes to 4 hours of
unless
Quiet-times, where no dispensing occurs, are required to start
to finish.
a previous 0.2 gph test has already passed within the last 24
quiet-time
to finish.
The manual 0.1 gph annual test needs 4 hours of
started, and takes about 13 minutes of
The LSU (Leak Sensing Unit)
The LSU (Leak Sensing Unit) has an O-Ring sealed valve at its base, which forces
all of the fuel flowing from the submersible pump through the LSU. A
microprocessor based printed circuit board is contained in the LSU. It uses a
proprietary technique to measure the actual product flow rate through a sensor
tube within the LSU, which can indicate a leak.
In most cases, the only required field wiring connections are two wires that are
connected in parallel to the existing Submersible Turbine Pump (STP) power-feedlines. A special copper sheathed, Mineral Insulated Cable (MI Cable) connects the
LSU to the electrical junction box at the pump discharge head.
Communications
The LSU not only receives power from the existing pump power-lines, but it
transmits data (communicates) over these lines. One of the power lines is routed
through a communications
pickup coil
quiet-time
quiet-time
inside the Control Unit (CU).
to finish after it starts.
before it’s
1 Page 1 - 2 TS-LLD INSTALLATION GUIDE
The CU (Control Unit)
The CU monitors data that it receives from the pickup coil. The control unit
automatically turns on the pump when no one is dispensing product and calculates
accurate liquid flow rates to determine if a line leak exists or not.
The dispense signal is also monitored to identify when a customer is about to
dispense product. The CU is tied directly to the existing Pump Relay (Motor
Control) Box that is inside the station. The control unit activates the pump relay,
which turns the pump on and permits product dispensing when no line leak or
errors exist.
When a leak or error is detected, the pump relay is deactivated, which
keeps the pump turned off and prevents product dispensing.
Operator Interface
Two lights, a 2 digit display, and a reset-test touch button are provided for operator
interface. One light turns on when leak tests run, and the other flashes when a line
leak is detected. The two digit display shows operational status codes / day counts
(since the last monthly 0/2 gph line leak test passed), or flashes line leak alarms,
warnings, and error codes when and if they occur.
Brief operating instructions, and a list of codes and display functions are printed on
the control unit faceplate. See Chapter 3 for complete details.
Overview Page 1 - 3 1
— Your Notes —
—
1 Page 1 - 4 TS-LLD INSTALLATION GUIDE
❖
—
2.0 TS-LLD Materials & Tools
Required
Contents:
• Do a Site Survey Before Attempting the Installation
• Materials Required
• Tools Required
Do a Site Survey Before Attempting the Installation
Submersible Turbine Pumps:
What is the Motor Control / Pump Relay Box or Starter Type ? and
What is the Model Number, HP, Manufacturer, and age of all Turbine Pumps ?
Electrical Supply:
What is the Voltage and Phase (240 VAC – Single or Three Phase ? ) of all
Turbine Pumps ?
Materials Required
❒
Petroleum absorbent / absorbing rags
❒
Pipe Dope — Non-hardening (Soft-Set), UL Classified, gas/oil resistant —
to seal the Leak Sensing Unit, and the 1/4 inch Tank Test Port plug at the pump
❒
MI Cable Adapter — for installation on the TS-LLD Leak Sensing Unit (LSU). The
TS-RJ 2" NPT Cable Adapter for Red Jacket® submersible pumps is
with the TS-LLD),
Order INCON part number:
TS-FE 3" straight Cable Adapter for FE Petro® STPs
❒
Stick-on
❒
(1) 1/4 inch NPT pipe plug for the tank test port at the pump head
the TS-LLD)
❒
Red wire nuts for LSU wiring at the pump head
❒
(1) 1µ Farad Line Filter capacitor for the pump relay box
– supplied with the TS-LLD)
❒
Wire: 14 AWG, 3 feet
DANGER
(supplied
the adapter for FE Petro® STPs must be ordered separately...
*
labels
(INCON P/N 240-1175 – supplied with the TS-LLD)
(supplied with
(supplied with the TS-LLD)
(INCON P/N 020-0028
(supplied with the TS-LLD)
❒
(6) spade lugs for #8 studs to connect the 14 AWG wire at the pump relay box
Materials and Tools Required Page 2.0 - 1 2.0
Materials Required
❒
(1) ring lug for the 14 AWG earth ground connection at the pump relay box
❒
(1) short 1/2 inch nipple — 2-1/2 to 3 inches long, or 1/2 inch 90 degree, and
hardware fittings to mount the CU to the relay box. (Or you may wall-mount the
control unit with appropriate fasteners, and use 1/2 inch EMT and fittings.)
❒
Steel stem Replacement Check Valve Kit (RedJacket P/N 144-184-5) to
*
replace older all plastic check valves – for older RedJacket pumps only
❒
Approved Pump Relay (Motor Control) Box – to comply with codes, retrofit
*
system to add a motor control box inside of the station
= Occasionally Required
*
❒
this Installation Manual – INCON P/N 000-1359 most current revision
❒
(1) Completed Warranty Registration Card –
❒
TS-LLD Quick Reference guide – INCON P/N 000-1447
TS-LLD).
station owner, shift managers / personnel
❒
Also, for use by the station owner, shift managers / personnel, provide the
name(s), phone number(s) of the local inspection agency and other applicable
information, instructions and regulations should a line leak be detected.
Leave all TS-LLD Quick Reference guide(s) on-site for use by the
(continued... )
(supplied with each TS-LLD)
(supplied with each
!
❒
Regulations and documentation: Applicable Local and State Codes, the
Manufacturers’ manuals and wiring diagrams of the — Dispenser, Submersible
Pump, and Relay Box (including other equipment not listed here and the sites’
electrical power distribution).
Tools Required
❒
Digital multimeter and test leads (high quality professional instrument)
❒
One each: wire strippers, cutters, and crimp splice tool
❒
Various sizes of flat and phillips bladed screwdrivers
❒
One 12 inch long adjustable wrench
❒
One 2 inch open end hex wrench
❒
Two 7/8 inch open end hex wrenches
❒
One socket set, extension, and square socket for a 1/4 inch NPT square headed
hole plug
—
2.0 Page 2.0 - 2 TS-LLD INSTALLATION GUIDE
❖
—
2.1 TS-LLD SAFETY
Contents:
• Important Safety Notes and Warnings...
Read and follow these DANGER, WARNING, and CAUTION
messages before starting any installation or service.
Important Safety Notes and Warnings
DANGER
servicing, or working on this equipment, make sure you turn off all
submersible pump power (240 VAC) and pump relay coil /
dispenser power at the electrical panel. Tag, secure / lockout
these circuit breakers in the off position to prevent accidental or
unauthorized circuit breaker closure. Failure to turn off power
will result in severe injury or death !
DANGER
on, or wiring-to a circuit – a lethal electrical-shock-hazard could
exist, which would kill you.
in the on position, even when the circuit breaker lever is turned off.
DANGER
pump to run leak-tests at full line pressure between periods of
product dispensing (while the dispense switch is off). BEFORE
performing any installation or service (such as replacing fuelfilters) – turn off / lockout all electrical power sources to the
submersible pump(s), and relieve fuel-line pressure. Failure to
turn off power, and relieve fuel-line pressure before work is started,
may cause a pressurized fuel spill.
create a fire or explosion hazard that could result in injury or death.
Electrical Shock Hazard. Before installing,
Verify that no voltage exists before working-
Note: circuit breaker contact(s) can fail
The TS-LLD automatically starts the submersible
A pressurized fuel spill would
NOTE
☞
INCON Danger stickers (see above left) are supplied with the
TS-LLD line leak detector. Apply these stickers on the pump relay
box cover, in locations near dispenser fuel-line filters, plugs,
emergency safety-shut-off valves, on the TS-LLD Leak Sensing
Unit (at the submersible pump housing), and other serviceable
components of a fuel line (where a spill would occur if the line
became pressurized). The selected surfaces must be clean, dry,
and in plain sight so that the warning can be read, and followed.
SAFETY Page 2.1 - 1 2.1
Safety Notes and Warnings (continued... )
DANGER
After any installation or service of the submersible pump or its
housing, inspect the MI Cable at the LSU (Leak Sensing Unit) for
damage, twists, kinks, or breaks... 240 VAC power flows through
this cable to the LSU.
damaged, twisted, kinked, or broken.
this area could cause an explosion, injury or death.
WARNING
dispenser, may be under pressure. Turn off all pump power and
relieve pipeline pressure (reference and follow the pump
manufacturer’s directions about how to do this). If the line leak
detector/plug (or any other part of the submersible pump and fuel
line) is removed without first relieving pressure, then a product
leak will occur. This could cause an environmental, fire, or
explosion hazard, and may result in injury or death.
WARNING
fuel dispensing equipment (volatile fuel may be within the pump’s
leak detector port). Allow no source of combustion near the work
area. Failure to follow these directions may cause an explosion
hazard, which could result in property damage and death.
Explosion Hazard — Flammable Vapor Area.
DO NOT apply power if the MI Cable is
Electrical sparks or fire in
The fuel line from the submersible pump to the
Be careful not to cause sparks when working on
CAUTION
codes, the National Electric Code (NEC), and the Automotive and
Marine Service Station Code (NFPA 30A) before installation or
maintenance.
Refer to all applicable Federal, State and local
This installation is designed for submersible pumps
which have a pump relay box in the station.
does not exist, then the system must be retrofitted to add a
pump relay (motor control) box in the facility to comply with
Codes.
CAUTION
not recommend operating the LSU while submerged for long
periods of time (drain sump and manhole immediately).
2.1 Page 2.1 - 2 TS-LLD INSTALLATION GUIDE
Although the LSU is water resistant, INCON does
—
❖
—
If a pump relay box
2.2 TS-LLD LSU Installation
Contents:
• LSU Installation Steps
(Typical in Pump Housing)
• Overall Site Installation Diagrams (typical Site,
in Angle Check Valve, RedJacket “BigFlo,” & FE
PETRO STP / IST pumps)
LSU Installation Steps
Follow the steps (below) in the order that they appear:
1) Install the appropriate size MI Cable Adapter on the LSU. Use an adjustable
wrench and a 7/8 inch wrench to tighten the MI cable adapter onto the TS-LLD as
shown in Figure 2.2-1. NOTE: The cable adapter that you install must match the
size of the junction box plug at the submersible pump housing (two different cable
adapters are shown in Figure 2.2-1). The 3 inch straight TS-FE cable adapter
must be ordered separately because the pump type and manufacturer varies.
TS- F E
3 INCH
M I CA BL E
ADAPTER
For FE Petro
Pumps
TS- RJ
2 INCH NPT
M I CA BL E
ADAPTER
For Red Jacket
Pumps
TS-LLD
LINE LEAK DETECTOR
LEAK SENSING UNIT
(LSU)
Figure 2.2-1 MI Cable Adapter Installation (before and after)
LSU Installation Page 2.2 - 1 2.2
DANGER
Fire, Explosion, & Electrical Shock Hazard. Before installing,
servicing, or working on this equipment, make sure all submersible pump power
and pump relay coil / dispenser power is turned off & locked out at the electrical
panel.
lines, and electrical shocks.
Prevent automatic or unauthorized pump start-ups, spills from pressurized
See Chapter 2.1 follow all Safety advise.
2) Relieve pipe line pressure. Reference the detailed instructions found in the
submersible pump manufacturers’ documentation about relieving pressure in the
pipe line.
WARNING
The pipe line is under pressure – relieve line pressure. If the
line leak detector / plug is removed before the pipe line pressure is relieved, then a
product leak will occur ! A explosion, fire, or environmental hazard may be created.
3) Remove the 2 or 3 inch junction box plug and the 2 inch line leak plug, or
mechanical line leak detector (if present), from the pump housing per Figure 2.2-2
or 2.2-3. Use petroleum absorbent / absorbing rags to collect and contain spills if
they occur (be sure to properly dispose of these afterwards). If a mechanical line
leak detector was removed, then apply pipe dope on the threads of the
supplied 1/4 NPT hole plug, and install this plug into the tank test port.
MECHANICAL
2" PLUG
LINE LEAK
DETECTOR
2" PLUG
1/4" PLUG
STATION
CONDUIT
PUMP HOUSING
Figure 2.2-2 Plug Location – RedJacket® Submersible Pump Housing
PIPELINE
2.2 Page 2.2 - 2 TS-LLD INSTALLATION GUIDE
3" PLUG
STATION
CONDUIT
PORT
PUMP HOUSING
1/4" PLUG
2" PLUG
PIPELINE
Figure 2.2-3 Plug Location – FE Petro Submersible Pump Housing
4) Apply Pipe dope to the line leak detector threads per Figure 2.2-4.
TS-LLD
LINE LEAK DETECTOR
LEAK SENSING UNIT
(LSU)
e
Pip
Dope
Pipe dope
only these
thre ads
Figure 2.2-4 TS-LLD Leak Sensing Unit – Thread Doping
LSU Installation Page 2.2 - 3 2.2
5) Insert the Leak Sensing Unit into the line leak port at the pump housing. See
Figure 2.2-5, or 2.2-6, and tighten the detector with a 2 inch hex – open end
wrench (no larger than 12" long to prevent overtightening and possible pump
housing damage or leaks). DO NOT overtighten the LSU in the pump head !
NOTE
☞
The MI Cable should be straight, vertical and able to rotate
freely with the LSU during the insertion or removal process.
M I CABLE
ADAPTER
M I CABLE
LINE LEAK
DETECTOR
STATION
CONDUIT
PIPELINE
PUMP
HOUS ING
Figure 2.2-5 Line Leak Detector Installation – RedJacket® Pump Housing
2.2 Page 2.2 - 4 TS-LLD INSTALLATION GUIDE
STATION
CONDUIT
PORT
PUMP
HOUSING
M I CABLE
ADAPTER
MI CABLE
LINE LEAK
DETECTOR
Figure 2.2-6 Line Leak Detector Installation – FE Petro Pump Housing
LSU Installation Page 2.2 - 5 2.2
6) Carefully bend the thin-wall MI cable by hand and align the 2 or 3 inch cable
adapter fitting with the
hands when bending to fit. DO NOT force or bend the MI cable against the
compression fittings. Be sure you leave enough room to work (as shown in Figure
2.2-7, or 2.2-8).
junction box
plug opening. Support the MI cable with both
NOTE
☞
Avoid breaking the MI cable — DO NOT bend the MI cable too
close to the fittings. An LSU that has a damaged MI Cable is
unusable and must be replaced before power is applied.
7) Carefully remove each wirenut, one at a time and check each for the absence of
power (see Figure 2.2-7, or 2.2-8).
M I CABLE
LINE LEAK
DETECTOR
STATION
CONDUIT
PUMP
HOUSING
Figure 2.2-7 Line Leak Detector Wiring – RedJacket® Pump Housing
2.2 Page 2.2 - 6 TS-LLD INSTALLATION GUIDE
PIPELINE
DANGER
Make sure you check these wires for the absence of power
before proceeding. All pump power (240 VAC) and pump relay / dispenser power
must be off before this installation is started, otherwise a lethal hazard will be
created which could kill you or others.
Note:
A circuit breaker contact(s) can
stick closed even when the circuit breaker is in the off position.
8) Leak Sensing Unit Wiring – Reference Figure 2.2-7, or 2.2-8.
a) Use one of the supplied red wire nuts, and twist one wire lead from pump
together with one of the black wire leads from the LSU.
b) Again use a red wire nut, and twist the remaining lead from pump together
with the remaining black wire lead from the LSU.
c)
For Canadian TS-LLD leak sensing units only:
connect the green (ground)
wire from the pump to the green LSU wire.
M I CABLE
ADAPTER
STATION
CONDUIT
PORT
PUMP
HOUSING
M I CABLE
LINE LEAK
DETECTOR
PIPELINE
Figure 2.2-8 Line Leak Detector Wiring – FE Petro Pump Housing
LSU Installation Page 2.2 - 7 2.2
9) Stuff the wires back into the pump housing and carefully finish bending the MI
cable so that the cable adapter engages the threaded opening of the junction box.
Make sure to push the wires down enough to avoid pinching, or cutting through
the wire insulation from the cable adapter when it is tightened down.
Reference
Figure 2.2-9, or 2.2-10.
10) Tighten the MI cable adapter (new junction box cover) after making sure that
compression fitting is loose and is able to rotate freely — to prevent bending
and twisting damage to the MI Cable. Apply electrically conductive pipe dope to
the cover or the junction box. Use a 12 inch adjustable wrench. Reference Figure
2.2-9, or 2.2-10.
M I CAB LE
STATION
CONDUIT
PUMP
HOUSING
Figure 2.2-9 MI Cable Adapter Installation – RedJacket® Pump Housing
LINE LEAK
DETECTOR
PIPELINE
2.2 Page 2.2 - 8 TS-LLD INSTALLATION GUIDE
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