Veeder-Root DPLLD Site Prep And Installation Manual

Site Prep and Installation Guide

DPLLD

Manual No: 577013-933 ● Revision: F

Notice

Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose.

Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing,
performance, or use of this publication.

Veeder-Root reserves the right to change system options or features, or the information contained in this publication.

This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be
photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root.

Contact TLS Systems Technical Support for additional troubleshooting information at 800-323-1799.

DAMAGE CLAIMS / LOST EQUIPMENT

Thoroughly examine all components and units as soon as they are received. If any cartons are damaged or missing, write a complete
and detailed description of the damage or shortage on the face of the freight bill. The carrier's agent must verify the inspection and sign
the description. Refuse only the damaged product, not the entire shipment.

Veeder-Root must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and
Conditions.

VEEDER-ROOT’S PREFERRED CARRIER

1. Contact Veeder-Root Customer Service at 800-873-3313 with the specific part numbers and quantities that were missing or
received damaged.

2. Fax signed Bill of Lading (BOL) to Veeder-Root Customer Service at 800-234-5350.

3. Veeder-Root will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer
Service will work with production facility to have the replacement product shipped as soon as possible.

CUSTOMER’S PREFERRED CARRIER

1. It is the customer’s responsibility to file a claim with their carrier.

2. Customer may submit a replacement purchase order. Customer is responsible for all charges and freight associated with
replacement order. Customer Service will work with production facility to have the replacement product shipped as soon as
possible.

3. If “lost” equipment is delivered at a later date and is not needed, Veeder-Root will allow a Return to Stock without a restocking fee.

4. Veeder-Root will NOT be responsible for any compensation when a customer chooses their own carrier.

RETURN SHIPPING

For the parts return procedure, please follow the appropriate instructions in the "General Returned Goods Policy” pages in the
"Policies and Literature" section of the Veeder-Root North American Environmental Products price list. Veeder-Root will not accept
any return product without a Return Goods Authorization (RGA) number clearly printed on the outside of the package.

©Veeder-Root 2017. All rights reserved

.

ii

Introduction

Contractor Certification Requirements ..............................................................................1

Product Marking Information .............................................................................................1

Related Documents ..................................................................................................1

Safety Warnings ...............................................................................................................3

Safety Symbols .................................................................................................................4

Reference Manuals ..................................................................................................4

Before You Begin ..............................................................................................................4

Warning Tags ...................................................................................................................5

Site Considerations

Manholes ..........................................................................................................................6

Unused Piping Runs .........................................................................................................6

Existing Check Valves ......................................................................................................6

Manifolded Product Lines .................................................................................................6

DPLLD Equipment Overview

DPLLD Components .........................................................................................................7

DPLLD Installation Example .............................................................................................7

DPLLD Transducer Installation

Red Jacket Standard and Quantum Pumps (DPLLD w/SwiftCheck) ................................8

Red Jacket Standard and Quantum Pumps (DPLLD w/Pressurstat) ..............................12

Red Jacket Quantum Pumps with SpikeCheck Valve ....................................................13

The Red Jacket Pump ....................................................................................................14

Red Jacket Maxxum Big-Flo ...........................................................................................15

FE Petro Pumps .............................................................................................................16

FE Petro High Capacity Pumps..............................................................................17

FE Petro Variable Speed Pump System Modifications ..........................................18

Table of Contents

DPLLD Field Wiring

DPLLD Transducers .......................................................................................................20

DPLLD Wiring Connections In the Console

DPLLD Transducer Wiring Connections .........................................................................22

Pump Wiring Connections ..............................................................................................22

DPLLD Equipment Checkout

1. Vent The Line .....................................................................................................31

2. Red Jacket Standard, Quantum, and Maxxum Pumps

with DPLLD Transducer and Pressurstat only ...................................................31

3. Determine DPLLD Transducer Pressure Offset .................................................32

4. Purge Air from the Line.......................................................................................32

5. Enable the Line for Dispensing...........................................................................32

iii

Figures

Table of Contents

Figure 1. Warning tag ............................................................................................5

Figure 2. Example DPLLD Equipment Installation .................................................7

Figure 3. Sealing Surface For SwiftCheck Valve’s External O-Ring .....................9

Figure 4. DPLLD Transducer Installation ...............................................................9

Figure 5. DPLLD Install W/Healy Mini-Jet System ..............................................10

Figure 6. Modifying The Pressurstat/Functional Element In Red Jacket Pumps.....11

Figure 7. PLLD/Pressurstat Installation ...............................................................12

Figure 8. DPLLD Installation In Red Jacket Quantum Pumps ............................13

Figure 9. Locating Discharge Port Plug For Line Leak Transducer .....................14

Figure 10. Example DPLLD Installation In A Red Jacket Maxxum Big-Flo Pump.....15

Figure 11. Location of DPLLD Transducer And Model ‘R’

Precision Check Valve In FE Petro Pump ............................................17

Figure 12. Identifying A FE Petro ‘R’ Style Precision Check Valve ........................ 17

Figure 13. Dip Switch SW2 And Rotary Switch Locations In The

FE-Petro IST-VFC Unit .........................................................................19

Figure 14. Field Connections Of DPLLD Transducer ............................................20

Figure 15. Epoxy Sealing Pressure Transducer Field Connections ......................21

Figure 16. DPLLD Transducer Wiring To USM Module .........................................22

Figure 17. DPLLD Pump Control Diagram For Red Jacket Relay Control Box .....23

Figure 18. Red Jacket Maxxum Big-Flo Single-Phase Wiring ...............................24

Figure 19. Red Jacket Maxxum Big-Flo 3-Phase Wiring .......................................25

Figure 20. DPLLD pUmp Control Diagram For Non-Red Jacket

Relay Control Box .................................................................................26

Figure 21. Wiring Diagram - Manifolded Lines DPLLD - Multiple Tanks ..................27

Figure 22. DPLLD Pump Control Diagram For Gilbarco Dispenser Isolation Box .28

Figure 23. Manifolded Product Lines - Dual FE Petro IST-VFC Controllers ..........29

Figure 24. Manifolded Product Lines - Dual Red Jacket IQ Controllers ................30

Figure 25. Pressurstat Adjustable Valve Assembly ...............................................32

Tables

Table 1. FE-IST-VFC Product Type Dip Switch (SW2) Settings ..........................18

Table 2. FE-IST-VFC Rotary Switch Positions W/V1.1/1.2 Software ...................19

iv

Introduction

NOTICE

This manual contains instructions for installing the components for Veeder-Root Digital Pressurized Line Leak
Detection (DPLLD). The DPLLD equipment performs 3.0 gph line leak tests following each dispense. Depending
on the software enhancement module installed, the DPLLD equipment will also allow, with certain pump types, 0.2
and/or 0.1 gph line tests at full pump pressure. The DPLLD equipment executes leak tests automatically to
eliminate the need for separate annual line leak testing.

1. The DPLLD, Digital Pressure Line Leak Detector, Form Number 8590, is Intrinsically Safe when
installed according to Control Drawing Number 331940-008.

2. The TLS-450PLUS/TLS-450 console/DPLLD sensors are not supported by the Red Jacket Variable
Speed Flow Controller (VSFC). The VSFC is designed for use with PLLD sensors/TLS-350
consoles only!

3. You must consult the Veeder-Root Line Leak Detection Systems Application Guide (P/N 577013-

465) for all information relating to DPLLD applicable pipe types, equipment requirements,
installation kits, and pump compatibilities.

4. A Sump Sensor is recommended for sites with line leak in the event the pump develops a leak.
Line leak will only detect a leak in the line, not in the pump.

Contractor Certification Requirements

Veeder-Root requires the following minimum training certifications for contractors who will install and setup the
equipment discussed in this manual:

Installer Certification (Level 1): Contractors holding valid Installer Certification are approved to perform wiring
and conduit routing; equipment mounting; probe, sensor and carbon canister vapor polisher installation; wireless
equipment installation; tank and line preparation; and line leak detector installation.

Technician Certification (Level 2/3): Contractors holding valid Technician Certifications are approved to
perform installation checkout, startup, programming and operations training, system tests, troubleshooting and
servicing for all Veeder-Root Series Tank Monitoring Systems, including Line Leak Detection. In addition,
Contractors with the following sub-certification designations are approved to perform installation checkout, startup,
programming, system tests, troubleshooting, service techniques and operations training on the designated system.

•Wireless 2

• Tall Tank

Warranty Registrations may only be submitted by selected Distributors.

Product Marking Information

RELATED DOCUMENTS

Documents Required to Install Equipment

This intrinsically safe apparatus is only for use as part of a Veeder-Root Automatic Tank Gauging System (ATG
Console with probes and sensors). To install intrinsically safe apparatus, use the specific control drawing that
appears on the nameplate of the applicable associated apparatus (ATG Console):

1

Introduction Product Marking Information

CLASS I Division 1, Group D

CLASS 1, Zone 0

Hazardous Location

Intrinsically Safe Apparatus

Non-Hazardous Location

Associated Apparatus

ATG Console

I.S. Sensor

Connections

DPLLD
Sensor

Intrinsically Safe

Wiring

White (+)

(+)

Black (-)

(-)

I.S.

Rigid Conduit

GENERAL PRODUCT WIRING DIAGRAM

Seal-Off

I.S.

Weatherproof

Junction Box

I.S. CIRCUIT FOR HAZLOC SENSOR

F/N 8590XX-XXX

S/N XXXXXX

-40°C < Ta < +60°C

CL I, DIV. 1, GP.D
CL I, ZONE 0
AEx ia IIA
Ex ia IIA
TC=T4

MANUAL NO. 577013-933

SECURITE INTRINSEQUE

Associated Apparatus

TLS-450PLUS&TLS-450/8600 331940-008

UL/cUL Control Drawing Number

The control drawings contain information related to the correct installation of the overall intrinsically Safe System.
This includes information such as maximum number of apparatus, specific apparatus allowed in the system,
maximum cable lengths, references to codes, proper grounding and so on. Control drawings can be found on the
accompanying Compact Disk (TECH DOCS CD) or on the INTERNET at veeder.com under SUPPORT; VR
TECHNICAL DOCUMENTS; DRAWINGS.

Product Label Contents

2

Introduction Safety Warnings

OFF

NOTICE

Safety Warnings

To protect yourself and your equipment, observe the following warnings and important information:

WARNING

This product is to be installed in systems operating near locations where
highly combustible fuels or vapors may be present.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY

WARNING

PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT,
RESULTING IN SERIOUS INJURY OR DEATH.

1. Read and follow all instructions in this manual, including all safety
warnings to protect yourself and others from serious injury, explosion, or
electrical shock.

2. Comply with all applicable codes including: the National Electrical Code;
federal, state, and local codes; and other applicable safety codes.

3. To protect yourself and others from being struck by vehicles, block off
your work area during installation or service.

4. Do not alter or modify any component or substitute components in this
kit.

5. Warning! Substitution of components may impair intrinsic safety.

6. Field wiring to the DPLLD Transducer must not share a conduit with any
non-intrinsically safe device’s wiring.

7. To prevent ignition of flammable or combustible atmospheres, turn off,
tag and lockout power to console and pumps before servicing.

8. Before installing or taking the transducer into a hazardous area, earth the
unit in a safe area to remove any static charge. Then immediately
transport the unit to the installation site. Do not rub or clean the unit prior
to installation. Cleaning is not required under normal service conditions.
Do not rub or clean the unit after installation. If the unit is not fixed to a
known earth point when installed, ensure that a separate earth
connection is made to prevent the potential of a static discharge. When
fitting or removing the unit, use of anti-static footwear or clothing is
required.

9. Materials used in the construction of this device do not contain, by mass,
more than 10% in total of aluminum, magnesium, zirconium and titanium
or 7.5% in total of magnesium, titanium and zirconium.

Failure to install this product in accordance with its instructions and warnings will result in
voiding of all warranties with this product.

3

Introduction Safety Symbols

OFF

G
A
S

WARNING

CAUTION

NOTICE

Safety Symbols

The following safety symbols may be used throughout this manual to alert you to important safety hazards and
precautions.

EXPLOSIVE

Fuels and their vapors are extremely explo­sive if ignited.

ELECTRICITY

High voltage exists in, and is supplied to,
the device. A potential shock hazard exists.

WEAR EYE PROTECTION

Fuel spray from residual pressure in the
lines can cause serious eye injuries.
Always wear eye protection.

GLOVES

Wear gloves to protect hands from irrita­tion or injury.

WARNING indicates a hazardous situa-
tion which, if not avoided, could result in
death or serious injury.

USE SAFETY BARRICADES

Always use safety cones or barricades,
safety tape, and your vehicle to block the
work area.

READ ALL RELATED MANUALS

Knowledge of all related procedures
before you begin work is important. Read
and understand all manuals thoroughly. If
you do not understand a procedure, ask
someone who does.

FLAMMABLE

Fuels and their vapors are extremely flammable.

TURN POWER OFF

Live power to a device creates a potential
shock hazard. Turn Off power to the device and
associated accessories when servicing the unit.

INJURY

Careless or improper handling of materials can
result in bodily injury.

APPROVED CONTAINERSS

Use nonbreakable, clearly marked containers,
suitable for collecting and transporting hazard­ous fuels during service.

CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

NOTICE is used to address practices not related
to physical injury.

USE SAFETY BARRICADES

Always use safety cones or barricades, safety
tape, and your vehicle to block the work area.

REFERENCE MANUALS

577013-465
577014-073
577013-879

Line Leak Application Guide
TLS-450PLUS Site Prep and Installation Manual
TLS-450 Console Site Prep and Installation Manual

Before You Begin

1. Ensure that the submersible turbine pump (STP) is properly grounded as per the manufacturer’s instructions.

2. A shutoff valve installed between the DPLLD transducer and the product pipeline is recommended. Al
not required
any product spill

for the DPLLD equipment to work, the valve will aid in troubleshooting the system and in reduci

age when performing service work in the sump.

4

though

ng

Introduction Warning Tags

WARNING

WARNING

THE SUBMERGED PUMP SYSTEM SUPPLYING THE
DISPENSERS MAY TURN ON UNEXPECTEDLY TO
PERFORM A LINE LEAK TEST. THIS MAY RESULT
IN FUEL SPRAYING DURING DISPENSER, PRODUCT
LINE, LEAK DETECTOR OR STP SERVICE.

PERFORM THE FOLLOWING BEFORE BEGINNING SERVICE:

1. CLOSE AFFECTED DISPENSER SHEAR VALVE AND TEST
FOR PROPER SHUTOFF OF THE VALVE IF PERFORMING
DISPENSER HYDRAULIC SERVICE.

2. REMOVE POWER TO THE SUBMERGED PUMP (STP) AND
TO THE CONSOLE AND THE LINE LEAK DETECTOR SYSTEM.

3. WEAR EYE PROTECTION.

4. COLLECT FUEL IN APPROVED CONTAINERS.
DO NOT CONTAMINATE ENVIRONMENT.

TO ORDER TAGS - USE PART NO. 329801-001

consoles\warntag.eps

OFF

G
A
S

3. The SwiftCheck valve requires a 3” hex socket (or wrench) for tightening it in the pump’s leak detector port.
The non-vented SwiftCheck valve requires a 1-1/2” hex socket (or wrench) for tightening it in the pump’s leak
detector port.

Warning Tags

Turn off, tag (using the warning tags provided), and lockout power to the console and sub­mersible pumps while installing the DPLLD equipment. This will prevent either a dispense
attempt or the DPLLD equipment from automatically starting up the pump.

Warning tags [Figure 1] are provided with the DPLLD equipment. For your safety and the safety of others who may
service dispensers, submersible pumps, or DPLLD equipment, you must attach a tag to each of the following
devices where it can clearly be seen by a service person performing work on the system:

•Console

• Submersible pump

• Dispenser filter

Figure 1. Warning tag

5

Site Considerations

Manholes

When using a SwiftCheck Valve, the manhole must provide at least 8 inches of clearance above the pump head to
install the DPLLD components.

Unused Piping Runs

Where piping runs have been installed for future use, but are connected to the active piping system, isolate the
inactive lines from the active lines using a shutoff valve. Failure to do so may harm system performance.

Existing Check Valves

You must ensure that there are no existing check valves already installed in the pipeline. The presence of any check
valve (other than the one used with the DPLLD equipment) can prevent the DPLLD equipment from detecting line
leaks in the area of pipeline downstream from the check valve.

Manifolded Product Lines

Follow these guidelines as you install a DPLLD equipment into multiple manifolded tanks:

• Dielectric unions and flexible piping elements should be used as required by federal, state, and local

requirements for the specific piping application. Location of unions may vary with configuration.

• An I/O Module in the console is required to control the pump on the higher-numbered tank and pump control

output for the primary tank, and the “Pump In” (Dispenser ON) signal for the set.

• A DPLLD transducer is only required in the master pump.

• Remove any other check valve or leak detect device in the line that is not shown.

• Refer to the Line Leak Application Guide for check valve requirements.

6

DPLLD Equipment Overview

DPLLD Components

• TLS-450/TLS-450PLUS console with DPLLD feature.

• DPLLD pressure transducer (one for each product line monitored) - vented or non-vented check valves may be

required depending on pump type and application

• USM Module to monitor DPLLD transducers

• I/O Module to control site master and slave STPs

DPLLD Installation Example

Figure 2 shows an example DPLLD installation for a single tank and a manifolded tank set having Red Jacket
Standard pumps.

Non-vented SwiftCheck or
high pressure valve

To I/O module in
TLS console
( STP power)

Sump

To Dispensers

Shut-off valve

STP

DPLLD transducer and
SwiftCheck valve

Sump

SINGLE

To Dispensers

Cord grip

Junction box

Seal off

To USM module in TLS console (line pressure)

To pump control box

STP

DPLLD transducer and
SwiftCheck valve

Shut-off valve

Sump

Cord grip

Junction box

Seal off

To USM module
in TLS console ( line pressure)

To pump control box

STP

MASTERSLAVE

Figure 2. Example DPLLD Equipment Installation

7

dplld\plldoverview.eps

DPLLD Transducer Installation

OFF

WARNING

WARNING

This section discusses DPLLD transducer installation for the following DPLLD approved pumps:

• Red Jacket Standard and Quantum pumps - DPLLD transducer/SwiftCheck valve (page 8)

• Red Jacket Standard and Quantum pumps - DPLLD transducer/Pressurstat (page 12)

• Red Jacket Quantum with SpikeCheck Valve (page 13)

• The Red Jacket (page 14)

• Red Jacket Maxxum Big-Flo (page 15)

• FE-Petro (page 16)

Red Jacket Standard and Quantum Pumps (DPLLD w/SwiftCheck)

Use this installation procedure to install a DPLLD transducer with a SwiftCheck valve in a Red Jacket Standard or
Quantum pump.

Disconnect, lock out, and tag all AC power to the TLS console, dispens­ers and submersible pumps.

When servicing equipment, use non-sparking tools and use caution when removing or in­stalling equipment to avoid generating a spark.

1. If a ball valve is installed down line from the pump, close it.

2. Do one of the following:

a. If the submersible turbine pump is equipped with a mechanical LLD, remove the mechanical unit and any

related tubing and fittings, or

b. If the submersible turbine pump is not equipped with a mechanical LLD, remove the 2-inch mechanical

LLD port plug.

3. Ensure that the sealing surface for the SwiftCheck valve’s external o-ring is smooth and free from corrosion,
pitting, and any material build-up [Figure 3].

Failure to ensure a smooth seal surface can result in false line leak alarms.

8