Franklin Fueling Systems TS-LLD User Manual

TS-LLD

Installation Guide

Electronic Line Leak Detector

Part Number: 000-1359, Rev. H

Copyright © March 2012

TS-LLD INSTALLATION GUIDE

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:

INTELLIGENTCONTROLS,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:[phone]	Phone:(800)	984-6266
Fax:[phone]	Fax:(207)	282-9002
E-mail: [e-mail]	E-mail: [e-mail]

Visit our web site at: http://www.intelcon.com

INCON ® is a registered trademark of Intelligent Controls, Inc. Tank Sentinel® is a registered trademark ofINCON

Red Jacket ® is a trademark of the Marley Pump Co. FE Petro ® is a registered trademark of FE Petro, Inc.

The INCON TS-LLD is covered by United States Patent Number 5,918,268 (June 29, 1999) Copyright 1995, 1996, 1997, 1998, 1999 Intelligent Controls, Inc. All rights reserved.

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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.

2.4 Optional TS-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

2.5 TS-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

3 TS-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 (copy, & Fax Reg. Form back to INCON) .......	6.0 - 3
Your Notes .........................................................................................................	6.0 - 4

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 Probable Cause (Action to take) .......	6.2 - 1
NOTE .....................................................................................................	6.2 - 2
Your Notes .........................................................................................................	6.2 - 4

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 LLDI 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

PPREFACE

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 or WARNING messages are highlighted by the WARNING graphic and contain instructions that must be followed to avoid faulty equipment operation, or an explosion or shock hazards. If ignored, severe injury or deathmay result !

DANGER messages are highlighted by the DANGER graphic and contain instructions that must be followed to avoid an explosion or electrical shock hazard. If ignored, severe injury or death will result !

— — 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:	Chapter Number &
	Name (TOP LEFT
	FIRST PAGE)
	Chapter Contents
Manual Name	Chapter Name
(EVEN NUMBERED	(ODD NUMBERED
PAGES)	PAGES)
Page Number	Page Number
Chapter 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)(1) Line Filter Capacitor, 1 µ Farad (for pump relay / motor control box)Sheet of (9) stick-on – DANGER labels

(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)

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 CAUTIONS and WARNINGS ! See Chapter 2.1 about Safety, before 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.

		— —
P	Page P - ii	TS-LLD INSTALLATION GUIDE

1TS-LLD Electronic

Line Leak Detector system – Overview

	Contents:
	•	Overview and theory of	• The LSU (Leak Sensing Unit)
		Operation	•	Communications
	•	Leak Test Requirements	• The CU (Control Unit)
		and Length	•	Operator Interface

Overview and Theory of Operation

- JU N C T IO N B O X S ID E

2 3 .5 IN C H E S A P P R O X .

O V E R A L L

L E N G T H

A S S E M B L E D

-L IN E L E A K P O R T S ID E

8 IN C H L E A D S

M I C A B L E

A D A P T E R

M I C A B L E

2 IN C H N P T

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.

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: A ll Dimens ions are in inches, and are approximate

0 .60	K n oc k o u t f o r
	1 /2	in c h f itting
2 .25	-	Ty pic al -
Line #:
P roduct:
4 .35
TO P & B O TTO M V IE W - C O N TR O L U N IT (C U )

3 .3 5

F R O N T V IE W

erial S U C DLLTS x x x x x x x x

umN xxxxxxxx ber

R IG H T S ID E V IE W

Figure 1.1 LSU Outline

Figure 1.2 CU Outline Dimensions

Overview	Page 1 - 1	1

Overview andTheory 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. Quiet-times, where no dispensing occurs, are required to start and finish any line leak test.

Leak Test Requirements and Length

The 3.0 gph hourly test starts after every dispenseand takes about 3 minutes of quiet-time to finish.

The 0.2 gph monthly-compliance test automatically startsafter a 3.0 gph test passes unless a previous 0.2 gph test has already passed within the last 24 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, the0.2 gph monthly-compliance test needs 13 minutes to 4 hours of quiet-time to finish.

The manual 0.1 gph annual test needs4 hours of quiet-time before it’s started, and takes about 13 minutes of quiet-time to finish after it starts.

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-feed- lines. 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 inside the Control Unit (CU).

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

2.0TS-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 (supplied with the TS-LLD), the adapter for FE Petro® STPs must be ordered separately...

Order INCON part number:

TS-FE 3" straight Cable Adapter for FE Petro® STPs *

Stick-on DANGER labels (INCON P/N 240-1175 – supplied with the TS-LLD)

(1) 1/4 inch NPT pipe plug for the tank test port at the pump head(supplied with the TS-LLD)

Red wire nuts for LSU wiring at the pump head(supplied with the TS-LLD)

(1) 1µ Farad Line Filter capacitor for the pump relay box (INCON P/N 020-0028

– supplied with the TS-LLD)

Wire: 14 AWG, 3 feet (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 (continued... )

(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 – (supplied with each TS-LLD)

TS-LLD Quick Reference guide – INCON P/N 000-1447 (supplied with each TS-LLD). Leave all TS-LLD Quick Reference guide(s) on-site for use by the station owner, shift managers / personnel!

Also, for use by the station owner, shift managers / personnel, providethe name(s), phone number(s) of the local inspection agency and other applicable information, instructions and regulations should a line leak be detected.

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 Electrical Shock Hazard. Before installing, 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 Verify that no voltage exists before workingon, or wiring-to a circuit – a lethal electrical-shock-hazard could exist, which would kill you. Note: circuit breaker contact(s) can fail in the on position, even when the circuit breaker lever is turned off.

DANGER The TS-LLD automatically starts the submersible 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. A pressurized fuel spill would create a fire or explosion hazard that could result in injury or death.

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 Explosion Hazard — Flammable Vapor Area.

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. DO NOT apply power if the MI Cable is damaged, twisted, kinked, or broken. Electrical sparks or fire in this area could cause an explosion, injury or death.

WARNING The fuel line from the submersible pump to the 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 Be careful not to cause sparks when working on 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.

CAUTION Refer to all applicable Federal, State and local codes, the National Electric Code (NEC), and the Automotive and Marine Service Station Code (NFPA 30A) before installation or maintenance. This installation is designed for submersible pumps which have a pump relay box in the station. If a pump relay box 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 Although the LSU is water resistant, INCON does 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

2.2TS-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-FE
	3 INCH
	M I CABLE	TS-RJ
	ADAPTER
		2 INCH NPT
	For FE Petro	M I CABLE
		ADAPTER
	Pumps	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 sureall submersible pump power and pump relay coil / dispenser power is turned off & locked out at the electrical panel. Prevent automatic or unauthorized pump start-ups, spills from pressurized lines, and electrical shocks. 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 perFigure 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	PIPELINE
PUMP HOUSING

Figure 2.2-2 Plug Location – RedJacket ® Submersible Pump Housing

2.2	Page 2.2 - 2	TS-LLD INSTALLATION GUIDE

3" PLUG

2" PLUG

STATION

CONDUIT

PORT

PUMP HOUSING

1/4" PLUG

PIPELINE

Figure 2.2-3 Plug Location – FE Petro Submersible Pump Housing

4) Apply Pipe dope to the line leak detector threads perFigure 2.2-4.

	TS-LLD
	LINE LEAK DETECTOR	Pipe dope
	LEAK SENSING UNIT
Pipe	(LSU)	only these
Dope		threads

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 C A B L E

A D A P TE R

M I C A B L E

L IN E L E A K

D E TE C TO R

S TA TIO N

C O N D U IT

PIPELINE

P U M P

HO U S IN G

Figure 2.2-5 Line Leak Detector Installation – RedJacket ® Pump Housing

2.2	Page 2.2 - 4	TS-LLD INSTALLATION GUIDE

M I CABLE

ADAPTER

MI CABLE

STATION
CONDUIT	LINE LEAK
PORT	DETECTOR
PUMP
HOUSING

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 handand align the 2 or 3 inch cable adapter fitting with the junction box plug opening. Support the MI cable with both 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 inFigure 2.2-7, or 2.2-8).

NOTE	Avoid breaking the MI cable — DO NOT bend the MI cable too

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).close to the fittings. An LSU that has a damaged MI Cable is

M I CABLE

LINE LEAK

DETECTOR

STATION	PIPELINE
CONDUIT

PUMP

HOUSING

Figure 2.2-7 Line Leak Detector Wiring – RedJacket ® Pump Housing

2.2	Page 2.2 - 6	TS-LLD INSTALLATION GUIDE

DANGER Make sure you check these wires for the absence of power before proceeding. All pump power (240 VAC) and pump relay / dispenser power must be off before this installation is started, otherwise a lethal hazard will be created which could kill you or others. Note: A circuit breaker contact(s) can stick closed even when the circuit breaker is in the off position.

8)Leak Sensing Unit Wiring – Reference Figure 2.2-7, or 2.2-8.

a)Use one of the supplied red wire nuts, and twist one wire lead from pump together with one of the black wire leads from the LSU.

b)Again use a red wire nut, and twist the remaining lead from pump together with the remaining black wire lead from the LSU.

c)For Canadian TS-LLD leak sensing units only: connect the green (ground) wire from the pump to the green LSU wire.

M I CABLE

ADAPTER

M I CABLE

LINE LEAK

DETECTOR

STATION

CONDUIT

PORT

PUMP

HOUSING

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 housingand 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. ReferenceFigure 2.2-9, or 2.2-10.

M I CABLE

LINE LEAK

DETECTOR

	STATION	P IP E L IN E
	CONDUIT

PUMP

HOUSING

Figure 2.2-9 MI Cable Adapter Installation – RedJacket ® Pump Housing

2.2	Page 2.2 - 8	TS-LLD INSTALLATION GUIDE