Franklin Fueling Systems TS-LLD User Manual

Download

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)

—

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

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

—

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:

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

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

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)

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.

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

M I CABLE

ADAPTER

STATION

CONDUIT

PORT

PUMP

HO USING

M I CABLE

LINE LEAK DETECTOR

PIPELINE

Figure 2.2-10 MI Cable Adapter Installation – FE Petro Pump Housing

LSU Installation Page 2.2 - 9 2.2

11) Tighten the MI cable compression fitting with a 7/8 inch wrench. Be careful

not to overtighten the compression fitting –

damage and failures

– torque to 25 lbs/ft. Reference Figure 2.2-11, or 2.2-12.

avoid MI cable twisting / bending

12) Recommended for Red Jacket installations: inspect and replace the check valve under the functional element – IF – it doesn’t have a stainless steel stem. Use

Red Jacket replacement part number: 144-184-5.

13) Finally, inspect the MI Cable at the LSU (Leak Sensing Unit) for damage, twists, kinks, or breaks —

replaced before power is applied.

M I Cable

Upper Compression Fittin

Lower Junction Box / Cable Adapter Fittin

DETAIL A

a LSU that has a damaged MI Cable is unusable and must be

Install a new LSU if the MI Cable is damaged.

Stainless Steel st em

Plastic

Check Valve

Detail

M I CABLE

STATION

CO NDUIT

PUMP

HO USING

PIPELINE

Figure 2.2-11 Tightening MI Cable Adapter Compression Fitting – RedJacket® Pump

2.2 Page 2.2 - 10 TS-LLD INSTALLATION GUIDE

DETAIL A

DANGER

damaged, twisted, kinked, or broken.

this area could cause an explosion, injury or death.

M I C ab le

Upper Compression Fittin

Low er Junc tion Box / Cable Adapter Fittin

Explosion Hazard — Flammable Vapor Area.

DO NOT apply power if the MI Cable is

Electrical sparks or fire in

M I CABLE

AD AP TE R

STATION

CONDUIT

PORT

PUMP

HOUSING

M I C AB LE

LINE LEAK DETECTOR

PIPELINE

Figure 2.2-12 Tightening MI Cable Adapter Compression Fitting – FE Petro Pump

LSU Installation Page 2.2 - 11 2.2

2.2 Page 2.2 - 12 TS-LLD INSTALLATION GUIDE

Reference Schematic Figure 2.3 - 8

Electrical Power Panel

Pump

Relay

Boxes

INCON TS-LLD Line Leak Detector

Typical Installation in Leak Detector Port

TS-LLD CUs (Control Units): # 2 and # 1

TS-LLD LSU # 1

(Leak Sensing Unit # 1)

at submersible

pump housin

Dispenser

# A

Dispenser

TS-LLD LSU # 2

(Leak Sensing Unit # 2)

at submersible

pump housin

# X

NOTE:

A TS-TGI Tank Gauge Interface

module is required to connect

module is required to connect the

the TS-LLD Line Leak Detector

TS-LLD Line Leak Detector system

system to an INCON TS-1000 Tank Sentinel console.

to an INCON TS-1000 Tank Sentinel console. See the TS-TGI Install

See the TS-TGI Install Manual.

Manual.

For TS-1001/2001 Tank Sentinel consoles, use the LLD / ...see the OPTIONAL TS-LLD TANK SENTINEL ATG CONSOLE INTERFACE chapter in this manual.

Existing Conduit (Pump 1)

Submerged Turbine Pump

Tank - Pump # 1

interface

Existing

Conduit

(Pump 2)

Figure 2.2-13 Typical Installation INCON TS-LLD Line Leak Detector

Epoxy

Filled

EYS Seal

Fitting

Explosionproof Junction Box

Tank - Pump # 2

LSU Installation Page 2.2 - 13 2.2

Reference Schematic Figure 2.3 - 8

Electrical Power Panel

Pump Relay

Boxes

INCON TS-LLD Line Leak Detector

External Leak Detector Port Installation

TS-LLD CUs (Control Units): # 2 and # 1

TS-LLD LSU (#1)

(Leak Sensin

at STP housin

Standard

Single Phase Installation

Dispenser

Unit)

# A

Dispenser

# X

TS-LLD LSU (#2)

(Leak Sensing Unit)

at External Leak Detector Port

NOTE:

A TS-TGI Tank Gauge Interface module is required to connect the TS-LLD Line Leak Detector system to an INCON TS-1000 Tank Sentinel console. See the TS-TGI Install Manual.

For TS-1001/2001 Tank Sentinel consoles, use the LLD / ...see the OPTIONAL TS-LLD TANK SENTINEL ATG CONSOLE INTERFACE chapter in this manual.

Epoxy

Filled

Fittin

interface

Existin

Conduit

(Pump 2)

Existin Conduit (Pump 1)

Submer Turbine Pump (STP)

("Standard" Single Phase

Tank - Pump # 1

Installation)

Figure 2.2-14 INCON TS-LLD Installation at External Leak Detector Port

EYS Seal

Explosionproof Junction Boxes

Tank - Pump # 2

Installation within an

External Leak Detector Port

( not pump housing)

2.2 Page 2.2 - 14 TS-LLD INSTALLATION GUIDE

y y

Electrical Power Panel

Pump Relay

Boxes

3 Phase

Pump Motor

Starter

INCON TS-LLD Line Leak Detector

BigFlo & Diaphragm Valve Installation

TS-LLD CUs (Control Units): # 2 and # 1

Epoxy Filled

EYS Seal

TS-LLD LSU (#1)

(Leak Sensing Unit)

at pump housing

Standard Single

Phase Installation

Fittings

Dispenser

# A

Dispensers

TS-LLD LSU (#2)

# B thru # X

(Leak Sensing Unit)

at Diaphragm Valve

see Detail A - A

NOTE:

An additional Sin Rela

Control Box (panel), two additional

wires, and possibl

le Phase 230 VAC

an additional conduit run to

the LSU, are required for 3 Phase Applications.

The INCON TS-LLD LSU MUST be installed

so the fasteners are ali

ned in a 12 & 6 o'clock (vertical) position as shown in Detail A - A. Tighten the LSU to meet this requirement.

Existing Conduit

(Pump 2)

Submerged

Pump (STP)

Detail A - A

Overhead Top View

(correct ali

nment)

Partial

Enlar

Side View

Existing Conduit (Pump 1)

Turbine

Tank - Pump # 1

("Standard" Sin

Installation)

le Phase

BigFlo Pump

(BigFlo Three Phase Pump and

Diaphragm Valve Installation)

BigFlo

STP

Pump

Explosionproof Junction

Box . . . . .

Tank - Pump # 2

Note: Use two conduits when conduit fill exceeds 40% full as specified b

our National Electric Code.

BIG-FLO PUMP & DIAPHRAGM VALVE

Reference Schematic Figures 2.3 - 9 & 10

Detail A

Installation (2 Explosion proof Conduit Outlet

Boxes & Hardware and 1 conduit run)

BIG-FLO PUMP & DIAPHRAGM VALVE

Detail B Alternate

Installation (2 Explosion proof Conduit Outlet

Boxes & Hardware and 2 conduit runs)

LSU Installation Page 2.2 - 15 2.2

3/4 inch Conduit & EYS Epoxy filled " Y " Seal fitting

Crouse-Hinds:

GUAD

or GUAM

& GUJC

BigFlo

STP

Pump

UL approved Explosion Proof Junction Boxes Class 1, Div's 1 & 2 Groups C, D

MI Cable

INCON TS-LLD

Line Leak Detector LSU

Diaphram Valve

3/4 inch Conduit & EYS Epoxy filled " Y " Seal fittings

BigFlo

To / From Pump Control Relay Box & 3 Phase Motor Starter

Underground Containment / Storage Tank

To Dispenser

Note: Use two conduits when conduit fill exceeds 40% full as specified by your National Electric Code.

Use recommended components or equivalent

To Pump Control Relay Box

From # 3 Phase Motor Starter

STP

Pump

Crouse-Hinds: GUJC Explosionproof Junction Box A 3/4 TO 1/2 inch bushing is also required for the TS-LLD LSU fitting

Figure 2.2-15 INCON TS-LLD Installation at BigFlo Diaphragm Valve

2.2 Page 2.2 - 16 TS-LLD INSTALLATION GUIDE

Reference Schematic Figures 2.3 - 11 & -12

❖

—

Electrical Power Panel

Motor

Control

Panels

3 Phase Starter

- or Variable Frequency

NOTE:

An additional Single Phase 230 VAC

Relay Control Box (panel), and two additional wires for the LSU, are required for Three Phase pump Applications.

Motor Control Panels may be either:

Single Phase 230 VAC Relay Control Boxes,

- or - Single or Three Phase 230 VAC Variable Frequency Controllers (VFCs).

Controller (VFC)

INCON TS-LLD Line Leak Detector FE PETRO STP and IST (or STP-VS2 VFC) Installation

TS-LLD CUs (Control Units): # 2 and # 1

TS-LLD LSU (#1)

(Leak Sensing Unit)

at STP housing

Existin Conduit (Pump 1)

Existing

Conduit

(Pump 2)

Submerged

Turbine

Pump (STP)

Dispenser

# A

TS-LLD LSU (#2)

(Leak Sensing Unit)

at IST pump housing

Epoxy

Filled

EYS Seal

Fitting

Dispenser

# X

Explosionproof Junction Boxes

Tank - Pump # 1

( "Standard" STP Single Phase

Installation )

( FE PETRO Three Phase:

IST pump or STP Installation )

Figure 2.2-16 INCON TS-LLD Installation at FE PETRO STP or IST pumps

Single or Three Phase 240 VAC Applications

Tank - Pump # 2

2.3 TS-LLD CU Installation & Wiring

Contents:

• Control Unit Installation Steps (Location, Product Configuration, TS-2000 Configuration, Mounting the Control Unit, Relay Box & Control Unit Wiring TABLE 2.3-1)

• Wiring Diagrams & Schematics (Pump Control Relay Box, Single Phase 240 VAC, 3 Phase 240 VAC, 3 Phase RedJacket BigFlo, 3 Phase 240 VAC - FE Petro - STP & IST applications)

• Final Installation Steps

Control Unit ( CU ) Installation Steps

Follow the installation steps (below) and in the order that they appear:

NOTE

☞

DANGER

Electrical Shock Hazard. BEFORE installing, servicing or

working on this equipment, 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 ! Check all wiring terminals for the absence of power before proceeding.

Note: Circuit breaker contact(s) can stick closed even when the circuit breaker lever is in the off position.

You must know the dispense line number, product dispensed, and which pump relay box (motor control box) is associated with this line.

1) Select an accessible mounting location for the control unit (see Figures 2.3-1 &

2.3-3), and remove the appropriate conduit knockouts. The CU is usually

mounted above the pump relay box (shown here)... other locations are possible.

1 485A

INTERNAL VIEW

TB 2

TB 1

2 485B 3 DSY1 4 DSY2 5 ALAR M

1 110V

2 NEU

3 P-OUT

4 P-IN

SIG RTN

KNOCKOUT S FOR ELECTRICAL FIT TINGS TOP VIEW SHOWN

CU ENCLO SURE BOTTOM VIEW

REM O V E KNOCKOUT FOR 1/2 INCH ELECTRICAL FITTING AT BOT TOM

Figure 2.3-1 CU Internal & Bottom Views, and Relay Box Top View

Control Unit Installation Page 2.3 - 1 2.3

BOX

Printed Circuit Board (P C B o a rd )

TS-LLD CO NTRO L UNIT (CU) ENCLOSURE

1 485A 2 485B

TB 2

3 DSY1 4 DSY2

Donut shaped Pic ku p Coil

TB 1

5 ALARM

1 110V

2 NEU

3 P-O UT

4 P-IN

SIG RTN

COVER (SHIELD ON)

P L AS TIC S H IEL D SH O W N MOUNTED OVER PC BOARD.

R E M O VE TH E S H IEL D TO SE T THE JUMPER LINK POSITION AS S H OW N BE L O W .

TH IS S H IE L D M U S T B E IN PLACE BEFORE TH E COVER IS RE-INSTALLED.

GREEN C ONNEC TOR (J1)

= 1/4 inch hole lo c a tio n s fo r w a ll mounting.

Alternate

Jum per

Link Position:

for Diesel, or Fuel Oils

DIESEL

GAS

Standard

Jum per

L i n k P o si ti o n s:

for Gas olin e

DIESEL

Standa rd TGI

Interface

Alternate

Jum per

Link Position:

for Gas olin e

DIESEL

for TS-2000 Interface

Jumper Link

Side V ie w

Standa rd TGI

Interface

Alternate

Jum per

Link Position: for Diesel, or Fuel Oils

DIESEL

for TS-2000 Interface

GAS

Figure 2.3-2 CU Component Location - Internal View

Control Unit Installation Steps (continued... )

GAS

J2J2

GREEN C ONNEC TOR (J1)

DIESEL

C ontrol Unit cover

COVER (SHIELD OFF)

GAS

PC BOARD

S h ie ld

Bottom View

2) Product Configuration (Top Jumper Link) — required only for Diesel, Fuel Oil, or Kerosene — skip this step if gasoline will be monitored. Remove the plastic shield in back of the control unit cover. Pull up and reposition the top blue jumperlink at J2, so that it is installed over the left two pins. See Figure 2.3-2 and reinstall the plastic shield when done.

3) INCON TS-2000 Configuration (Bottom Jumper Link) — this step is required only when the TS-LLD will be wired to or interfaced to an INCON model TS-2000 ATG console. Remove the plastic shield from the control unit cover. At J2, pull up and reposition the bottom jumper-link so that its installed over the left two pins. See Figure 2.3-2 and the applicable INCON Application Note about wiring to

a TS-2000. Reinstall the plastic shield when done.

2.3 Page 2.3 - 2 TS-LLD INSTALLATION GUIDE

(

(es)

NIPPLE

PUMP RELAY BOX

WARNING: DISCONNECT POWER

BEFORE REMOVING COVER

To 208/230 VAC single phase Power Source

electr ical power

anel) - circui t

breakers

90° FITTING

PUMP RELAY BOX

WARNING: DISCONNECT POWER

BEFORE REMOVING COVER

- - Al ter nate Mounti n

To Di s Switch

enser

To Submersibl e Pump explosion

roof Junction Box

WALL MOU N TED & EMT

PUMP RELAY BOX

WARNING: DISCONNECT POWER

BEFORE REMOVING COVER

- - Alternate Mounti ng B - -

WARNING Avoid electrical shock hazards. Disconnect all electrical power source s BEFORE removing any enclosure cover !

NOTE: Ground equipment as required by your local and National Electric Codes.

A - -

Figure 2.3-3 TS-LLD CU Typical Mounting and Conduit Routing

NOTE

☞

4) Mount the CU to the pump relay box (see Figure 2.3-3 above for typical

mounting methods). You may mount the control unit to a wall through the two 1/4 inch mounting holes — use fasteners that are appropriate for the wall construction. The centers of these holes are shown on the inside label of the control unit. In addition, make sure that the UP arrow is pointing up as shown in

Figure 2.3-2.

Control Unit Installation Page 2.3 - 3 2.3

Control Unit Installation Steps (continued...

}

5) Wiring at the Pump Control Relay Box:

a) Remove the wire from S2 to the relay coil b) Remove the wire from M2 to the relay N.O. contact c) Install the 1µ Farad “Line Filter” capacitor (INCON P/N 020-0028) between

terminals L1 and L2

d) Wire the CU to the pump relay box as described below TABLE 2.3-1 and as

shown in Figures 2.3-4 & 2.3-5. Strip 1/4 inch of insulation off each end (for termination at the control unit and for the spade crimp connectors at the pump relay box). Use connectors sized for 14 AWG wire.

NOTE

☞

Other pump relay boxes may have different terminations, and/or may be wired differently than what is shown in this manual.

Typical Single Phase Wire Connection List TABLE 2.3 -1

PUMP RELAY BOX — to — TS-LLD CONTROL UNIT ( CU )

)

From

L2 BLK 14 AWG (supplied) 110 V (AC Line Power input) TB1 - 1

N WHT 14 AWG (supplied) Neu (Line Power Neutral) TB1 - 2

Relay Coil RED 14 AWG (supplied) P-OUT (Pump On - output signal, TB1 - 3

S2 BRN 14 AWG (supplied) P-IN (Pump On - input signal, TB1 - 4

Relay N.O.

Ground Stud GRN 14 AWG (supplied) GND (Equipment Ground) Ground Stud

Wire

Color

ORG 14 AWG (supplied) 240 VAC (Pump Motor Power) { see below }

Wire Gauge Circuit (Description) To

110 V AC, to Pump Relay Coil)

{ Pump Motor Power - the 14 gauge

orange wire is pre-routed through the

N O T E -

pick-up coil at the Control Unit.

relay box

terminal, & wire the other end to the

pump relay N.O. contact (Figure 2.3-

4)... no wiring/connection at CU

{ Ground according to

, wire one end to the M2

your

National Electric Codes.

At the

Local and

- N O T E

NOTE

☞

Electricians: All AC wiring at the control unit (TB1-1 110V and TB1-4 P-IN)

must be in-phase and read 0 VAC in respect to each other and must read from 110 to 130 VAC in respect to ground. Reference Figures 2.3-4 thru

2.3-10. These are “typical” diagrams and may not represent the actual wiring.

A 0 VAC potential must exist from TB1-1 to the hot side of dispenser on switch S1 ( or to S2 ) with the dispense switch on. Take voltage readings at the pump relay box. Use the leg that is in-phase with S1 ( L1 or L2 that reads 0 VAC) and wire it to TB1-1 ( 110V ). For 3 phase applications — DO NOT use any leg that

reads more than 130 VAC to Ground

2.3 Page 2.3 - 4 TS-LLD INSTALLATION GUIDE

No termination - wire runs through the d onut-s hap e d P ic kup Coil

Figure 2.3-4 Typical Single Phase 240 VAC Pump Relay Box & Control Unit

RLY N.O. CONTACT (ORG)

Pickup Coil

M2 (ORG)

TS-LLD Control Unit

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

TB2

Control Unit Installation Page 2.3 - 5 2.3

Wiring Diagram

Remove wires (shown as dashed lines)

NO TE : Only the new wirin that's required within the Pump Relay Box, is shown in this d ia

ram .

Pump Relay Box

PUMP RELAY

- - COM - -

- - - COIL - - -

N.O.

S1 M2S2 M1 N L2L1

RLY COIL (RED)

GROUND

STUD/SCREW

L2 (BLK)

N (WHT)

1 110V

2 NEU

3 P-OUT

S2 (BRN)

GROUND

(GRN)

#8-32 Ground S tud

4 P-IN SIG RTN

Install the 1uF Line Filter Capacitor (INCON PN 020-0028) Be tween L1 & L2

DANGER Electrical shock hazards! Turn off and lock-out the submersible pump power source (terminated at L1 and L2), and the pump relay power source (terminated at S2, from the dispenser switch) BEFORE workin on this equipment. Failure to turn off these power sources will result in severe injury or death.

TB1

Reference Site Layout

Figures 2.2 - 13 & 14

From: 208/230 Volt, Single Phase, Electrical Power Source

Neutral Bus

LINE

LOAD

COM

N.O.

COM

N.O.

Remove Original Wiring

BLK

TS-LLD Leak Sensing Unit (Installed at the pump housing.)

BLK

OFF

Line Filter Cap (See Note 1)

Dispenser Switch (or switches)

GROUND

208/230 Volt, Single Phase, Electrical Power Panel

3 Pole Switched-Neutral Circuit Breaker

COIL

S2S1

115 V.

No connection at CU -- wire is run through the donut-shaped Pickup Coil

RLY N.O. Contact

M2 (ORG)

L2 (BLK)

N (WHT) RLY COIL (RED)

S2 (BRN)

GROUND (GRN)

Remove Original Wiring

208/230 Volt, Single Phase Submersible Pump Motor Relay Box

TS-LLD Control Unit

(use bottom, 1/2 inch

conduit knockout)

Pickup Coil

#8-32 Ground Stud

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

1 110V

2 NEU

3 P-OUT

4 P-IN SIG RTN

TB2

TB1

NOTES:

Single Phase

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE SUBMERSIBLE PUMP POWER SOURCE, AND THE PUMP RELAY POWER SOURCE AT THE CIRCUIT BREAKER - BEFORE - WORKING ON THIS EQUIPMENT. FAILURE TO TURN OFF THESE POWER SOURCES WILL RESULT IN SEVERE INJURY OR DEATH.

Submersible Pump Motor with Thermal Overload

MI Cable Adapter (cover) for Explosion Proof junction box

1) Install the 1uF Line Filter Capacitor (INCON PN 020-0028) between input AC line terminals at the Relay Box.

2) The TS-LLD is installed at the submersible pump housing (see Chapter 2.2 for details).

3) Follow your local and National Electrical Codes for electrical grounding requirements.

4) If three phase is available, see Figure 2.3-6.

2.3 Page 2.3 - 6 TS-LLD INSTALLATION GUIDE

Figure 2.3-5 Typical Single Phase 240 VAC Pump & Control Unit

Interface Schematic

1 110V

2 NEU

TB1

4 P-IN

3 P-OUT

TB2

1 485A

3 DSY1

2 485B

5 ALARM

4 DSY2

Power Source = L1

TS-LLD Control Unit (CU)

ram

SIG RTN

Dia

NOTES

GND

No connection.

Wire is routed

through the

donut-shaped

Pickup Coil

RLY N.O. (ORG)

GND

Neutral (WHT)

M1 (ORG)

L1 Line (BLK)

RLY COIL (RED)

Dispense ( BRN)

Pump On Sig.

1) The Leak Sensing Unit (LSU) is installed at STP # 1

2) In line check valves are required at the output of

each RedJacket Submerged Turbine Pump

3) All ancillary pumps must be controlled / enabled

by the Aux. Relay Box as shown.

4) Only STP #1 Runs during line leak tests

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE

SUBMERSIBLE PUMP POWER SOURCE AT THE CIRCUIT BREAKER - BEFORE -

WORKING ON THIS EQUIPMENT. FAILURE TO TURN OFF PUMP & DISPENSER

POWER SOURCE WILL RESULT IN SEVERE INJURY OR DEATH.

GND

L1 L2 S2 S1

L2 S2 S1

Aux. Relay Box

GND

Dispense

Switch(es)

Relay Box # 2

Pump Control

GND

(dashed lines)

Remove Wires

Conduit

to pump

Junction

Box

STP # 2 Motor

INCON TS-LLD - 1 LSU Multiple Pumps & Manifolded Lines - Wirin

Electrical

Power

Panel

L1 L2

L1 L2 S1S2

P/N

020-0028

Cap at L1 and L2

M1 M2

Install Line Filter

STP #1 Motor & LSU

TS-LLD LSU

at Leak Detection Port:

STP # 1 Pump Housing

(remove dashed wires)

Relay Box # 1

Pump Control

Figure 2.3-6 Single Phase 240 VAC Multiple Pump & Manifolded Line with Single LSU & CU

Interface Schematic

Control Unit Installation Page 2.3 - 7 2.3

TS-LLD Line Leak Detector —

Mechanical Blender Interface

When connecting a TS-LLD line leak detector to systems with mechanical blenders, tie the: premium, all mid-grades, and regular dispenser switch signals together (electric blenders can be wired normally). Wire both premium and regular TS-LLD Control Units at TB1-4 (P-IN). See the typical (partial) wiring diagram below. Because the mid-grades are blended mixtures of the premium and regular octanes, any product dispense will abort leak tests at the premium and regular Control Units.

CAUTION

The

dispense on

signals must be

in phase

to avoid electrical shorts and damage. Verify that all dispenser switch signals are in phase before you tie them together (in phase = 0 Volts AC in respect to each other and 120 Volts AC in respect to Neutral or ground). Note that both pumps will be active on any dispense.

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

1 110V 2 NEU

SIG RTN

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

1 110V 2 NEU

SIG RTN

N.O.

PREMIUM Dispense Switch (es)

N.O.

MID-GRADE Dispense Switch (es)

N.O.

REGULAR Dispense Switch (es)

Dispense

(on) si

(on) signal

(on) si

nal

Dispense

nal

TB2 -

PREMIUM

TS-LLD

Control Unit

TO: PREMIUM MOTOR

START RELAY COIL

Tie to

ether

TB2 -

REGULAR

TS-LLD

Control Unit

TO: REGULAR MOTOR

START RELAY COIL

TB1 -

Figure 2.3-7 Blended Dispensers to TS-LLD Control Unit – Interface Schematic

2.3 Page 2.3 - 8 TS-LLD INSTALLATION GUIDE

L1 ( or L3)

Reference Site Layout

Figures 2.2 - 13 & 14

See

Note

From: 208/230 Volt, Three Phase, Electrical Power Source, utilizing two lines to power a Single Phase load. (See Note 1)

Neutral Bus

LINE

LOAD

COM

N.O.

See

Note

L1 (or L3)

COM

N.O.

Remove Original Wiring

BLK

TS-LLD Leak Sensing Unit (Installed at the pump housing.)

M2M1

BLK

OFF

Line Filter Cap (See Note 2)

Dispenser Switch (or switches)

GROUND

MI Cable Adapter (cover) for Explosion Proof junction box

208/230 Volt, Single Phase, Electrical Power Panel

3 Pole Switched-Neutral Circuit Breaker

COIL

Remove Original Wiring

Single Phase Submersible Pump Motor with Thermal Overload

115 V.

S2S1

NOTES:

1) Only use phases L1 & L2, or L3 & L2. DO NOT use phase L1 & L3.

2) Install the 1uF Line Filter Capacitor (INCON PN 020-0028) between AC input line terminals at the Relay Box.

3) The TS-LLD is installed at the submersible pump housing (see Chapter 2.2 for details).

4) Follow your local and National Electrical Codes for electrical grounding requirements.

5) 230 VAC must not enter the Control Unit! All Control Unit AC wiring must be 110 volts (110V power = TB 1-1, dispenser switch [ S2 ] on signal = TB 1-4, and pickup coil [ M2 ] sense lead all must be derived from the same phase [ L2 ] ).

208/230 Volt, Single Phase Submersible Pump Motor Relay Box

No connection at CU -- wire is run through the donut-shaped Pickup Coil

RLY N.O. Contact

Pickup Coil

M2 (ORG)

L2 (BLK)

N (WHT) RLY COIL (RED)

S2 (BRN)

GROUND (GRN)

TS-LLD Control Unit

(use bottom, 1/2 inch

conduit knockout)

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

1 110V

2 NEU

3 P-OUT

4 P-IN SIG RTN

#8-32 Ground Stud

TB2

TB1

Figure 2.3-8 Three Phase 240 VAC Supply – Single Phase 240 VAC Pump & Control Unit

Interface Schematic

Control Unit Installation Page 2.3 - 9 2.3

Reference Site Layout Figure 2.2 - 15

GND

TB2

1 485A

5 ALARM

4 DSY2

2 485B

3 DSY1

Power Source = L1

TS-LLD Control Unit (CU)

Pickup Coil

No connection.

Run wire

L1 and L2)

Cap (between

Install Line Filter

RLY N.O. (ORG)

through the

donut-shaped

Pickup Coil

P/N

020-0028

2 NEU

1 110V

Neutral (WHT)

L1 Line (BLK)

M1 (ORG)

TB1

4 P-IN

3 P-OUT

SIG RTN

GND

S2 (BRN)

Pump On Sig.

(L1 is source)

RLY COIL (RED)

NOTES

1) If the motor starter coil is 230 VAC then do not wire to neutral --

wire to M1.

2) Observe color code L1 L2 L3 phase sequence for proper rotation

of motor.

3) All conduit fittings, EYS seal fittings, and junction boxes in

manholes or other Hazardous areas are to be explosionproof

rated for: Class 1, Div 1, Group D and wet locations

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE

SUBMERSIBLE PUMP POWER SOURCE (L1, L2, L3 - AT THE CIRCUIT

BREAKER) - BEFORE - WORKING ON THIS EQUIPMENT. FAILURE TO TURN

OFF THE THREE PHASE POWER SOURCE WILL RESULT IN SEVERE INJURY

OR DEATH.

INCON TS-LLD & RedJacket Big Flo Three Phase Wiring Diagram

for newer 3 wire Three Phase motors

BLK

TS-LLD

LSU (Leak

Sensing Unit)

at diaphragm

valve

BLK

GND

Electrical

Power

Panel

L2L1

Aux.

Control

Relay

M2S2S1 M1

Box

(remove

dashed

wires)

N (N o t e 1)

L2L1 L3

Dispense

Switch

Separate

wires

must be

run.

T2T1 T3

RED

ORG

Three Phase BigFlo

Three

Phase

Motor

Starter

(ref.

Note 1)

STP...newer 3 wire version...

Overloads (OLs) in series w/ T1 & T3

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 Page 2.3 - 10 TS-LLD INSTALLATION GUIDE

Reference Site Layout Figure 2.2 - 15

GND

TB2

1 485A

3 DSY1

2 485B

4 DSY2

5 ALARM

Power Source = L1

TS-LLD Control Unit (CU)

h the

No connection.

Run wire

throu

P/N

020-0028

L1 and L2)

Cap (between

Install Line Filter

Pickup Coil

RLY N.O. (ORG)

donut-shaped

Pickup Coil

2 NEU

1 110V

Neutral (WHT)

L1 Line (BLK)

M1 (ORG)

TB1

4 P-IN

3 P-OUT

SIG RTN

GND

RLY COIL (RED)

S2 (BRN)

Pump On Si

See Note 5

NOTES

1) If the motor starter coil is 230 VAC then do not wire to neutral --

wire to M1.

2) Observe color code L1 L2 L3 phase sequence for proper rotation

of motor.

3) All conduit fittings, EYS seal fittings, and junction boxes in

manholes or other Hazardous areas are to be explosionproof

rated for: Class 1, Div 1, Group D and wet locations

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE

SUBMERSIBLE PUMP POWER SOURCE (L1, L2, L3 - AT THE CIRCUIT

BREAKER) - BEFORE - WORKING ON THIS EQUIPMENT. FAILURE TO TURN

OFF THE THREE PHASE POWER SOURCE WILL RESULT IN SEVERE INJURY

OR DEATH.

INCON TS-LLD & RedJacket Big Flo Three Phase Wiring Diagram

for older 5 wire Three Phase motors

BLK

Electrical

Power

Figure 2.3-10 Three Phase 240 VAC Supply – Starter – Motor Control Box – and BigFlo Pump

GND

Panel

TS-LLD

LSU (Leak

Sensing Unit)

at diaphragm

valve

S1 S2 M2 M1

Dispense

Switch

N (N o t e 1)

Motor

Starter

(ref.

Note 1)

Separate

wires

must be

run.

T2T1 T3

RED

ORG

BLK

L1 L2 L3

Aux.

Control

Relay

Box

(remove

dashed

L2L1 L3

Three

wires)

Phase

(5 wire) Interface Schematic to TS-LLD

Control Unit Installation Page 2.3 - 11 2.3

Three Phase BigFlo

STP... older version

with separately wired

internal OverLoads ( OLs )

Reference Site Layout Figure 2.2 - 16

GND

P/N

020-0028

Install Line Filter

Cap at L1 and L2

(remove dashed wires)

Aux. Control Relay Box

GND

2 485B

3 DSY1F14 DSY2

1 485A

TB2

5 ALARM

2 NEU

1 110V

TB1

3 P-OUT

Power Source = L1

TS-LLD Control Unit (CU)

No connection.

Wire is routed

through the

donut-shaped

Pickup Coil

NL2

Pickup Coil

RLY N.O. (ORG)

Neutral (WHT)

L1 Line (BLK)

M1 (ORG)

RLY COIL (RED)

N (N o t e 1)

4 P-IN

SIG RTN

GND

S2 (BRN)

Pump On Sig.

(source = L1)

Dispense

GND

Switches

Dia

s, and junction boxes in

NOTES

s, EYS seal fittin

1) If the motor starter coil is 230 VAC then do not wire to neutral --

wire to M1.

2) Observe color code L1 L2 L3 phase sequence for proper rotation

of motor.

3) All conduit fittin

manholes or other Hazardous areas are to be explosionproof

rated for: Class 1, Div 1, Group D and wet locations

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE

SUBMERSIBLE PUMP POWER SOURCE (L1, L2, L3 - AT THE CIRCUIT

BREAKER) - BEFORE - WORKING ON THIS EQUIPMENT. FAILURE TO TURN

BLK

TS-LLD

LSU (Leak

Sensing Unit)

at IST Pump

Housing

GND

Conduit to pump Junction Box

ORG

INCON TS-LLD & FE PETRO Three Phase STP Wirin

OFF THE THREE PHASE POWER SOURCE WILL RESULT IN SEVERE INJURY

OR DEATH.

Leak

Detection

Port

Electrical

Power

Panel

Figure 2.3-11 Three Phase 240 VAC Supply – Starter – and Motor Control Box

2.3 Page 2.3 - 12 TS-LLD INSTALLATION GUIDE

L2L1 L3

T2T1 T3

L1 L2 L3

Three

Phase

Motor

Control

Panel

Starter

...see

NOTES

1 and 2

Standard Interface Schematic to TS-LLD

BLK

RED

( OLs )

...OverLoads

STP 3 phase Motor

are in series with M1and M3

Reference Site Layout Figure 2.2 - 16

GND

No connection.

Wire is routed

P/N

020-0028

Install Line Filter

Cap at L1 and L2

2 NEU

1 110V

TB1

4 P-IN

3 P-OUT

SIG RTN

TB2

2 485B

3 DSY1

1 485A

4 DSY2F15 ALARM

Power Source = L1

TS-LLD Control Unit (CU)

through the

donut-shaped

Pickup Coil

RLY N.O. (ORG)

Neutral (WHT)

L1 Line (BLK)

M1 (ORG)

GND

RLY COIL (RED)

S2 (BRN)

Pump On Sig.

See Note 5

NOTES

1) Observe color code L1 L2 L3 phase sequence for proper rotation

of motor.

2) All conduit fittings, EYS seal fittings, and junction boxes in

manholes or other Hazardous areas are to be explosionproof

rated for: Class 1, Div 1, Group D and wet locations

INCON TS-LLD & FE PETRO IST (or STPs with VS2 suffix)

DANGER ELECTRICAL SHOCK HAZARDS. TURN OFF AND LOCK-OUT THE

SUBMERSIBLE PUMP POWER SOURCE (L1, L2, L3 - AT THE CIRCUIT

BREAKER) - BEFORE - WORKING ON THIS EQUIPMENT. FAILURE TO TURN

OFF THE THREE PHASE POWER SOURCE WILL RESULT IN SEVERE INJURY

OR DEATH.

Three Phase or Single Phase Wiring Diagram

BLK

TS-LLD

LSU (Leak

Sensing Unit)

at IST Pump

Conduit to pump Junction Box

Red

BLK

ORG

pump motor

(remove dashed wires)

Aux. Control Relay Box

GND

Electrical

Power

Panel

L3 L2 L1

S2 M2 NL2

GND

L3 L2 L1

Dispense

Switches

HOOK

Signal)

(Dispense

GND

M3 M2 M1

FE PETRO IST three phase

L3 is

optional

Three

Phase

wiring

Variable

Frequency

Controller

(VFC)

Figure 2.3-12 Three Phase 240 VAC Supply – FE PETRO Variable Frequency Controller,

Motor Control Box – and IST Pump Interface Schematic to TS-LLD

Housing

Leak Detection

Port

Overloads (OLs)

are in series w/ M1 & M3 )

Control Unit Installation Page 2.3 - 13 2.3

Use a perm anent ink m a rk ing pen and write the Line # Product: on the labe ls b e low .

For Exam ple 1

Lin e # :

Gas

Product:

CU TOP VI EW

INTERNAL VIEW

LLD # 1

Lin e # 1

G asoline

CU RI GHT SIDE VI EW

x x x x x x x x

TS-LLD CU Serial N umber

Line #:

Pr oduct:

G as

1 485A 2 485B

TB2

3 DSY1 4 DSY2 5 ALARM

1 110V

2 NE U

TB1

3 P -OUT

4 P-IN

SIG R TN

Final Installation Steps

6) Recheck your wiring. Make sure all terminations are correct and tight.

7) Use a permanent ink marking pen to: write the Line # and the Product being monitored on two

x x x x x x x

CU labels — The label inside of the control unit, and the label located on the top right of the cover label (so the box and cover can be reinstalled as a matched-set). See Figure 2.3-6 to the left.

8) Reinstall the correct CU cover on the box – as

CU Serial Num ber

a matched-set. See Figure 2.3-6 to the left.

9) Reinstall the pump relay box cover. See Figures 2.3-1 & 2.3-3.

10) Nine INCON Danger stickers are supplied with each line leak detector (P/N 240-1175). Apply

one sticker: 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, and onto 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.

Finally, see the next few Sections of this Chapter about Optional Tank Gauge Console Interface and the After Installation Steps / Testing.

KNOCKO UT FOR 1/ 2 I NCH ELECTRICAL FITTING AT T OP &

CU ENCLO SURE TO P VI EW

Shield

BOTTOM

Line #: Pr oduct:

Figure 2.3-13 Control Unit

Final Assembly

—

❖

—

2.3 Page 2.3 - 14 TS-LLD INSTALLATION GUIDE

2.4 Optional TS-LLD – Tank Sentinel ATG Console Interface

Contents:

• TS-1000 TS-TGI Interface

• TS-2000 Interface

• TS-1001 / TS-2001 LLDI Interface

TS-1000 Tank Gauge Interface

The TS-LLD can be interfaced to an INCON TS-1000 console with the addition of a TS-TGI module. The TGI module (Tank Gauge Interface module) can interface up to 4 TS-LLD systems with the TS-1000.

methods covered in this Section have not been evaluated by Underwriters Laboratories and are not considered part of this Listing.

NOTE – The devices and installation

For Installation, Programming, and Testing issues of the TS-LLD & TS-1000 tank gauge console see the INCON, TS-TGI Installation Guide, manual P/N 000-1051.

EFI

Figure 2.4-1 TS-1000 & TS-TGI Hardware Layout (Motor Control Boxes not shown)

TS-LLD – Tank Sentinel ATG Console Interface Page 2.4 - 1 2.4

TS-TGI

Field Wirin Diagram 240-1196 Rev. A

TS-TGI CHANNEL 1 to CU / LINE # 1 wiring shown typical

Use: Shielded Pair, 20AWG Cable

1 485A 2 485B

TB2

3 DSY1 4 DSY2

- DC to TB1SIG RTN

+ DC to TB2- 5 (ALARM)

Shield to TB1SIG RTN

TB1

5 ALARM

1 110V

2 NEU

3 P-OUT

4 P-IN

TS-TGI with cover off

SIG RTN

(4) #8-32 MOUNTING SCREWS

TS-KB

1 485A 2 485B

TB2

3 DSY1 4 DSY2 5 ALARM

TS-LLD Control Unit (CU) / LINE # N with cover off

1 110V

2 NEU

TB1

3 P-OUT

4 P-IN

SIG RTN

TS-1000 Internal View

( with door open )

Figure 2.4-2 TS-1000 – TS-TGI Module – TS-LLD Control Unit Wiring Diagram

4 line report header (standard)

6/20/1999 09:05 AM

LINE TEST REPORT

Example TS-1000 &

4 line report header (standard)

6/23/1999 10:08 AM

ACTIVE ALARM REPORT

(Not with TS-2000)

TS-2000 ATG Reports:

INCON ENVIRONMENTAL

74 INDUSTRIAL PARK RD

SACO ME

SITE # 00001

4 line report header (standard)

6/23/1999 09:45 AM

ALARM REPORT

6/23/1999 09:45 AM 3 GPH LINE LEAK LINE NO. 1

LOW BRI 6 ACTIVE

3 GPH LINE LEAK LINE NO. 1

4 line report header (standard)

6/31/1999 11:01 AM

ALARM HISTORY REPORT

6/19/1999 03:45 PM POWER UP

6/23/1999 09:45 AM 3 GPH LINE LEAK LINE NO. 1

6/29/1999 10:14 AM .2 GPH LINE LEAK LINE NO. 4

TEST TIME 04:32 PM TEST DATE 6/19/1999 TEST RESULT PASSED

4 line report header (standard)

6/23/1999 10:12 AM

LINE TEST HISTORY

TEST TIME 04:32 PM TEST DATE 6/19/1999 TEST RESULT PASSED

TEST TIME 08:19 PM TEST DATE 6/20/1999 TEST RESULT PASSED

TEST TIME 09:45 AM TEST DATE 6/23/1999 TEST RESULT FAILED

LINE 1

2.4 Page 2.4 - 2 TS-LLD INSTALLATION GUIDE

(J1)

TS-2000 Tank Gauge Interface

Remove the TS-LLD control unit cover & plastic shield, and reposition the blue jumper links as shown in the diagram below. Do this when wiring to the discrete input terminals of an INCON model TS-2000 ATG.

NOTE

TS-LLD Alarm Output ratings (from TB2-5) are: + 5 VDC, 60 milliAmps max. (resistive loads)

☞

INCON TS-2000 AUTOMATIC TANK GAUGE: Discrete Input Interface terminals for the TS-LLD Line Leak Detector

INPUT 4 { spare 2 }

{ spare 1 } INPUT 3

Use: INPUT 1 for Line 1 INPUT 2 for Line 2 INPUT 3 for Line 3 INPUT 4 for Line 4

Collector transistor with a 270 ohm resistor tied to an internal + 5 V DC supply.

INPUT 2 { leaktest }

{ setup } INPUT 1

J5-Even

Numbered Terminals

DC Input

Discrete Input Si

(GND)

J5-Odd Numbered Terminals

nal

RED

BLK

— the output is from an Open

INCON TS-LLD Line Leak Detector

- Control Unit

2 Pulses = Passed 0.2 GPH Test 3 Pulses = Failed 0.2 GPH Test Activated = Failed 3.0 GPH Test

One Pulse = + 5 vdc On 1 second and Off 1 second

TB2-5

TB1SIG RTN

ENCLOSURE

1 485A 2 485B

TB2

3 DSY1 4 DSY2

TB1

5 ALARM

1 110V

2 NEU

3 P-OUT

4 P-IN

SIG RTN

Green Connector

REPOSITION JUMPER LINKS

Alternate

Jumper

Link Position: for Diesel, or Fuel Oils

DIESEL

GAS

for TS-2000 Interface

Plastic shield is mounted over the PC board

Remove the shield to set the jumper link to the correct position as shown below

(replace the shield before reinstallin

the cover).

Alternate

Jumper

Link Position:

for Gasoline

DIESEL

GAS

for TS-2000 Interface

COVER (SHIELD OFF)

Factory Default

Jumper

Link Positions:

DIESEL

GAS

PC BOARD

DIESEL

for Gasoline

GAS

Standard TGI

(TS-1000) Interface

COVER (SHIELD ON)

Figure 2.4-3 TS-2000 – TS-LLD Line Leak Detector Interface

TS-LLD – Tank Sentinel ATG Console Interface Page 2.4 - 3 2.4

Programming the TS-2000

Alarm Relays

From ALARM RELAYS setup menu, select YES for LN LEAK RY1 to activate the audible alarm inside of the console should a line leak occur. Select YES for LN LEAK RY2 to control an external device that is wired to these contacts.

Alarm Reports

From SYSTEM setup menu, enable Report Alarms to have alarm reports printout automatically at the console report printer. As with the TS-1000, Line Test Reports and Line Test History Reports can be printed using the report key (see previeous page for examples).

TS-1001 / TS-2001

The Line Leak Detector Interface to these console uses a 4 conductor, 22 AWG, communications grade cable for the RS-485 protocol. See Figures 2.4-4 and

2.4-5 for additional details.

Communications Wirin

240 AC POWER WIRING Trou

LLDI

Interface

Trough Only

h Only

See the TS-1001 / TS-2001 Setup Programming Guide (P/N 000-1053) for programming details and available reports.

Many line-related reports can be printed at the console by using the report key. See the TS-1001 / TS-2001 Sample Reports Document (P/N 000-1394) for Line – Test, Diagnostic, and History Reports. Also, in the sample reports document, see Line Alarm Reports for active line

alarms, cleared line alarms, or line

alarm history reports.

Motor Control Panels

( Relay Boxes - or - Starters )

Figure 2.4-4 TS-1001 / TS-2001 LLDI Typical Connecting Hardware Layout

2.4 Page 2.4 - 4 TS-LLD INSTALLATION GUIDE

)

TS-LLDI ( Line Leak Detector Interface )

W A R N I N G: AVOID ELECTRICAL SHOCK HAZARDS. EXTERNAL POWER SOUCES MAY BE PRESENT LOCATE AND DISCONNECT ALL EXTERNAL POWER SOURCES BEFORE WIRING OR SERVICING THESE CIRCUITS.

Enlarged View of Terminal Strip # J13

TB2-1 (485A)

TB2-2 (485B)

TB2-3 (DSY 1)

TB1-SIG RTN

Enlarged View

TS-LLD Control Unit (CU)

Interface Terminals:

1 485A 2 485B

TB2

3 DSY1 4 DSY2 5 ALARM

TS-LLD Control Unit (CU) box

GND

TB1

4 P-IN

SIG RTN

NOTE:

CAUTION installation: Read and reference the TS-LLD Manual about Safety, and CU Installation (and wiring steps).

WARNING

Turn off and disconnect all power to the pumps and dispensers before wiring at the TS-LLD Control Units.

3) Up to four TS-LLD Control Units ( CUs ) can be interfaced to the TS-1001 console and up to eight CUs can be interfaced to the TS-2001 console.

BEFORE

attempting this

Avoid electrical shock hazards —

TB2

TB1

CU #1

CU #2

1 485A 2 485B 3 DSY1 4 DSY2 5 ALARM

1 110V

2 NEU

3 P-OUT

4 P-IN

SIG RTN

TS-LLD CU cover (back view)

THIS SHIELD MUST BE IN PLACE BEFORE THE

COVER IS RE-INSTALLED.

GREEN CONNECTOR (J1

COMMUNICATIONS CABLE: 22 AWG, 4 CONDUCTOR...

CU #3

...NOTE --- DO NOT RUN COMMUNICATIONS CABLE IN SAME CONDUIT AS LINE VOLTAGE WIRES.

last CU #N

TS-1001 / 2001 CONSOLE TS-LLD INTERFACE TERMINALS AT J13:

485A COMM LINE

485B COMM LINE

DSY CONTROL UNIT I.D. LINE

S. RTN RS-485 COMMUNICATIONS SIGNAL RETURN

TANK / LINE #1 TS-LLD CU #1:

TB2-1 485A

TB2-2 485B

TB2-3 DSY1

TB2-4 DSY2

TB1-SIG RTN

TANK / LINE #2 TS-LLD CU #2:

TB2-1 485A

TB2-2 485B

TB2-3 DSY1

TB2-4 DSY2

TB1-SIG RTN

TANK / LINE #3 TS-LLD CU #3:

TB2-1 485A

TB2-2 485B

TB2-3 DSY1

TB2-4 DSY2

TB1-SIG RTN

JUMPER NEEDED AT LAST UNIT ONLY

LAST TANK / LINE #N

TS-LLD CU #N:

TB2-1 485A

TB2-2 485B

TB2-3 DSY1

TB2-4 DSY2

TB1-SIG RTN

Figure 2.4-5 TS-1001 / TS-2001 LLDI Wiring Diagram

TS-LLD – Tank Sentinel ATG Console Interface Page 2.4 - 5 2.4

— Your Notes —

—

2.4 Page 2.4 - 6 TS-LLD INSTALLATION GUIDE

❖

—

2.5 After Installation – Steps & Testing

Contents:

• After Installation Steps / Testing

• Important Warranty Information

• Important Customer Documentation

After Installation Steps & Testing (follow steps in order):

1) Make sure that all wiring is checked – completed – and correct, that all electrical box covers are reinstalled, and that all personnel are clear. Surround the LSU and 1/4 inch pipe plug fittings with absorbent. Remove safety tags and lockouts from the submersible pump circuit breakers at the electrical panel and then reapply power (turn the circuit breakers on).

2) Immediately after a power-up, the control unit will display several numbers for a few seconds. Verify that the following is displayed:

nn (2 digit software version number [ Ver # ] of the CU ...after any power-up),

NN (2 digit Ver # of the LSU ...after second and subsequent power-ups),

DD (the total number of days since the last 0.2 monthly leak test passed. This

will show the current day count or a 00 for new installations).

3) Verify that the Line Leak Test light is on. The system should automatically start a 0.2 gph line leak test after power-up, or whenever the day count changes at the display.

the line pressurized.

4) Verify that the Line Leak Detector, and the 1/4 inch NPT pipe plug (at the Tank Test port) are not leaking product around these threads. If there is a leak, then:

a) Power down (turn off and lockout all power again) — see Chapter 2.1

b) Clean the pump housing with absorbent rags

c) Retighten the pipe plug / the line leak detector again. Follow the installation

The submersible pump is turned on at various times during a test to keep

See Chapter 3 for operation and testing.

steps and diagrams shown in Chapter 2.2 in reverse (from Step # 11 to Step # 5), and then forward again (from Step # 5).

d) Repeat steps 1) through 4 c) above until the pump housing is free of leaks.

Remove the absorbent and properly dispose of these materials.

CAUTION

disconnect and straighten the MI Cable before tightening/loosening the LSU.

Testing the System After Installation Page 2.5 - 1 2.5

Avoid damaging the MI Cable – loosen the compression fitting,

After Installation Steps (continued... )

5) Push the control unit RESET - TEST button momentarily to test the system operation. Verify that the:

a) Line Leak Test light goes out when the RESET - TEST button is pushed

b) An 88 is displayed while the button is held down (indicating that the system is

okay, and that all display segments are okay).

Do not hold the TEST push-button down longer than four seconds, otherwise a

0.1 gph manual (annual precision) line leak test will start.

6) Recommended – dispense a small amount of product (a gallon or so) from each dispenser to remove air that may be trapped in line during installation or service.

Note

that air trapped in the line may initially cause false alarms.

7) Verify that leak tests run and finish (Line Leak Test light turns on about 30 seconds after a dispense and indicates that automatic 3 gph and 0.2 gph line leak tests are running). The Line Leak Test light will go out when these tests finish (15 minutes to 4 hours later if dispensing is prevented... 1 hour is typical). Note: the light will also go out when a test is aborted (by pushing RESET-TEST), or when a dispense occurs.

8) Follow-up with the Customer within 30 days and ask for a display reading. If the days are counting up instruct them to leave the pump breakers on 24 hours a day (so tests can finish during quiet times / after normal business hours).

Important — Warranty Registration

After installation, completely fill-out the postage-paid Warranty Registration Card. Have the customer / owner / manager sign this card give a copy to him. Finally, fax a copy or mail the original card back to INCON. Please make certain that you fill out the CU & LSU serial numbers.

Important — Customer Documentation

❒

Leave a copy of the completed Warranty Registration card with the customer.

❒

Leave copies of the TS-LLD Quick Reference Guide with the customer (INCON

P/N 000-1447 — latest revision).

❒

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.

One is supplied with each TS-LLD system.

❒

Provide the name(s) and phone number(s) of the local Distributor and Service

provider for the future use and reference by the customer.

—

2.5 Page 2.5 - 2 TS-LLD INSTALLATION GUIDE

❖

—

3 TS-LLD System Operation & Testing

Contents:

• System Operation

• Normal Displays (Day Counts, Diagnostic Codes)

• Fault displays (Test fails, Monthly Compliance Warnings)

• Indicator lights, RESET-TEST button USE

• Starting a 0.1 Manual Precision Leak Test

• Normal Operation (Sequence of Events)

• Out of Compliance (Dispensing Disabled)

• Frequently Asked Questions

• What to do: When a Leak Test Fails ? (Leak is Detected)

System Operation

The TS-LLD system can perform three different pressurized line leak tests, two of which run automatically. The automatic line leak tests are: a hourly test, and a

precision

0.1 gph annual test that must be started manually at the control unit...

the 0.1 annual test is also known as a

standard

0.2 gph monthly-compliance test. The third test is a

manual test

gross

3.0 gph

A Quick Reference Guide is provided with every TS-LLD system. It was designed specifically for use by your customer at his station. Inform your customer to keep a log of all alarm and error codes. This log could be FAXed to you and would prove to be very useful diagnostic tool. Distributors and Installers: you may order more guides by contacting INCON and asking for part number 000-1447 or for 000-1482, which is a color-laminated version. Certain restrictions may apply.

Need Help ?

Call INCON Technical Service @ 1-800-984-6266 (or FAX: 1-207-282-9002) for help with leak alarms, or diagnostic codes. Also, please call if alarms, warnings, or error codes occur frequently or repeatedly.

DANGER

This line leak detector may start the pump at any time during a line

leak test to maintain fuel line pressurize. Avoid Fire, Explosion hazards, and

Electrical shock hazards... make sure that all dispenser and submersible pump power is turned off / locked out before attempting any service (such as:

replacing fuel line filters). Inspect the copper Mineral Insulated Cable (MI Cable) at the Leak Sensing Unit for damage, kinks, or breakage. Make sure to do this after any installation or service is done in the containment sump / pump head and BEFORE power is applied. See Chapter.Section 2.2 in this manual about installation and inspection.

Never apply power if the MI Cable is damaged !

System Operation & Testing Page 3 - 1 3

CU Component Location & Function

Control Unit (CU) Display

Line Leak Test light

(shown testing)

Line Leak Detected light

Display Functions, Codes &

Concise Instructions

Reset Test

touch

button

➀ ➁

➂ ➃

➄

RESET

TEST

LINE LEAK TEST

LINE LEAK DETECTED

NORMAL: DAYS SINCE MONTHLY LEAK TEST PASSED

FLASHING: 1=FAILED ANNUAL (0.1 GPH) LEAK TEST

INTELLIGENT CONTROLS,INC.

TS-LLD

LINE LEAK DETECTOR

DISPLAY FUNCTION

2=FAILED MONTHLY (0.2 GPH) LEAK TEST

3=FAILED HOURLY (3.0 GPH) LEAK TEST

29 – 32=MONTHLY COMPLIANCE WARNING

33 – 87=ERROR CODES

88=SYSTEM OK (PRESS TEST TO ACTIVATE

PRESS RESET TO CLEAR ALARM

PRESS TEST FOR 5 SECONDS TO RUN ANNUAL TEST

)

Figure 3-1: Control Unit Cover – Component Location

Control Unit Display

➀

The 2-digit, 7 segment LED will display: day-counts, RESET-TEST touch-button diagnostic codes, and

possibly Diagnostic Codes Between 0.2 Gph Test-cycles

when the system is operating normally. The display will also rapidly flash: line leak detected / test-fail alarm codes, monthlycompliance warning codes, or error codes when faults occur.

Normal Displays

( on steady / solid )

Day Counts

Ordinarily, the display shows the total number of days since the last 0.2 gph

monthly-compliance test passed. The

day count

is on steady (not flashing) and advances one day for every 24 hours that a monthly test does not finish with a passed result. The normal display range is from 00 (zero days) to 28 days, i.e.

= zero days (a 0.2 gph test has passed within the last 24 hours), up to

= twenty eight days have elapsed since the last monthly-compliance test

passed (also see Monthly-Compliance Warning which begins on Day # 29)

Fault Displays

( rapidly Flashing – twice per second )

Alarms, Warnings, and Error codes, ranging from 80 to 85, are displayed when the following conditions occur.

See Chapter 6.1 & 6.2 about Error Codes

a. Line Leak Test Failure – Flashing Leak Alarm Codes

Identifies the minimum leak rate detected (in gallons per hour)

1 2 3

0.1 gph line leak was detected (annual precision test failed)

0.2 gph line leak was detected (monthly compliance test failed) 3 gph line leak was detected (hourly gross leak test failed)

3 Page 3 - 2 TS-LLD INSTALLATION GUIDE

When a Leak Test Fails / Line Leak is Detected:

1) The display flashes one of the single-digit Line Leak test-fail Alarm Codes

2) Dispensing is disabled for that line / product, pump is turned off (can be reset)

3) The Line Leak Detected light flashes continuously and keeps flashing until another

test of equal or greater precision passes... this light cannot be reset or turned-off

4) The leak test fail / line leak alarm can be printed out or faxed if the LLD has been

optionally

interfaced with an INCON ATG

b. Monthly-Compliance Warning – Flashing Day Codes

A 0.2 gph monthly-compliance test still hasn’t passed. Up to four flashing warning codes can displayed when the line is nearly out of compliance with State and Local regulations (a 0.2 gph test must pass each month).

29 30 31 32

produced on Day number 29 (first monthly-compliance warning) produced on Day number 30 (second warning) produced on Day number 31 (third warning) produced on Day number 32 (fourth and last warning)

On day 33 a Flashing 84 Error-Code is produced, which causes a hard shutdown that can’t be overridden by a reset... no further dispensing is allowed until a 0.2 gph test passes (see Out of Compliance later in this Chapter).

Indications:

1) A flashing Monthly-Compliance Day Code Warning is displayed (see b. above)

2) Dispensing stops but can resume if the Reset Test button is pushed (permits up to

24 hours of additional dispensing or until the day-count changes to the next day)

Recommendation:

Prevent dispensing and let the test finish. The monthly compliance waring may indicate a malfunction within the system and may require a service call to the site.

c. Flashing Display Error Codes

The following error codes may occur... see Chapter 6.1 & 6.2 for more details.

80 81 82 83 84

A dispense occurred during a manual Annual Leak Test A component failed within the LSU A leak test pass or fail could not be determined (result = indeterminate) The LSU is not communicating with the CU The line is out of compliance (a monthly compliance test has not passed in

the last 33 days)... no dispensing is allowed until a monthly test passes.

LSU screen / flow tube is blocked and requires cleaning

System Operation & Testing Page 3 - 3 3

CU Component Location & Function (Continued... )

Line Leak Test light

Turns on when any line leak test starts and stays on during the entire test. The light only turns off when:

1) a test finishes

2) a dispense occurs

3) the Reset Test button is pushed

Line Leak Detected light

Flashes on and off continuously when a line leak test fails. This light will continue to flash until another test – of equal or greater precision – finally passes.

➁

➂

Display Functions, Codes & Concise Instructions

RESET TEST touch button ➄... press to:

• Abort, Stop, or Cancel any line leak test (the Line Leak Test light ➁ will also turn off when the RESET TEST is pushed)

➃

• Clear any flashing Error codes and Enable product dispensing (except the Flashing 83 or 84 Error codes)... error codes will reappear if the problem remains

• Reset and restart automatic line leak testing (the leak detected light ➂ cannot

NOTE

☞

Display Diagnostic Test Codes:

Starting a Manual 0.1 gph Precision Leak Test

NOTE

☞

be reset if a leak was detected)...

is dispensed.

• Perform a Self-Test (one push displays an 88) see Chapter - Section 6.1

• Display diagnostic codes (see Chapter - Section 6.1)

• Start a manual, 0.1 gph annual precision line leak test

See Chapter - Section 6.1 for directions about Diagnostic Display Test Codes

Requirements:

Prevent dispensing / bag dispenser during this time. The manual test needs 4

hours of quiet-time BEFORE it is started, and takes about 13 minutes to finish.

Automatic Line Leak Tests resume after product

Definition:

3 Page 3 - 4 TS-LLD INSTALLATION GUIDE

quiet-time is the inactive period –between– product dispensing

NOTE

☞

A Flashing 80 Error code will be produced, and dispensing inhibited, if a dispense is attempted when an annual test is running. This error can be cleared by pushing the RESET-TEST touch button.

How to Start a Manual Test

Press and hold the RESET-TEST touch button down more than 5 seconds until the Line Leak Test light ➁ turns on. Do not hold the reset-test button down longer than 4 seconds unless a manual test is desired.

Normal Operation – Sequence of Events / Steps

1.) Product Dispense – Begin

a) Aborts / Cancels / Stops any line leak test that is running, and turns off the Line

Leak Test light

b) Perform a functional self-check and allow product dispensing IF okay

c) Prevent dispensing (turn the pump off) IF an error or fault was detected

2.) Product Dispense – End

After a short delay the 3.0 gph line leak test starts.

3.) The 3.0 gph Gross Hourly Test

Starts automatically — after every dispense and before a 0.2 gph test, or before a

0.1 gph test. a) The 3.0 gph hourly test takes about 3 minutes of quiet-time to finish

b) The Line Leak Test light ➁ stays on throughout this test

c) The process will begin again from

4.) The 0.2 gph Monthly-Compliance Test

➁

( dispenser: nozzle out / lever up / switch on )

( dispenser: nozzle in / lever down / switch off )

Step 1.) when Product is Dispensed

– or –

NOTE

☞

a) Requires from 13 minutes – to – 4 hours of uninterrupted quiet-time to finish

The total time required to complete the monthly test depends on the specific conditions at the site and within the line. Tests finish rather quickly when an obvious pass or fail condition exists. Tests times are lengthened when a more detailed analysis is required.

b) The 0.2 gph test is made up of one or more, 13-minute test-cycles.

c) The Line Leak Test light ➁ stays on throughout the entire test

System Operation & Testing Page 3 - 5 3

)

Normal Operation – Sequence of Events / Steps (Continued... )

A 0.2 gph Test Automatically Starts:

1) when the system is powered up (as is the case in new installations, the CU attempts 0.2 gph leak tests until one finally passes).

2) when a 3 gph leak test passes (after a dispense) passed within the last 24 hours (when this happens: the day-count is reset and displays a 00, and the Line Leak Test light only turns on for about 3 minutes — during 3 gph leak tests)

3) when the display advances to the next day (the CU waits 24 hours before starting another monthly-compliance test)

4) when a line is Out-of-Compliance

unless

another 0.2 gph test has

Out of Compliance

If a 0.2 gph Monthly-Compliance line leak test does not pass by day 33, then the line will be Compliance. These are:

Out of Compliance

. Three things happen when a line is Out of

1) a Flashing 84 error code is displayed,

2) the Line Leak Test light turns on because a 0.2 gph monthly compliance test is automatically started, and

3) product dispensing is disabled (stopped / shutdown).

None of these events can be stopped, reversed, or reset. The monthly leak

test must pass (and be in Compliance) before product can be dispensed again. This test should finish in about 1 hour and reset the day count to 00 and

turn the Line Leak Test light off. See the Troubleshooting Guide in Chapter 6.2 of this manual about flashing 84 alarm error codes if this test does not finish.

3 Page 3 - 6 TS-LLD INSTALLATION GUIDE

Frequently Asked Questions

Why do Days Count Up ?

A monthly-compliance test has not passed. This can be caused by very frequent dispensing (the quiet-time between product dispensing is too short for the test to finish). This may happen in very busy stations or when the pump power is turned off after business hours. Also see Chapter 6.2 in this manual.

Why do Error Codes 29, 30, 31, or 32 Appear ?

See Monthly Compliance Warnings and Why Days Count Up earlier in this Chapter.

How do I Display the Last Alarm or Error Code ?

See how to Display Diagnostic Test Codes in Chapter 6.1 by using the RESET TEST touch button

How do I Reset Flashing Error Codes ?

How do I Allow Dispensing ?

How do I Clear Flashing Codes ?

First find out what the Flashing Code represents (Leak Alarm, Error, or Warning). The display ➀ will rapidly Flash an Alarm or Error Code twice per second when either line leak or error is detected, but only the Line Leak Detected light ➂ will rapidly Flash when a line leak alarm occurs. In this Chapter see: How to Verify a Leak — when a leak Alarm is produced, or see using the RESET TEST touch button and its operation.

Why can’t I Reset and Dispense ?

See Chapter 6.2, for Alarms, Errors, and Warnings that disable dispensing.

Error Code 84 cannot be reset because the line is Out of Compliance.

Out of Compliance discussion earlier in this Chapter.

How do I Verify a Leak ? Does it Exist ? or was it a False Alarm ?

See Chapter 4 about Line Leak Detection, and this Chapter about using the RESET TEST button. Remember that the Line Leak Detected Light ➂ will continue to flash on and off until another test, of equal or greater precision finally does pass.

See the

Visually inspect the sump and dispenser areas whenever the TS-LLD reports a leak !

Continued next page...

System Operation & Testing Page 3 - 7 3

Frequently Asked Questions (Continued... )

How do I Start a Manual Test ?

See this Chapter about using the RESET-TEST button to Start a 0.1 gph Annual Precision Leak Test (also see the test Requirements before you start it).

How Often Should the Manual Test be Run ?

See Chapter 4 about Line Leak Detection and INCONs recommended frequency (the manual test cannot be started when a flashing 84 error code is displayed).

What Should I Do:

When a 3 gph Leak Test Fails / Gross Leak is Detected ?

The display shows a flashing 3 Alarm code —

instructions in Chapter 4

When a 0.2 gph Leak Test Fails / Leak is Detected ?

The display shows a flashing 2 Alarm code —

Chapter 4

When a 0.1 gph Annual Precision Leak Test Fails / Leak is Detected ?

The display shows a flashing 1 Alarm code — follow the instructions in Chapter 4

Visually inspect the sump and dispenser areas whenever the TS-LLD reports a leak !

mmediately follow the

follow the instructions in

—

3 Page 3 - 8 TS-LLD INSTALLATION GUIDE

❖

—

4 TS-LLD Line Leak Detection

Contents:

• When a Line Leak is Detected

• Steps to take When a Line Leak is Detected

• How Often Should a Manual 0.1 gph Test be Run ?

• Need Help (with line test failures) ?

When a Line Leak is Detected

The TS-LLD line leak detection system: disables the Submerged Turbine Pump, flashes the Line Leak Detected light, and displays a flashing test-fail Alarm code when a line leak test fails.

CAUTION single alarm. Confirm the presence of a leak before attempting any repairs !

NOTE

☞

Steps to take When a Line Leak is Detected:

Leak tests occasionally fail when no leaks actually exist because of: product line instability, thermal contractions within the line, or pump / vapor recovery system malfunction. Air trapped within the line may also cause false leak alarms (this is especially true after new installations / maintenance / service). See Chapter 2.4... has product been dispensed after installation or service ? When was the last maintenance / service done ?

1) Identify what type of leak was detected...

= 3 gph leak = hourly test failed (gross / large leak)

= 0.2 gph leak = monthly-compliance test failed

= precision 0.1 gph leak = annual / manual test failed

2) Stop / Prevent dispensing

3) Inspect the piping system, dispenser, fittings, and hoses for obvious leaks. Open

the dispenser enclosure, and inspect the fittings and fuel filter for leaks

maintenance or service was done recently).

DO NOT excavate and repair a fuel-line solely on the basis of a

(bag or tape poly over dispenser and dispense lever).

Flashing

test-failed Alarm codes:

(especially

4) If no leaks are found during inspection, then start another leak test to verify

the previous failure

turn off until another test of equal or greater precision passes).

Start another test Chapter 3 about the requirements of and how to start a 0.1 manual test to start automatic 3 gph and 0.2 gph line leak tests: push the Reset Test button to clear a failed test and

(The Line Leak Detected light will keep flashing and will not

(same type that originally failed as identified in step one)

simulate a dispense

Line Leak Detection Page 4 - 1 4

(see the next page about this).

... See

– or –

Step 4 (continued... )

Simulate a dispense by – move the dispense lever up and wait a few seconds

after the pump has turned on, and then move the dispense lever down

5) Prevent dispensing while this test is running (bag or tape poly over the dispenser and dispense lever)

6) If a leak is found, or if the second line leak test also fails, then:

a) Shut off all power to the affected pump and dispenser & contact INCON

Technical service

b) Take corrective action in accordance with local, State, and Federal regulations

c) Contact the local inspection agency, and follow all procedures and

instructions as required by State Laws and Regulations.

WARNING

to contact his local inspection agency and comply with the reporting and procedure requirements of local / State / Federal Laws and Regulations. These must be followed explicitly. Serious legal, health and safety hazards could result from not taking the proper action. Where the codes and regulations conflict with this manual, follow the regulations.

NOTE

☞

How Often Should a Manual 0.1 gph Test be Run ?

The site (station owner, shift manager(s), and personnel)

Important — Customer Documentation as listed in Chapter.Section # 2.4. This

data is required for their reference (our valued customer).

copy of this documentation for your future reference.

State and local regulations will dictate the need for and frequency of the 0.1 gph annual test and inspections. Make sure you and and requirements for compliance testing and inspections.

When a line leak is detected, it is the station owner’s obligation

the site

must have access to the

TIP

Also keep a

are aware of the issues

Need help ?

Contact INCON Technical Service at 1-800-984-6266 (FAX #: 207-282-9002) for help with: a Line Leak Test failure, repeated Line Leak Test failures, or multiple Line Leak Test failures. Also see Chapter 3, for additional information about System Operation & Testing, and Chapter 6.1 & 6.2 for information about Alarm – Error Codes, & Troubleshooting.

—

4 Page 4 - 2 TS-LLD INSTALLATION GUIDE

❖

—

5 TS-LLD Maintenance & Service

Contents:

• Cleaning the Control Unit

• Control Unit Replacement Parts

• Rump Relay Control Box Replacement Parts

• Leak Sensing Unit Replacement Parts

LSU Removal for Service / Inspection and Cleaning

•

• After Maintenance or Service DO

NOTE

☞

This chapter contains instructions ranging from routine cleaning to maintenance inspections, replacement instructions, and

as required.

Replacement part numbers are shown here as well.

Cleaning the Control Unit

Clean the Control Unit (CU) exterior with a soft sponge or cloth that is

dampened

DANGER

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.

from pressurized lines, and electrical shocks.

Safety advise.

with a solution of water and mild detergent

Fire, Explosion, & Electrical Shock Hazard. Before installing,

Prevent automatic or unauthorized pump start-ups, spills

Control Unit Replacement Parts

Items

Frequency = A/R

maintenance frequency

– A/R by Customer

See Chapter 2.1 and follow all

Replacement Part Numbers

...

A/R means

slightly

a) Fuse F1

b) Terminal Board ....................................................... P/N = 010-0072

c) Replacement cover faceplate (with new Software ) ........... P/N = TS-FPU

d) Entire Control Unit US .................................................. P/N = TS-CU

Are the CU box label and cover label correctly marked with the product and line #? Are the jumper links behind the cover (at J2) correctly configured ? Reference

Chapter 2.3 for product & jumper link configuration(s).

.......................................................

Canadian ....................................... P/N = TS-CU/C

Pump Relay Control Box Replacement Parts

Items

Line Filter Capacitor @ Pump Relay (Motor Control) Box ........ P/N = 020-0028

...

Maintenance & Service Page 5 - 1 5

Frequency = A/R

Replacement Part Numbers

P/N = 430-0010

Leak Sensing Unit (LSU) Adapters & Replacement Parts

Items

Frequency = A/R

Replacement Part Numbers

a) M I Cable Adapter 2 inch NPT ......................................... P/N = TS-RJ

b) M I Cable Adapter 3 inch Straight Thread ....................... P/N = TS-FE

c) Leak Sensing Unit USA .................................................. P/N = TS-LSU

d) Leak Sensing Unit Canadian ........................................... P/N = TS-LSU/C

e) Leak Sensing Unit Screen .................................................. P/N = 270-0002

f) Leak Sensing Unit O-Ring .................................................. P/N = 250-0048

LSU Removal for Service / Inspection and Cleaning

The LSU is removed or replaced whenever the following service steps are done.

Review Chapters 2.0 through 2.2 before removing or replacing a LSU.

1) With all pump power off and line-pressure relieved: follow the installation steps & diagrams shown in Chapter 2.2

in reverse order

to remove the LSU.

2) Carefully straighten the MI Cable enough to provide clearance from other components while the LSU is being unscrewed (removed) from the pump.

3) Clean the LSU Screen and Flow Tube

flashing 85 Error Code is displayed at the CU –

replace the Screen as required

LSU Screen

LSU O-Rin

LSU Leak Sensing Flow Tube (outlet at bottom)

4) Inspect LSU O-Ring

cleaned

– replace O-Ring as required

......when the LSU screen is

O-Rings are made from a special material that are UL rated – use no substitutes.

INCON LSU O-Rings. (Also see Appendix A about Applicable Liquid Products.)

......when a

. The LSU

Install only genuine

Bottom & Side Views

5) Reinstall / Install the Leak Sensing Unit per steps shown in Chapter 2.2

6) Inspect the M I Cable at the LSU for damage, kinks, sharp bends, and breaks

before reapplying power

......whenever the containment sump has been

accessed ......and after all maintenance or service of the Submerged Turbine

Pump or other related components (such as the piping system).

7) Replace the LSU per Chapter 2.2 – before power-up

......whenever the MI Cable

has been damaged, or when the LSU has malfunctioned / become inoperable.

After Maintenance or Service DO –

Make sure that the system is operating properly ! See Chapters 2.4 and 3 for

information about System Operation and Testing, and Chapters 6.1 & 6.2 for about Error Codes & Troubleshooting.

—

❖

—

5 Page 5 - 2 TS-LLD INSTALLATION GUIDE

6.0 Service & Factory Support

Contents:

• Where to Find Help

• Service

• Factory Support

• Phone & Fax numbers

• INCON Office Hours:

• Before calling INCON:

Where to Find Help

Chapter 6 is divided into four problem solving sections for your reference. These are:

Service and Factory Support Section 6.0 Alarms and Error Codes Section 6.1 Trouble Shooting Guide Section 6.2 Warranty Section 6.3

Refer to the Table of Contents and Figures in this manual to find where other helpful information is located.

• Return Shipments

• Warranty Registration Card (blank... can be copied, filled-in the copy and FAX back to INCON)

Service

NOTE

☞

A Quick Reference Guide is provided with every TS-LLD system. It was specifically designed for use by your customer at his station. He has been instructed to keep a log of all alarm and error codes. This log could be FAXed to you and would prove to be very useful diagnostic tool. Distributors and Installers: you may order more guides by contacting INCON and asking for part number 000-1447. Certain restrictions may apply.

Only authorized service technicians / organizations are permitted to install and work on this equipment. Contact INCON for authorized service technicians in your area.

Continued next page...

Service and Factory Support Page 6.0 - 1 6.0

Factory Support

Need Help ?

diagnostic codes. Also, please call if alarms, warnings, or error codes occur frequently or repeatedly.

Phone & Fax numbers:

Call INCON Technical Service for help with leak alarms, or

Sales Technical Service

Phone: (800) 872-3455 ** Phone: (800) 984-6266

Fax: (207) 283-0158 Fax: (207) 282-9002

E-mail:

sales@intelcon.com tech@intelcon.com

** Technical Service Help is available 24 hours a day

INCON Office Hours:

8 a.m. to 5 p.m. EST Monday through Friday

Before calling INCON:

• Have the CU or LSU Serial Numbers on hand for units you’re having trouble with.

• The TS-LLD Warranty Registration Card should have this information (it should have been filled-out completely and mailed or FAXed back to INCON after installation). NOTE: The example Warranty Registration card on the next page can be copied and used for FAX in registration.

Return Shipments

If it should become necessary to return the LSU or CU to INCON please use the original packaging materials if possible. Return shipping damage due to inadequate or inappropriate packaging is your responsibility. Make sure the returngoods

Before returning anything to INCON, you must first obtain a Return Material Authorization (RMA) number. Shipments of returned equipment, which have not been authorized, will be returned freight collect.

shipment

is insured.

Call INCON Technical Service Department from the site for RMA numbers. Our personnel will give you the correct shipping address, and provide other details and instructions that you will need when you call for the RMA number.

6.0 Page 6.0 - 2 TS-LLD INSTALLATION GUIDE

ENVIRONMENTAL CONTROLS DIV.

SACO MAINE USA

BUSINESS REPLY MAIL

FIRST-CLASS PERMIT NO. 12 SACO ME

ATTN: TECHNICAL SERVICE INTELLIGENT CONTROLS INC PO BOX 638 SACO ME 04072-9962

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

POSTAGE WILL BE PAID BY THE ADDRESSEE

Warranty Registration Form: (copy, fill-in, & FAX Registration Form back to INCON)

TS-LLD

Telephone No. 1-800-984-6266

— Please print, or type —

TS-LLD

Installation Date: Line # of

BACK SIDE FRONT SIDE

Purchased From:

Installers Name & Certificate Number:

Site Information:

Company Name: Telephone No.

Mgr. / Contact Name: Reg. hours of Operation

Street Address:

circle

Reg. UL Mid. UL Prem. UL Red Jacket

Diesel #2 Fuel Oil Kerosine FE Petro™ Flexible (& below)

Other Other ...manufacturer:

Product Pump Type & HP

Turbine Pipe Type Size Length

Warranty Registration Form

♦♦

♦

♦♦

FAX No. 1-207-282-9002

Write in, or tape-on

Serial No. labels

here

Dispenser / Manufacturer Type:

Functional Element / age:

circle

Are blenders used ? Yes No

Is this an IST application ? Yes No

Is this a Big Flo®pump ? Yes No

Steel

Fiberglass

LSU Serial No.CU Serial No.

000-1480 REV. C

TS-LLD

Registration activates your warranty — mail, or Fax in today !

Service and Factory Support Page 6.0 - 3 6.0

— Your Notes —

—

6.0 Page 6.0 - 4 TS-LLD INSTALLATION GUIDE

❖

—

6.1 Test Fail Alarms, Warnings & Error Codes

Contents:

• Normal Display Codes (on steady – not flashing)

• Flashing Alarm, Warning, and Error Display Codes

• Diagnostic Display Codes

Display Codes

The following Normal, Alarms, Warnings, and Error Codes are displayed at the control unit at this publication date.

Normal Display Codes (on steady – not flashing)

DISPLAY CODE DESCRIPTION

00 to 28 Number of Days since a 0.2 gph monthly-compliance leak test

passed (00 = zero days, 09 = nine days). The display counts up (advances a day) for every 24 hours that the test has not finished with a passed result.

88 System OK... the control unit electronics and all segments of the

2 digit display are working correctly.

Flashing Display Codes (Alarms, Warnings, and Error Codes)

Flashing Error Codes can occur in range from 80 to 85 only !

DISPLAY CODE DESCRIPTION

1 Alarm 0.1 gph Annual (manual) Leak Test Failed

2 Alarm 0.2 gph Monthly-Compliance leak test Failed

3 Alarm 3 gph Hourly – gross – leak test Failed

29 – 32 Warning !

days (represented by the flashing number) since the last 0.2

gph Monthly-Compliance test passed.

80 Error Manually started, 0.1 gph Annual precision leak test was

aborted... a dispense was attempted while the test was running

81 Error A component failed within the Leak Sensing Unit

the line is almost out of compliance

Also see 84 Error Code.

! It has been

82 Error Indeterminate 0.2 gph leak test result — the line was not

thermally stable. This error will not disable dispensing and can be viewed when RESET-TEST is pushed 4 times.

Test Fail Alarm & Error Codes Page 6.1 - 1 6.1

Flashing Error Codes (continued... )

Flashing Error Codes can occur in range from 80 to 85 only !

DISPLAY CODE DESCRIPTION

83 Error Leak Sensing Unit is not communicating with the Control

Unit

84 Error The line is Out of Compliance (it has been at least 33 days

since the last 0.2 gph Monthly-Compliance test has passed.

85 Error Leak Sensing Unit requires service

Diagnostic Display Codes

These are obtained by repeatedly pressing the RESET button... DO NOT hold the TEST button

down longer than 4 seconds, otherwise a manual leak test will start.

First press:

88 System OK... all 7 segments of the 2 digit display are on and are

working correctly when 88 is displayed (88 is solid/not flashing).

Second press:

XX Solid or flashing number which represents the average tempera-

ture differential of the last 0.2 gph leak test. Record this number

for assistance from INCON.

Third press:

XX Solid or flashing number for the accumulated power reading of

the last 0.2 gph leak test (00 - 99 solid ...solid 99 represents a number from 99 to 149 and flashing 99 represents a number from 150 and above). Record this number for assistance from INCON.

Fourth press:

XX Flashing number which represents the last flashing Leak

Detected Alarm code or Error code. Record this number for

assistance from INCON.

— Your Notes —

— ❖ —

6.1 Page 6.1 - 2 TS-LLD INSTALLATION GUIDE

6.2 TS-LLD Troubleshooting Guide

Contents:

• Problem

• Description / Symptoms

• Probable Cause (and Action to Take)

Display Codes

This chapter contains a current listing of Warnings, Alarms, and Error Codes that may be displayed at the control unit. Before attempting any service, maintenance or troubleshooting work on this system, be sure to review and follow all instructions, and heed all cautions and warnings in this manual... see Chapter 5. Also, review all appropriate manufacturers’ documentation, and applicable codes.

WARNING

Disconnect power sources before troubleshooting and before removing any enclosure cover. Failure to turn power off will create an electrical shock hazard which may cause injury or death !

Abbreviations used in this Chapter:

STP = Submerged Turbine Pumps / Submersible Pumps LSU = Leak Sensing Unit CU = Control Unit

Problem Description/Symptom Probable Cause (Action to take)

No Display No LED lights on

Can’t Dispense (Check STP Circuit Breakers... are they on ?)

Can’t Dispense Flashing 29, 30, 31 or 32

Power is off

CU fuse F1 is open/blown

about replacing F1)

CU box was wired incorrectly.

Chapter 2.3).

Monthly-Compliance Warning !

(Push RESET TEST to permit pumping for another day (up to 24 hours)...see Chapter

3.) Days may keep counting up in busy stations

where there isn’t enough quiet-time between dispensing to finish a monthly test.

(Are the turbines turned off after hours ?) (Ask the station to keep the circuit breakers /

turbine(s) on so the monthly tests can finish after hours.)

(See Chapter 5

See

Troubleshooting Guide Page 6.2 - 1 6.2

Problem Description/Symptom Probable Cause (Action to take)

Can’t Dispense Flashing: 3, 2, or 1 False Leak Alarms & Leak Detected Light ON (check / replace)

Multiple Nuisance Alarms (check / repair)

Can’t Dispense Flashing: 3

& Leak Detected Light ON

Can’t Dispense Flashing: 2

& Leak Detected Light ON (see Chapter 4 about the Steps to take

Can’t Dispense Flashing: 1

& Leak Detected Light ON (see Chapter 4 about the Steps to take

NOTE

Flashing Alarm Error Codes are limited to a range of

RedJacket Functional Element – bad

Vapor Recovery system malfunction

Check Valve leaking

(check / replace)

Air in lines

(dispense product after installation to remove air from the lines)

3 gph (or greater) GROSS Line Leak !... Test Failed

to take When a Line Leak is detected)

Monthly 0.2 gph Line Leak / Test Failed

When a Line Leak is detected)

Annual 0.1 gph Manual Leak Test Failed

When a Line Leak is detected)

(see Chapter 4 about the Steps

☞

80 to 85

ONLY !

Can’t Dispense Flashing 80 Error Code

Can’t Dispense Flashing 81 Error Code

Counting Days Diagnostic Error Code 82

Flashing (when viewed)

A manual 0.1 Annual leak test was aborted by an attempted dispense.

(Push RESET to permit pumping when an annual test was unintentionally started – or – Do not hold the RESET TEST button down longer than 4 seconds unless a manual test is intended. Bag the dispenser / prevent dispensing during the test and for 4 hours before starting a Annual leak test ...also see Chapter. 3)

LSU internal component failure

(Push TEST-RESET to permit dispensing once again. Schedule service at this site.)

A 0.2 monthly leak test aborted because the line was not thermally stable

(A test will abort when the test result is indeterminate after 18 cycles... neither a pass or fail result can be determined. The monthly test will start again after another dispense. Call INCON when days count up and when this Diagnostic Error Code is consistently displayed.)

6.2 Page 6.2 - 2 TS-LLD INSTALLATION GUIDE

Problem Description/Symptom Probable Cause (Action to take)

Can’t Dispense Flashing 83 Error Code

Can’t Dispense Flashing 84 Error Code

Can’t Dispense Flashing 85 Error Code

No communications between LSU and CU

(New installations: Check for loose wiring, or wiring errors, or omissions )

Previously functioning systems — Press RESET to allow dispensing for another 4 hours and call INCON Tech Service)

The line is Out-of-Compliance because a Monthly Compliance Test has not passed in the last 33 days)

(This Error Code cannot be reset by pressing the RESET TEST button — product dis-

pensing is not allowed when Out of Compliance. A new 0.2 gph test automati-

cally starts when this Error is displayed. Prevent dispensing and give the test time to finish { from 13 minutes to 4 hours later }.

This may happen in extremely busy stations. Are the turbines turned-off after hours ?

Ask the station to keep the circuit breakers / turbines on so tests can finish after hours.

Call INCON if the Leak Test does not finish. A valve seat may have failed at the LSU which would cause indeterminate test result (neither pass or fail), and will cause the days to count up. )

The LSU requires service.

(Press RESET to allow dispensing for another 4 hours. Schedule service when this error occurs repeatedly.

See Chapters about Safety, Installation, Maintenance and Testing and call INCON)

Please call our service department for tips and solutions to other problems not addressed at the time of this publication. Also, call INCON technical service when warnings, alarms, or error codes happen often or repeat often. Also, see Chapter 6.0 before calling INCON.

Troubleshooting Guide Page 6.2 - 3 6.2

— Your Notes —

—

6.2 Page 6.2 - 4 TS-LLD INSTALLATION GUIDE

❖

—

6.3 TS-LLD Warranty & Terms

Contents:

• TS-LLD Warranty (Terms)

• Warranty Disclaimer and Limitation of Liability

• For Further Information, Contact INCON

ARRANTY

INCON

detector system that any part thereof will be free of defects of material and workmanship for 12 months of operation from the date of installation as indicated on the mail-in TS-LLD Warranty Registration Card (or facsimile thereof), or 18 months from the date of shipment, whichever occurs first. During this period INCON will, at its option, modify, repair or replace defective products at no charge. This is a materials only warranty, and does not include labor or service charges.

INCON will not accept shipments of returned products without a Return Material Authorization (RMA) number. RMA numbers are obtained by contacting INCON Technical Service Department — NO RMAs will be given without the unit Serial Number(s). Returned material remains the property of the buyer until replaced or repaired.

Warranty Disclaimer and Limitation of Liability

There are no warranties which extend beyond those expressly set forth in this document. INCON disclaims and excludes all implied warranties including without limitation those pertaining to merchantability and fitness for a particular purpose.

warrants to the original end user of the TS-LLD line leak

INCON expressly disclaims and excludes any liability for consequential

or incidental damages for breach of any expressed or implied warranty arising in connection with this product or this manual, including without limitation, purchaser’s loss of stored liquids, or damage to the ground, underground or environment, whether arising under theories of tort, negligence, strict liability, contract or otherwise.

After installation, make sure to sign and return the completed Warranty Registration card to INCON. This form validates the express warranty stated here ! (See page 6.0 - 3 for a blank Warranty Registration card that you can copy, fill-in, and FAX-back to INCON.)

Warranty Page 6.3 - 1 6.3

NOTE

☞

For further information, contact INCON

Some states do not allow the exclusion or limitation of incidental or consequential damages or a limitation on the duration of implied warranties, so the limitation or exclusion may not apply to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to state.

Technical Service Department at:

INCON PO BOX 638 SACO MAINE 04072 USA

Voice: 1-800-984-6266 Fax: 1-207-282-9002 E-mail tech@intelcon.com

— Your Notes —

—

6.3 Page 6.3 - 2 TS-LLD INSTALLATION GUIDE

❖

—

Appendix A

TS-LLD Technical Specifications

Abbreviations: LSU = Leak Sensing Unit, CU = Control Unit, STP = Submerged Turbine Pump

Operating Specifications

Application

Leak detection monitoring of pressurized underground fuel lines

Applicable Liquid Products

Gasoline

Gasoline / Alcohol Blends (10 % Max.

Ethanol or Methanol),

Gasoline / MTBE Blends (20 % Max. MTBE),

Kerosene, Diesel Fuel, or Fuel Oil

Leak Detection Tests

3 gph and 0.2 gph (automatic tests), and

0.1 gph (manual test)

Electrical Specifications

Power Supply (Frequency: 60 Hz)

120 VAC (CU) – from pump control relay box

208 to 240 VAC (LSU) – single phase from

STP power lines

Power Consumption

40 Watts maximum (both CU and LSU)

Current Overload Protection

500 Milliamps at: 100 VAC & 120 VAC (CU)

2 Amps at: 240 VAC (LSU)

Alarm Output: Open Collector (TB2-5)

Voltage Rating

+5 VDC (internal 270 ohm resistor tied

to internal +5 VDC supply)

Current Rating

Safety and Mounting Location (LSUs)

Explosion Proof brass housing for installation in Class I, Division 1, Group D hazardous locations. LSU is mounted at the STP housing (above Underground Storage Tank)

Operating Pressure (LSU)

50 psig maximum running pressure

Allowable Pipe Type and Length

(Per 3rd Party Test Qualifications):

Type Max. Volume Max. Length

2 inch Flex 49.6 (gallons) 540 (feet) ID = Internal Diameter

2 " ID Steel or Fib 163 1000 Flex = Flexible pipe

3 " ID Steel or Fib 163 443 Steel = Rigid pipe

ID Steel or Fib 163 350 Fib = Fiberglass

Communications Distance

RS 485 Communications Protocol ( TB2: terminals 1-4 )

NOTE

☞

60 Milliamperes (resistive loads)

1000 feet maximum distance (between the Control Unit and the Leak Sensing Unit).

22 – 28 AWG, 4 wire communications cable, 1000 feet maximum distance (between a Control Unit and a Tank Sentinel console).

Appendix A Page A - 1 A

Appendix A

TS-LLD Technical Specifications

Abbreviations: LSU = Leak Sensing Unit, CU = Control Unit, STP = Submerged Turbine Pump

Environmental Specifications

Operating Temperature

32° to 121° F (0° to 40° C) CU

0° to 121° F (-17° to 40° C) LSU

Storage Temperature

- 40° to 150° F (- 40° to 65° C)

Operating Humidity (CU)

0 to 95% non-condensing

Splash Resistance (CU)

Not to be exposed to direct spray, splash, or drips.

Cleaning — See Chapter 5

Mechanical Specifications

Display — Type:

Alphanumeric LED (Light Emitting Diode)

— Size:

1 Line, 2 Digit, 7 Segment (0.54 inches high)

Dimensions (overall in inches)

3.35 x 4.35 x 2.25 (H x W x D [ Depth ] ) CU

23.5 x 2.4 (H x D [ Diameter ] ) LSU

Safety Approvals and Listings

Model TS-LLD USA

6L79 LISTED

Electronic Line Leak Detector

Mounting Location (CU)

Dry indoor location (near the pump relay / motor control box)

WARNING

The TS-LLD control unit must be mounted indoors where explosive or flammable vapors are not present, otherwise, an explosion hazard will be created which can result in property damage, injury, or death.

—

Model TS-LLD/C Canada

6L79 LISTED

Electronic Line Leak Detector

Listed Leak Detection Equipment

Precision Level 2 and Level 3 ULC/ORD–C107.12

See Serial Number labels for the Model and Serial numbers

❖

NOTE

☞

—

A Page A - 2 TS-LLD INSTALLATION GUIDE

U User Feedback Form

We’ll listen – we promise !

Please complete and return

this form ...Mail or FAX to

Your ideas and opinions are important to us ! Please help us improve our

products, our service, and our organization... use black ink and print clearly.

Your Name (and Position):

Company Name and Street Address:

(please – no PO Box numbers)

Documentation Provided:

Document & Manual Names:

Document & Manual Part Numbers:

Product: Model and Serial Numbers:

Technical Publications Manager INTELLIGENT CONTROLS INC 74 INDUSTRIAL PARK ROAD SACO ME 04072 USA

FAX #: 207-286-8414

Documentation and Manual rating:

Installation Date: Today’s Date:

Please circle (1 = no / poor, 2 = fair, 3 = okay, 4 = good, 5 = yes / excellent, N = don’t know)

The documentation is easy to use 12345N Information is easy to find 12345N The Table of Contents is useful to find data 12345N Information is well organized 12345N Information is clear and easy to understand 12345N Information is complete and accurate 12345N The illustrations are clear and easy to follow 12345N The number of illustrations are adequate 12345N

Comments

Suggestions ? (please be specific)

User Feedback Form (front side) Page U - 1

Sale / Supply Orders:

Please circle (1 = no / poor, 2 = fair, 3 = okay, 4 = good, 5 = yes / excellent, N = don’t know)

Your order was processed quickly 12345N

You were treated professionally

with respect 12345N

You got what you wanted quickly / on time 12345N

Sales Suggestions

Technical Service / Support

Please circle (1 = no / poor, 2 = fair, 3 = okay, 4 = good, 5 = yes / excellent, N = don’t know)

Your call was processed quickly 12345N

Help and advice was professional

accurate 12345N

You were not kept on hold (for a long time) 12345N

Service / Support Suggestions

The INCON system or product:

Please circle (1 = no / poor, 2 = fair, 3 = okay, 4 = good, 5 = yes / excellent, N = don’t know)

Was easy to install / service / expand / update 12345N

Was easy to program / setup 12345N

Operates well and as expected 12345N

Product Comments & Suggestions

Thanks for your help & advise !

—

Page U - 2 User Feedback Form (back side)

❖

—

TS-LLD INSTALLATION GUIDE

PO BOX 638 SACO ME 04072

TS-LLD Installation Guide

Franklin Fueling Systems TS-LLD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual