VST GREEN MACHINE VST-GM-CS2-101 Installation, Operation, Maintenance, & Troubleshooting Manual

Download

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 1

GREEN MACHINE ™ - North America

(Patents Pending)

Model # VST-GM-CS2-101

Installation, Operation, Maintenance, & Troubleshooting Manual

Rev. 4.5 – Published April 2019

Manual #9600-003

Vapor Systems Technologies, Inc.

650 Pleasant Valley Drive Springboro, Ohio 45066 (937) 704-9333 PH (937) 704-9443 FX www.vsthose.com

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 2

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 3

Table of Contents

Table of Contents................................................................................................................................................... 3

Table of Figures ..................................................................................................................................................... 9

About VST ............................................................................................................................................................ 13

Notice .................................................................................................................................................................. 13

Warranty ............................................................................................................................................................. 13

Safety .................................................................................................................................................................. 14

Table of Terms & Abbreviations ........................................................................................................................... 15

Regulations & Jurisdiction ................................................................................................................................... 16

GREEN MACHINE Overview ................................................................................................................................. 17

GREEN MACHINE Theory of Operation ................................................................................................................ 18

GREEN MACHINE Dimensions & Weight .............................................................................................................. 19

How the GREEN MACHINE is Shipped .................................................................................................................. 19

Chapter 1: General Contractor Installation ......................................................................................................... 21

1 Installation Instructions ................................................................................................................................. 21

1.1 Installation Safety for all Contractors ....................................................................................................... 21

1.2 Preparing the GREEN MACHINE for Installation ....................................................................................... 21

1.3 Installing the Legs on the GREEN MACHINE ............................................................................................. 22

1.4 GREEN MACHINE Dimensions & Weight .................................................................................................. 23

1.5 Ground Mount Locations .......................................................................................................................... 23

1.6 Setting the Concrete Pad .......................................................................................................................... 24

1.7 Installing the GREEN MACHINE on the Concrete Pad ............................................................................... 25

1.8 Roof-Top Installation ................................................................................................................................ 28

1.9 Canopy-Top Installation ............................................................................................................................ 28

1.10 Vent-Stack Mount Installation ............................................................................................................. 29

1.11 Pre-Installation Site Survey .................................................................................................................. 31

1.12 Pre-Installation Site Survey .................................................................................................................. 31

1.13 GDF Contact Information ..................................................................................................................... 31

1.14 Snapshot of Site Requirements ........................................................................................................... 32

1.15 Other Information to Document ......................................................................................................... 35

1.15.1 Gasoline Stations............................................................................................................................. 35

1.15.2 Dispensers ....................................................................................................................................... 36

1.15.3 Vent Risers ...................................................................................................................................... 36

1.15.4 VST GREEN MACHINE ...................................................................................................................... 36

1.15.5 Electrical .......................................................................................................................................... 37

1.15.6 Additional Documentation .............................................................................................................. 37

1.16 Sample Sketch ...................................................................................................................................... 40

1.16.1 Your Sketch ..................................................................................................................................... 41

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 4

Chapter 2: Vapor Piping Installation ................................................................................................................... 43

2 Vapor Piping Installation Overview ............................................................................................................... 43

2.1 General Notes ........................................................................................................................................... 43

2.2 Flexible Piping ........................................................................................................................................... 45

2.3 Vapor Inlet and Vapor Return Piping Installation ..................................................................................... 46

2.4 Air Outlet Piping Installation .................................................................................................................... 47

2.5 Vapor Piping Post-Installation .................................................................................................................. 47

2.6 Vapor Piping Bill of Material ..................................................................................................................... 49

Chapter 3: Electrical Installation ......................................................................................................................... 51

3 Electrical Safety ............................................................................................................................................. 51

3.1 Electrical Requirements ............................................................................................................................ 51

3.2 Electrical Installation ................................................................................................................................ 52

3.3 Electrical Installation Code Requirements ................................................................................................ 52

3.4 Electrical Components .............................................................................................................................. 53

3.5 Electrical Wiring Installation ..................................................................................................................... 53

3.5.1 INSTALLING THE VST CONTROL PANEL: ............................................................................................... 53

3.5.2 OPTION 1: POWER TO THE VST CONTROL PANEL FROM THE MAIN ELECTRICAL DISTRIBUTION PANEL. 54

3.5.3 OPTION 2: POWER THE VST CONTROL PANEL FROM THE STATION EMERGENCY SHUT-OFF (ESO) RELAY. 54

3.5.4 Wiring the Electrical Components at the GREEN MACHINE Location. ................................................ 55

3.5.5 Wiring the Overfill Alarm Field Wiring ................................................................................................. 55

3.5.6 Wiring the VST Control Panel to the GREEN MACHINE ....................................................................... 56

3.5.7 Wiring the Pressure Sensor.................................................................................................................. 56

3.5.8 Vacuum Pump Motor Wiring Diagram ................................................................................................ 56

3.5.9 Applying Power to the VST Control Panel ............................................................................................ 56

Chapter 4: Control Panel ..................................................................................................................................... 67

4 VST Control Panel Overview .......................................................................................................................... 67

4.1 Main Screen Overview .............................................................................................................................. 68

4.2 Maintenance Screen Overview ................................................................................................................. 69

4.3 Alarm Screen Overview ............................................................................................................................ 71

Chapter 5: OPEN: NO CONTENT ......................................................................................................................... 73

5 Left intentionally blank .................................................................................................................................. 73

Chapter 6: Testing & Start-Up ............................................................................................................................. 75

6 Post-Installation GREEN MACHINE Testing & Start Up ................................................................................. 75

6.1 VST Control Panel Initial Start-Up Power: ................................................................................................ 75

6.2 Before beginning the Testing and Start-Up procedures ........................................................................... 76

6.3 Post Installation Start-Up Tests ................................................................................................................ 76

6.4 Bump Test ................................................................................................................................................. 79

6.4.1 Purpose of the Bump Test ................................................................................................................... 79

6.4.2 Preparation for the Bump Test ............................................................................................................ 79

6.4.3 Bump Test Procedure .......................................................................................................................... 80

6.5 Functionality Test ..................................................................................................................................... 82

6.5.1 The Purpose of the Functionality Test ................................................................................................. 82

6.5.2 Preparation for the Functionality Test ................................................................................................. 82

6.5.3 Functionality Test Procedures ............................................................................................................. 84

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 5

6.6 Programming the Fuel Management System Overfill Alarm Relay for the GREEN MACHINE .................. 87

6.7 Testing the Overfill Alarm on the GREEN MACHINE VST Control Panel ................................................... 88

6.7.1 TLS-350 Overfill Alarm Test .................................................................................................................. 88

6.7.2 TLS-450 Overfill Alarm Test .................................................................................................................. 89

6.7.3 TLS 450 Plus Overfill Alarm Test .......................................................................................................... 90

6.8 Changing the Date and Time Procedure ................................................................................................... 91

6.8.1 Changing the Date and Time Procedure .............................................................................................. 91

6.9 Submitting Appendix B to VST for the Verification CODE ........................................................................ 93

6.9.1 Start Up of the GREEN MACHINE ......................................................................................................... 93

6.9.2 Procedures ........................................................................................................................................... 93

Chapter 7: Maintenance Procedures .................................................................................................................... 95

7 Maintenance Overview ................................................................................................................................. 95

7.1 Maintenance Procedures ......................................................................................................................... 95

7.2 Recommended Replacement Parts .......................................................................................................... 97

7.3 Functionality Test ..................................................................................................................................... 98

7.3.1 The Purpose of the Functionality Test ................................................................................................. 98

7.3.2 Preparation for the Functionality Test ................................................................................................. 98

7.3.3 Functionality Test Procedures ........................................................................................................... 100

7.4 Pressure Sensor Verification Test ........................................................................................................... 103

7.4.1 Safety: ................................................................................................................................................ 103

7.4.2 Procedure: ......................................................................................................................................... 103

7.5 Rubber Flange Sleeve Replacement ....................................................................................................... 107

7.5.1 Removing the Rubber Flange Sleeve ................................................................................................. 107

7.5.2 Replacing the Rubber Flange Sleeve .................................................................................................. 108

7.6 Cleaning the Control Valves .................................................................................................................... 109

7.6.1 Removing the Valve Solenoid and Core Assembly ............................................................................. 110

7.6.2 Replacing the Valve Solenoid and Core Assembly ............................................................................. 111

7.7 Check the Air Outlet for Liquid Condensation ........................................................................................ 112

Safety ............................................................................................................................................................... 112

7.7.1 Removing the Drain Plug ................................................................................................................... 112

7.7.2 Replacing the Drain Plug .................................................................................................................... 112

7.8 Separator Check Procedure .................................................................................................................... 114

7.8.1 Safety ................................................................................................................................................. 114

7.8.2 7.7.1 Removing and Inspecting the Separator ................................................................................... 114

7.8.3 7.7.2 Reinstalling the Existing Separator ........................................................................................... 115

7.8.4 Installing a New Separator ................................................................................................................. 115

Chapter 8: Troubleshooting .............................................................................................................................. 117

8 Troubleshooting Procedures ........................................................................................................................ 117

8.1 Troubleshooting Procedures Overview .................................................................................................. 117

8.1.1 Troubleshooting the GREEN MACHINE and the VST Control Panel ................................................... 117

8.2 Alarm Overview ...................................................................................................................................... 118

8.2.1 Alarm List ........................................................................................................................................... 119

8.3 Troubleshooting Procedures .................................................................................................................. 120

8.4 Power to the VST Control Panel or PLC Controller is OFF ...................................................................... 121

8.4.1 Control Panel General Information.................................................................................................... 123

8.4.2 Option 1: Control Panel is Powered from Distribution Panel ............................................................ 124

8.4.3 Option 2: Control Panel is Powered from ESO Breaker ..................................................................... 126

8.5 Pressure Sensor Alarm ............................................................................................................................ 134

8.5.1 Pressure Sensor Alarm: Troubleshooting Steps ................................................................................ 135

8.6 Vacuum Pump Alarm .............................................................................................................................. 137

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 6

8.6.1 Vacuum Pump Alarm: Troubleshooting Steps .................................................................................. 138

8.7 Maintenance Switch Alarm .................................................................................................................... 146

8.8 Overfill Alarm .......................................................................................................................................... 147

8.8.1 Overfill Alarm Troubleshooting Steps ................................................................................................ 148

8.9 SD Card Alarm ......................................................................................................................................... 150

Chapter 9: Replacement Procedures ................................................................................................................. 151

9 Replacement Parts Procedures .................................................................................................................... 151

9.1 List of Replacement Parts ....................................................................................................................... 151

9.1.1 North America VST Control Panel Replacement Parts ....................................................................... 152

9.1.2 Replacement Procedures by Part ...................................................................................................... 155

9.2 PLC (Controller) Replacement ................................................................................................................ 155

9.2.1 Removing the PLC .............................................................................................................................. 155

9.2.2 Installing the New PLC ....................................................................................................................... 156

9.3 Control Panel Small Components Replacement ..................................................................................... 158

9.3.1 Vacuum Pump Motor Breaker Replacement ..................................................................................... 158

9.3.2 Vacuum Pump Motor Solid-State Relay Replacement ...................................................................... 159

9.4 Pressure Sensor Replacement ................................................................................................................ 161

9.4.1 Removing the Pressure Sensor .......................................................................................................... 161

9.4.2 Installing the Pressure Sensor ............................................................................................................ 162

9.5 Rubber Flange Sleeve Replacement ....................................................................................................... 165

9.5.1 Removing the Rubber Flange Sleeve ................................................................................................. 165

9.5.2 Replacing the Rubber Flange Sleeve .................................................................................................. 166

9.6 Vacuum Pump Motor (Only) Replacement ............................................................................................ 167

9.6.1 Removing the Vacuum Pump Motor ................................................................................................. 167

9.6.2 Replacing the Vacuum Pump Motor .................................................................................................. 168

9.7 Control Valve Replacement .................................................................................................................... 170

9.7.1 Removing the Valve Solenoid and Core Assembly ............................................................................. 171

9.7.2 Replacing the Valve Solenoid and Core Assembly ............................................................................. 172

9.8 Vacuum Pump (Only) Replacement ........................................................................................................ 173

9.8.1 Preparation for Cleaning the Tubes and Manifold ............................................................................ 173

9.8.2 Removing the Vacuum Pump ............................................................................................................ 175

9.8.3 Replacing the Vacuum Pump ............................................................................................................. 176

9.8.4 Preparation for Cleaning the Tubes and Manifold ............................................................................ 177

9.8.5 Cleaning the Tubes and Manifold ...................................................................................................... 181

9.8.6 Reassemble the Tubes and Valve Components ................................................................................. 182

9.8.7 Conduct a Functionality Test ............................................................................................................. 182

9.8.8 Ending Stage ...................................................................................................................................... 182

9.9 Canister Housing Replacement ............................................................................................................... 183

9.9.1 Removing the Canister Housing, Tubing, and Fittings ....................................................................... 183

9.9.2 Installing the new 8” Canister Housing .............................................................................................. 183

9.10 Separator Replacement ..................................................................................................................... 185

9.10.1 Safety ............................................................................................................................................ 185

9.10.2 Removing and Inspecting the Separator ....................................................................................... 185

9.10.3 Installing a New Separator ............................................................................................................ 186

9.11 Leak Test ............................................................................................................................................ 187

9.11.1 Purpose of the Leak Test ............................................................................................................... 187

9.11.2 Preparation for the Leak Test ....................................................................................................... 187

9.11.3 Leak Test Procedure ...................................................................................................................... 190

Chapter 10: Operator Instruction Sheet ............................................................................................................ 193

10 Alarm Instructions ....................................................................................................................................... 193

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 7

10.1 Controller Screen ............................................................................................................................... 193

10.2 Pressure Sensor Alarm ....................................................................................................................... 193

10.3 Vacuum Pump Alarm ......................................................................................................................... 193

10.4 Maintenance Switch Alarm ................................................................................................................ 194

10.5 Overfill Alarm ..................................................................................................................................... 194

10.6 SD Card Alarm .................................................................................................................................... 194

10.7 How to Remove and Insert the SD Card into Unitronics PLC Slot ...................................................... 197

Chapter 11: GM Operator Training Guide ......................................................................................................... 199

11 About VST .................................................................................................................................................... 199

11.1 GREEN MACHINE Theory of Operations ............................................................................................ 199

11.2 VST Control Panel .............................................................................................................................. 201

11.2.1 VST Control Panel Overview ......................................................................................................... 201

11.2.2 Main Screen .................................................................................................................................. 202

11.2.3 Maintenance Screen ..................................................................................................................... 203

11.2.4 Alarm Screen ................................................................................................................................. 205

11.3 Alarms Overview ................................................................................................................................ 205

11.3.1 GM Status ...................................................................................................................................... 205

11.3.2 Pressure Sensor Alarm .................................................................................................................. 205

11.3.3 Vacuum Pump Alarm .................................................................................................................... 206

11.3.4 Maintenance Switch Alarm ........................................................................................................... 206

11.3.5 Overfill Alarm ................................................................................................................................ 206

11.3.6 SD Card Alarm ............................................................................................................................... 207

11.4 Station UST Environmental Compliance Testing and Services ........................................................... 209

11.5 Locks and Keys ................................................................................................................................... 209

Appendix A - General Contractor Check-Out Form ............................................................................................. 211

Appendix A – General Contractor Check-Out Form ............................................................................................ 212

Appendix B - Start-Up Contractor Check-Out Form ............................................................................................ 215

Appendix B - Start-Up Contractor Check-Out Form ............................................................................................ 216

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 8

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 9

Table of Figures

Figure 1-1: Bolting sequence to attach legs to the GREEN MACHINE base ........................................................... 22

Figure 1-2: Concrete mounting pad dimensions .................................................................................................. 26

Figure 1-3: GREEN MACHINE Ground Mounting Pad ........................................................................................... 27

Figure 1-4: Vent Stack Installation....................................................................................................................... 30

Figure 1-5: Example of a GDF Layout ................................................................................................................... 38

Figure 1-6: Example of a GREEN MACHINE with Vapor Piping Layout ................................................................. 39

Figure 2-1: Vapor Piping Overview ...................................................................................................................... 44

Figure 2-2: GREEN MACHINE Connections ........................................................................................................... 45

Figure 2-3: Pressure Sensor w/ 3-Way Isolation Valve Open ............................................................................... 48

Figure 3-1: VST Control Panel - GM Disabled - Enter CODE Main Screen ............................................................. 57

Figure 3-2: GREEN MACHINE Installation Overview Option 1 .............................................................................. 58

Figure 3-3: The Control Panel Power and ESO Connections Option 1 .................................................................. 59

Figure 3-4: The GREEN MACHINE Installation Overview Option 2 ........................................................................ 60

Figure 3-5: The Control Panel Power Connection Option 2 .................................................................................. 61

Figure 3-6: The VST Control Panel Field Wiring .................................................................................................... 62

Figure 3-7: GREEN MACHINE Internal Junction Box Field Wiring ......................................................................... 63

Figure 3-8: Pressure Sensor Wiring Diagram ....................................................................................................... 64

Figure 3-9: Vacuum Pump Motor Wiring Diagram ............................................................................................... 65

Figure 4-1: VST North America Control Panel, Front View ................................................................................... 67

Figure 4-2: Main Screen ...................................................................................................................................... 68

Figure 4-3: Maintenance Screen Overview .......................................................................................................... 69

Figure 4-4: Pressure Sensor Alarm shown on the Alarm Screen .......................................................................... 71

Figure 6-1: Main Screen with the GM DISABLED – ENTER CODE .......................................................................... 75

Figure 6-2: Vapor Piping Overview ...................................................................................................................... 78

Figure 6-3: Maintenance Screen .......................................................................................................................... 79

Figure 6-4: Bump Confirmation Screen................................................................................................................ 80

Figure 6-5: Vacuum Pump Motor Wiring Diagram ............................................................................................... 81

Figure 6-6: Maintenance Screen .......................................................................................................................... 82

Figure 6-7: GREEN MACHINE Vapor Piping Layout ............................................................................................... 83

Figure 6-8: Functionality Test Screen .................................................................................................................. 85

Figure 6-9: Functionality Test Confirmation Button............................................................................................. 86

Figure 6-10: GREEN MACHINE Operation Diagram .............................................................................................. 87

Figure 6-11: Output Relay Setup ......................................................................................................................... 89

Figure 6-12: Main Screen .................................................................................................................................... 91

Figure 6-13: Time & Date .................................................................................................................................... 92

Figure 6-14: VERIFICATION CODE screen ............................................................................................................. 94

Figure 6-15: Enter the Verification CODE screen ................................................................................................. 94

Figure 7-1: VST PLC Main Screen w/no alarms .................................................................................................... 96

Figure 7-2: Maintenance Replacement Parts ....................................................................................................... 97

Figure 7-3: Maintenance Screen .......................................................................................................................... 98

Figure 7-4: GREEN MACHINE Vapor Piping Layout .............................................................................................. 99

Figure 7-5: Functionality Test Screen ................................................................................................................ 101

Figure 7-6: Functionality Test Confirmation Button........................................................................................... 102

Figure 7-7: GREEN MACHINE Operation Diagram .............................................................................................. 102

Figure 7-8:Pressure Sensor & 3-Way Valve, Normal Operation .......................................................................... 104

Figure 7-9: Pressure Sensor & 3-Way Valve, TEST Position ................................................................................ 105

Figure 7-10: Main Screen w/Pressure Reading .................................................................................................. 106

Figure 7-11: Vac Pump Rubber Flange Sleeve Replacement .............................................................................. 107

Figure 7-12: Replacing the Rubber Flange Sleeve .............................................................................................. 108

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 10

Figure 7-13: GREEN MACHINE Control Valves Identification Tags ..................................................................... 109

Figure 7-14: Vale Solenoid Assembly................................................................................................................. 110

Figure 7-15: Solenoid Base Interior ................................................................................................................... 110

Figure 7-16: Valve Core Assembly ..................................................................................................................... 111

Figure 7-17: Air Outlet, Drain Tee, and Plug ...................................................................................................... 113

Figure 7-18: Separator Location ........................................................................................................................ 114

Figure 7-19: Separator Fitting Orientation ........................................................................................................ 116

Figure 8-1: VST GREEN MACHINE Control Panel Main Screen ............................................................................ 118

Figure 8-2: VST GREEN MACHINE Control Panel Main Screen with an Alarm Active .......................................... 119

Figure 8-3: VST Control Panel Alarms and Faults Screen Example ..................................................................... 120

Figure 8-4: Power to the North America VST Control Panel or Controller is OFF ............................................... 121

Figure 8-5: Electrical Field Wiring Diagram ........................................................................................................ 128

Figure 8-6: Incoming Power Connections .......................................................................................................... 129

Figure 8-7: VST Control Panel Powered from ESO Relay .................................................................................... 130

Figure 8-8: Electrical Overview Installation Drawing ......................................................................................... 131

Figure 8-9: VST Control Panel Components – Front Cover ................................................................................. 132

Figure 8-10: VST Control Panel 115 VAC Power Circuit Diagram ........................................................................ 133

Figure 8-11: Pressure Sensor Alarm Troubleshooting Procedure ....................................................................... 134

Figure 8-12: Pressure Sensor Wiring Diagram (24VDC Power and 4-20 mA Signal) ............................................ 136

Figure 8-13: Vacuum Pump Troubleshooting Procedures ................................................................................... 137

Figure 8-14: Vacuum Pump Power and Control Circuit ...................................................................................... 143

Figure 8-15: VST Control Panel Electrical Components ...................................................................................... 144

Figure 8-16: GREEN MACHINE isometric with Control Valves Identification Labels ........................................... 145

Figure 8-17: GREEN MACHINE Controller Alarm Screen .................................................................................... 147

Figure 8-18: Fuel Level Tank Alarms .................................................................................................................. 149

Figure 9-1: North America GREEN MACHINE Replacement Parts....................................................................... 151

Figure 9-2: VST Control Panel, Front Cover Replacement Parts ......................................................................... 153

Figure 9-3: VST Control Panel, Inside the Front Cover Replacement Parts ......................................................... 153

Figure 9-4: VST Control Panel, Inside Panel Replacement Parts ........................................................................ 154

Figure 9-5: Removing the PLC Connectors ......................................................................................................... 156

Figure 9-6: The PLC with Connectors Removed ................................................................................................. 157

Figure 9-7: Removing the PLC Hold Down Clips ................................................................................................. 157

Figure 9-8: Vacuum Pump BRK2 ........................................................................................................................ 158

Figure 9-9: Vacuum Pump Solid State Relay ...................................................................................................... 160

Figure 9-10: Pressure Sensor Replacement ....................................................................................................... 163

Figure 9-11: Wiring the Pressure Sensor Inside the Internal Junction Box ......................................................... 164

Figure 9-12: Vac Pump Rubber Flange Sleeve Replacement .............................................................................. 165

Figure 9-13: Replacing the Rubber Flange Sleeve .............................................................................................. 166

Figure 9-14: Vacuum Pump Components .......................................................................................................... 167

Figure 9-15: Junction Box Motor Wiring Diagram .............................................................................................. 169

Figure 9-16: GREEN MACHINE Control Valves Identification Tags ..................................................................... 170

Figure 9-17: Valve Solenoid Assembly ............................................................................................................... 171

Figure 9-18: Valve Assembly ............................................................................................................................. 172

Figure 9-19: Vacuum Pump Components .......................................................................................................... 173

Figure 9-20: Items Associated with Cleaning the GREEN MACHINE Tubing and Manifold.................................. 174

Figure 9-21: Tubes 1-6 removed ........................................................................................................................ 174

Figure 9-22: Vacuum Pump Assembly and Components.................................................................................... 175

Figure 9-23: Manifold Valves............................................................................................................................. 177

Figure 9-24: GM Control Valve Assembly and Components............................................................................... 178

Figure 9-25: How to remove the Red Cap from the Solenoid Base ..................................................................... 178

Figure 9-26: Manifold with the Solenoids Removed, showing the Solenoid Bases ............................................. 178

Figure 9-27: Solenoid with Solenoid Base and Red Cap ...................................................................................... 179

Figure 9-28: Solenoid with Solenoid Base and Red Cap installed........................................................................ 179

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 11

Figure 9-29: Solenoids (with the Solenoid Bases Installed) Arranged Out of the Way ........................................ 179

Figure 9-30: Manifold Ready for Cleaning .......................................................................................................... 180

Figure 9-31: Vacuum Pump with the Blowout Tube Installed ............................................................................. 180

Figure 9-32: Maintenance Screen ....................................................................................................................... 181

Figure 9-33: Removing/Installing the Canister Housing ..................................................................................... 184

Figure 9-34: Separator Location ........................................................................................................................ 185

Figure 9-35: Separator Fitting Orientation ........................................................................................................ 186

Figure 9-36: Vapor Piping Overview .................................................................................................................. 188

Figure 9-37: Maintenance Screen ...................................................................................................................... 189

Figure 9-38: Leak Test Screen ............................................................................................................................ 189

Figure 9-39: GREEN MACHINE Vapor Inlet, Return, and Air Outlet Connections ................................................ 191

Figure 9-40: Leak Check Fixture ......................................................................................................................... 192

Figure 9-41: GREEN MACHINE with Vapor Inlet, Vapor Return, and Air Outlet.................................................. 192

Figure 10-1: Main Screen .................................................................................................................................. 195

Figure 10-2: Maintenance Screen ...................................................................................................................... 195

Figure 10-3: Faults & Alarm Screen ................................................................................................................... 196

Figure 10-4: Password Screen ........................................................................................................................... 196

Figure 10-5: Inserting and Removing the SD Card from the PLC ........................................................................ 197

Figure 11-1: GREEN MACHINE Gasoline Station Overview ................................................................................ 200

Figure 11-2: VST Control Panel .......................................................................................................................... 201

Figure 11-3: Main Screen .................................................................................................................................. 202

Figure 11-4: Maintenance Screen ...................................................................................................................... 203

Figure 11-5: Overfill Alarm shown on the Faults & Alarms Screen..................................................................... 205

Figure 11-6: Inserting and Removing the SD Card from the PLC ........................................................................ 208

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 12

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 13

About VST

Vapor Systems Technologies, Inc. began in 1990 with the vision of One Company – One Integrated Solution.

Today, that philosophy is still in place and getting stronger. Recognizing that a healthier environment is a need and not an option, VST has dedicated its

undivided attention to the ever-changing, stringent regulations that govern fugitive vapors at gasoline dispensing facilities (GDF). To this challenge, VST is committed to a continual R&D campaign of developing the most current, technologically advanced solutions to service not only the United States, but also the world.

VST specializes in the development, engineering, and manufacturing of products that are sold into the GDF segment of the petroleum industry. The VST focus provides our customers and users with exceptional products, services, and innovative solutions for improving the fueling-station experience as

well as the world’s air quality.

VST’s product offering includes curb pump and vapor recovery hoses, safety breakaways, nozzles, and

emission-control system - GREEN MACHINE. The ENVIRO-LOC™ vapor-recovery product offering represents the most innovative concept in the industry for trapping fugitive vapors from the front end (vehicle refueling) to the back end (vent risers) of the GDF site.

Notice

Vapor Systems Technologies, Inc. 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.

No part of this publication may be translated to another language without the prior written consent of Vapor Systems Technologies, Inc.

Warranty

See the VST website for full warranty statement: http://www.vsthose.com/warrantyreg.aspx

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 14

Safety

ELECTRICITY

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

TURN POWER OFF

Turn power OFF to the device and its accessories when installing and servicing the unit. Live power creates a potential spark hazard.

EXPLOSIVE

Gasoline and its vapors are extremely explosive if ignited.

NO POWER TOOLS

Sparks from electric power tools can ignite gasoline and its vapors.

FLAMMABLE

Gasoline and its vapors are extremely flammable.

NO PEOPLE IN THE AREA

Unauthorized people in the work area during installation and service of the device create a potential for personal injury.

NO SMOKING

Gasoline and its vapors can be ignited by sparks and embers of burning cigarettes.

READ ALL RELATED MATERIALS

Read, understand, and follow all instructions, warnings, and requirements before you begin work.

NO OPEN FLAMES Open flames from sources like lighters and matches can ignite gasoline and its vapors.

USE SAFETY BARRICADES

Unauthorized people in the work area during installation and service of the device create a potential for personal injury. Therefore, always isolate your work area by using safety cones, barricades, etc.

PINCH RISK

Stay clear. Keeps hands and tools away from rotating machinery and moving parts.

ROTATING MACHINERY

Stay clear. Keep hands and tools away from rotating machinery.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 15

Safety, continued…

• The GREEN MACHINE will be installed near locations where highly flammable

and explosive gasoline vapors may be present.

• Installation of the GREEN MACHINE must comply with the National Electric Code,

federal, state, and local codes, as well as other applicable safety codes.

• Use extreme caution due to the risk of fire or explosion, which could result in

serious injury or even death.

• If you are working in an area where vehicle traffic may occur, always block off

the work area during installation, testing, and service to protect yourself and others.

• Do not use power tools that can generate sparks if there is a risk of flammable or

explosive vapors being present.

• Read and understand all materials related to installing, testing, and operating

the GREEN MACHINE prior to installation.

CAUTION: ALL SERVICEABLE / REPLACEMENT PARTS MUST BE OBTAINED FROM VST TO MAINTAIN SUITABILITY FOR A DIVISION 2 LOCATION.

Table of Terms & Abbreviations

ASC:

Authorized Service Contractor

Permeate:

Air return to atmosphere

ATG:

Automatic Tank Gauge

PMC:

Pressure Management Control

CVLD:

Continuous Vapor Leakage Detection, another name for Vapor Leak Detection

PTO:

Permit to Operate

EVR:

Enhanced Vapor Recovery

P/V Valve:

Pressure Vacuum Valve

GDF:

Gasoline Dispensing Facility

RVP:

Reid Vapor Pressure

GM:

GREEN MACHINE

TLS:

Tank Level System

ISD:

In-Station Diagnostics

TS:

Troubleshooting

MAG

Probe:

A type (brand) of Tank Inventory Probe

Ullage:

Vapor space above liquid in a UST

NEC:

National Electric Code

UST:

Underground Storage Tank

NFPA:

National Fire Protection Association

VCK:

Vapor Collection Kit

ORVR:

On-Board Refueling Vapor Recovery

VOC:

Volatile Organic Compounds

OSHA:

Occupational Safety Health Administration

VST:

Vapor Systems Technologies, Inc.

PLC:

Programmable Logic Controller

IWC:

Inches Water Column

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 16

Regulations & Jurisdiction

•

Under vapor recovery regulations, local and national authorities have primary authority for regulating gasoline stations.

•

Before modifying the facility, gasoline station operators should contact the national and local authorities for specific information and requirements on local vapor-recovery requirements.

•

Be sure to read and understand all site requirements before beginning an installation.

•

“The area inside the GREEN MACHINE cover has been evaluated as a Class I, Division 2 hazardous area as defined by the National Electric Code /NFPA 70 Article 514 table

514.3(B)(1) and verified by Intertek”

•

Always obtain approval from the local authority having jurisdiction.

•

Installation of the GREEN MACHINE must comply with (if applicable):

•

Fire Marshal

•

NEC

•

Water Board

•

NFPA 30 and 30A

•

Local Air Pollution Dist.

•

UL/ETL

•

ICC

•

Any other applicable federal, state, and local codes

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 17

GREEN MACHINE Overview

Ref#

Part Name

Part Description

Vapor Filtration Cartridge

Captures and cleans VOC’s from the vapor emissions

Vapor Piping

Piping for the transfer of vapor

Liquidtite Flexible Conduit

Used for installing wires to the junction box

1” NPT Vapor Inlet Connection

Port for pulling vapors from the UST

¾” Electrical Connection

Conduit connection for wirings from the Control Panel to the GREEN MACHINE

1” NPT Vapor Return Connection

Port for returning vapors to the UST

1” NPT Air Outlet Connection

Port for venting air to atmosphere

Control Valves (5 ea.)

Control the flow of vapor to and from the UST

Vac Pump Motor Only

Drives the Vacuum Pump

10.

Vac Pump Only

For transporting vapors to and from the UST

11.

Internal Junction Box

Houses all wiring connections for the Control Panel to the GREEN MACHINE

12.

Pressure Sensor

Used to monitor the UST vapor pressure

13.

Pressure Sensor Isolation Valve

Open: During normal operation for line pressure Close: To prevent the Pressure Sensor from damage during testing

14.

Separator

Protects Vacuum Pump from debris

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 18

GREEN MACHINE Theory of Operation

•

The VST GREEN MACHINE operates based on monitoring the Underground Storage Tank (UST) system pressure.

•

The GREEN MACHINE controller provides UST pressure data via a pressure transducer, located in the GREEN MACHINE, and manages the GREEN MACHINE operation.

•

The pressure data is provided to the VST Control Panel for system monitoring functions.

•

The closed loop vapor piping solution continuously operates the system to control UST pressure below 0.2 IWC.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 19

GREEN MACHINE Dimensions & Weight

Unit

Dimensions

Weight

GREEN MACHINE

L-39” x W-27” x H-49.89”

Height includes 24” legs

227 lbs.

w/out Cover

w/out Control Panel

Aluminum Cover

L-39” x W-27” x H-25”

(one-piece unit)

24 lbs.

VST Control Panel

L-14” x W-12” x H-8”

22 lbs.

How the GREEN MACHINE is Shipped

•

Verify that all the items are in the shipping crate:

•

GREEN MACHINE - VST-GM-CS2-101.

•

Aluminum Cover

•

VST Control Panel

•

(4) 24” Steel Legs

•

(16) 3/8” bolts / washers / nuts to attach the legs to the GREEN MACHINE base

•

(1) 0.063” dia. Orifice

•

(6) Locks with keys (same)

•

(3) 1” Brass Full Port Ball Valves, Locking

•

Packet #1: Station Owner/Operator Paperwork

•

Packet #2: General Contractor Paperwork

•

Packet #3: Vapor Piping Installation

•

Packet #4: Electrical Installation

•

Packet #5: Start-Up and Testing Contractor Paperwork

•

Shipping Check

•

When you open the container:

•

Verify that all the items are in the shipping container.

•

Visually inspect all the items for any obvious damage.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Page 20

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Page 21

Chapter 1: General Contractor Installation

1 Installation Instructions

1.1 Installation Safety for all Contractors

• The GREEN MACHINE will be installed near locations where highly flammable and explosive

gasoline vapors may be present.

• Installation of the GREEN MACHINE must comply with the National Electric Code, federal,

state and local codes, as well as other applicable safety codes.

• Use extreme caution due to the risk of fire or explosion, which could result in serious injury

or even death.

• If you are working in an area where vehicle traffic may occur, always block off the work area

during installation, testing, and service to protect yourself and others.

• Do not use power tools that can generate sparks if there is a risk of flammable or explosive

vapors being present.

• Read and understand all materials related to installing, testing, and operating the GREEN

MACHINE prior to installation.

1.2 Preparing the GREEN MACHINE for Installation

Follow these steps to prepare the GREEN MACHINE for installation:

Verify that all the items are in the shipping crate:

•

GREEN MACHINE - VST-GM-CS2-101.

•

Aluminum Cover

•

VST Control Panel

•

(4) 24” Steel Legs

•

(16) 3/8” bolts / washers / nuts to attach the legs to the GREEN MACHINE base

•

(1) 0.063” dia. Orifice

•

(6) Locks with keys (same)

•

(3) 1” Brass Full Port Ball Valves, Locking

•

Packet #1: The Installation, Operations, Maintenance, and Troubleshooting (IOMT) 3-Ring Binder with SD Cards and Operator Instructions

•

Packet #2: General Contractor Paperwork

•

Packet #3: Vapor Piping Installation

•

Packet #4: Electrical Installation

•

Packet #5: Start-Up and Testing Contractor Paperwork

Visually inspect all the items for any obvious damage.

CAUTION: Uncrate and install the four legs on the GREEN MACHINE prior to transporting to the installation site. Installing the legs on site without proper support may cause damage to the unit.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Page 22

1.3 Installing the Legs on the GREEN MACHINE

Support the GREEN MACHINE with a forklift or a set of saw horses so the legs can be installed.

Install the 4 legs on the GREEN MACHINE. The four 3/8” carriage bolts for each leg MUST BE INSTALLED AND TIGHTENED IN THE SEQUENCE INDICATED ON Figure 1-1.

All the carriage bolts must be installed so the head of the bolt is flush with the base as shown.

Figure 1-1: Bolting sequence to attach legs to the GREEN MACHINE base

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Page 23

1.4 GREEN MACHINE Dimensions & Weight

Unit

Dimensions

Weight

GREEN MACHINE

L-39” x W-27” x H-49.89”

Height includes 24” legs

227 lbs.

w/out Cover

w/out Control Panel

Aluminum Cover

L-39” x W-27” x H-25”

(one-piece unit)

24 lbs.

VST Control Panel

L-14” x W-12” x H-8”

22 lbs.

1.5 Ground Mount Locations

•

NOTE: Minimum vapor-piping slope must always be maintained for all GREEN MACHINE mounting options.

•

VST requires a minimum slope of ¼” per foot on all vapor piping away from the

GREEN MACHINE to the vent risers.

•

Select a location for the concrete pad as close as possible to the vent risers to minimize piping and pressure drop.

•

The GREEN MACHINE must be protected from damage:

•

Install bollards or another suitable method to protect the GREEN MACHINE.

•

VST recommends a clear 18” perimeter around the GREEN MACHINE for maintenance and testing.

•

The GREEN MACHINE must be located within 100 feet of the vent risers.

•

To minimize the installation cost and to maximize operating efficiency, locate the GREEN MACHINE adjacent to the existing vent risers.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

VST recommends setting the GREEN MACHINE on a concrete pad with the following minimum dimensions: 42” long x 30” wide, 6” thick.

•

Install the concrete pad as outlined in this manual.

•

Follow the local jurisdiction’s building codes.

•

VST does not provide any hardware to install the GREEN MACHINE on the pad.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Page 24

1.6 Setting the Concrete Pad

•

The soil must have the following capabilities:

•

Allowable bearing pressure: 1000 psf

•

Lateral bearing: 150 psf

•

Coefficient of sliding: 0.25

•

The GREEN MACHINE must be installed on a concrete pad, on grade, and permanently anchored to the concrete pad.

•

Install the concrete pad level.

•

Use steel re-enforced rebar in the pad for additional strength.

•

The GREEN MACHINE CANNOT be installed directly on or anchored directly to asphalt. It must be installed and anchored directly to a concrete pad.

•

The GREEN MACHINE can be installed on an existing concrete pad, provided:

•

The existing concrete is of sufficient strength and thickness to support the GREEN MACHINE.

•

VST recommends a minimum of 6” thick concrete to accommodate 3-1/2” – 4” expansion-type anchor bolts.

•

Cracked concrete without re-bar may NOT be of sufficient strength to properly support the GREEN MACHINE.

•

The GREEN MACHINE is installed level.

•

NOTE: VST CANNOT BE HELD RESPONSIBLE FOR DAMAGE CAUSED BY IMPROPER GREEN MACHINE FOUNDATION SUPPORT.

•

VST does not provide any hardware to install the GREEN MACHINE on the pad.

•

VST recommends using an 18” minimum clearances around the perimeter of the GREEN MACHINE for maintenance and service.

•

Concrete pad minimum dimensions:

•

42” long x 30” wide

•

6” thick (minimum)

•

See Figures 1-2 and 1-3

•

Install expansion-type bolts after completing the concrete pad. The bolts must be:

•

3/8” diameter

•

Embedded 3-1/2” to 4” into the slab

•

Extend approx. 1-1/2” above the top of the slab

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Page 25

1.7 Installing the GREEN MACHINE on the Concrete Pad

•

After the concrete has properly cured, install the expansion anchor bolts according to the manufacturer’s recommendations. See Figures 1-2 and 1-3.

•

For applications that require expansion anchors that are especially suited to seismic and cracked concrete, VST recommends using the HILTI KWIK TZ (KB-TZ) BOLT, KB-TZ 3/8” X 5”, (item number 00304583) or approved equal.

•

The contractor or design engineer is responsible for sizing the expansion anchors and the concrete pad to meet seismic and cracked concrete specifications required by local, state, and federal jurisdictions.

•

Since seismic regulations may be different by location, VST has not included a specific drawing for this application.

•

For seismic design reference, www.us.hilti.com.

•

After the appropriate anchor bolts have been installed, position the GREEN MACHINE onto the anchor bolts in the cement slab.

•

Bolt the GREEN MACHINE into place (according to the manufacturer recommended installation guidelines) with 3/8” galvanized lock washers and bolts that are included with the expansion bolt.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 26

Figure 1-2: Concrete mounting pad dimensions

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 27

Figure 1-3: GREEN MACHINE Ground Mounting Pad

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 28

1.8 Roof-Top Installation

•

NOTE: Minimum vapor-piping slope must always be maintained for all GREEN MACHINE mounting options.

•

VST requires a minimum slope of ¼” per foot on all vapor piping away from the

GREEN MACHINE to the vent risers.

•

The GREEN MACHINE may be installed on a station’s roof provided the structure can support the weight of the GREEN MACHINE.

•

All safety and code concerns must be taken into consideration prior to a roof-top installation.

•

Due to a variety of roof construction designs, VST cannot recommend how the GREEN MACHINE should be mounted on the roof; however, the GREEN MACHINE must be installed at a height allowing the piping inlet and outlets to be above or through the building parapet.

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed and the GREEN MACHINE secured to a steel structure attached to the roof.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

A Design Engineer is responsible for designing the support structure, support base, all required hardware and bolting connections, and the support structure foundation to meet all regulatory specifications that may be required by local jurisdictions.

1.9 Canopy-Top Installation

•

NOTE: Minimum vapor-piping slope must always be maintained for all GREEN MACHINE mounting options.

•

VST requires a minimum slope of ¼” per foot on all vapor piping away from the

GREEN MACHINE to the vent risers.

•

The GREEN MACHINE may be installed on a station’s canopy provided the structure can support the weight of the GREEN MACHINE.

•

Due to a variety of canopy construction designs, VST cannot recommend how the GREEN MACHINE should be mounted on the canopy.

•

All safety and code concerns should be taken into consideration prior to a canopy-top installation.

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed and the GREEN MACHINE secured to a steel structure attached to the canopy support structure.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 29

Canopy-Top Installation, continued…

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

1.10 Vent-Stack Mount Installation

•

NOTE: Minimum vapor-piping slope must always be maintained for all GREEN MACHINE mounting options.

•

VST requires a minimum slope of ¼” per foot on all vapor piping away from the

GREEN MACHINE to the vent risers.

•

The GREEN MACHINE may be installed elevated on the existing vent risers provided there is an existing structure that can support the weight of the GREEN MACHINE, or a structure can be installed to support the weight of the GREEN MACHINE.

•

Due to a variety of construction designs, VST cannot recommend how the GREEN MACHINE should be installed or mounted on a vent riser support structure; however, the structure that supports the GREEN MACHINE must be designed and installed at a height allowing the piping inlet and outlets to connect to the existing vent risers.

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed for the GREEN MACHINE to be secured to a steel support structure.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

All safety and code concerns must be taken into consideration prior to vent stack mount installation.

•

See Figure 1-4 for illustration.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 30

Figure 1-4: Vent Stack Installation

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 31

1.11 Pre-Installation Site Survey

•

Vapor Systems Technologies, Inc. created a “Pre-Installation Site Survey” as a guide to help installers and troubleshooters in the planning of a GREEN MACHINE installation.

•

The “Pre-Installation Site Survey” is to be completely filled out in advance of an installation so that installation problems and delays are reduced or avoided.

1.12 Pre-Installation Site Survey

Your Name:

Company Name:

Company Address:

City, State, Zip

Country

Phone:

E-Mail:

Projected Processor Installation Date:

1.13 GDF Contact Information

GDF Name:

GDF Address:

GDF City, State, Zip:

GDF Country:

GDF Phone:

GDF Fax:

GDF #:

GDF Contact Person:

GDF Contact Person E-mail:

NOTES:

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 32

1.14 Snapshot of Site Requirements

Local Air Pollution Control Districts

•

Gasoline stations must contact the local/national authorities for specific requirements.

•

Permits may be required to modify a gasoline station.

Installation Requirements

•

The GREEN MACHINE must be within 100 feet of the Vent Risers regardless of the installation location.

•

VST requires a minimum slope of ¼” per foot on all vapor-piping away from the GREEN MACHINE to the Vent Risers or to any other UST connection.

•

A minimum clearance of 18” around the GREEN MACHINE for maintenance and testing is required.

•

The GREEN MACHINE must be protected from damage: Install bollards or other suitable method to protect the GREEN MACHINE.

Automatic Tank Gauge, Fuel Management Controls

•

Must have an appropriate automatic tank gauge fuel measurement control with an overfill alarm contact installed.

•

The GREEN MACHINE Controller will use the overfill alarm contacts to shut OFF the GREEN MACHINE so gasoline cannot enter the GREEN MACHINE in case of an overfill. If gasoline enters the GREEN MACHINE because of an overfill, the warranty will be voided.

VST Control Panel

•

VST Control Panel completely powers the GREEN MACHINE via one 115 VAC, single-phase, 20-amp breaker.

•

The VST Control Panel arrives from the factory internally pre-wired and pre-tested.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 33

Snapshot of Site Requirements, continued…

Vent Risers

•

UST’s must be manifolded either above ground if there are multiple vent risers or at the

vapor piping below ground.

•

Only one existing vent riser connected to the USTs is required for the installation of the GREEN MACHINE.

•

A new vent riser is required, and is connected to the Air Outlet on the GREEN MACHINE.

•

VST requires all vapor-piping connecting to the GREEN MACHINE must be sloped away from the GREEN MACHINE a minimum of ¼” per foot slope.

•

Any type of trap, regardless of the GREEN MACHINE location, is not permitted in any vapor lines connected to the GREEN MACHINE.

UST Manifolding

•

All gasoline UST’s MUST be manifolded either above or below ground.

Ground Installation Requirements

•

The GREEN MACHINE must be protected from damage.

•

VST recommends a clear 18” perimeter around the GREEN MACHINE for maintenance and testing.

•

The GREEN MACHINE must be located within 100 feet of the vent risers.

•

To minimize the installation cost and to maximize operating efficiency, locate the GREEN MACHINE adjacent to the existing vent risers.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

VST recommends setting the GREEN MACHINE on a concrete pad with the following minimum dimensions: 42” long x 30” wide, 6” thick.

•

Follow the local jurisdiction’s building codes.

•

VST does not provide any hardware to install the GREEN MACHINE on the pad.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 34

Snapshot of Site Requirements, continued…

Roof Top Installation Requirements

•

The GREEN MACHINE may be installed on a station’s roof provided the structure can support the weight of the GREEN MACHINE.

•

All safety and code concerns must be taken into consideration prior to a roof-top installation.

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed and the GREEN MACHINE secured to a steel structure attached to the roof.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

Canopy Top Installation Requirements

•

The GREEN MACHINE may be installed on a station’s canopy provided the structure can support the weight of the GREEN MACHINE.

•

Due to a variety of canopy construction designs, VST cannot recommend how the GREEN MACHINE should be mounted on the canopy.

•

All safety and code concerns must be taken into consideration prior to a canopy top installation.

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed and the GREEN MACHINE secured to a steel structure attached to the canopy support structure.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 35

Snapshot of Site Requirements, continued…

Vent Stack Installation Requirements

•

The GREEN MACHINE has 24” legs that can be bolted on the base, but the legs may be removed for the GREEN MACHINE to be secured to a steel support structure.

•

A new air outlet vent riser connected to the GREEN MACHINE must be installed to release air to the atmosphere.

•

All safety and code concerns must be taken into consideration prior to vent stack mount installation.

•

1.15 Other Information to Document

1.15.1 Gasoline Stations

Monthly throughput (gallons)

Hours open (example: 9am-11pm or 24 hrs.)

Number of Underground Storage Tanks

Size of Underground Storage Tanks (gallons)

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 36

1.15.2 Dispensers

Make & Model

Conventional, Assist, or Balance (OD of Vapor Pipe)

MPD or Unihose

Number of dispensers

Is the current hose a VST hose

 Yes  No

Do the current hoses have a retractor

 Yes  No

Curb hose length

Whip hose length

Hose configuration

 Standard  Lazy J  Curly Q

1.15.3 Vent Risers

Number of vent risers

Location & size of vent risers (show on sketch)

Where are the USTs manifolded

 Above Ground  Below Ground

1.15.4 VST GREEN MACHINE

What are the possible locations that can be used for the VST GREEN MACHINE

 Ground  Roof  Canopy  Vent Riser

Will a waiver or variance be needed for a ground-mount location

 Yes  No

Does the site have overfill protection?

Can we connect to the fuel management system signal for the VST GREEN MACHINE

 Yes  No

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 37

1.15.5 Electrical

Does the GDF have 1-Phase 115V available?

 Yes  No

Are there any existing conduits at or near the proposed VST GREEN MACHINE location (for example: lights, signs, vacuum)?

 Yes  No

Available breaker space for a 115V 1-phase circuit?

 Yes  No

Will a sub-panel need to be installed?

 Yes  No

1.15.6 Additional Documentation

•

Include photos of each of the above items as needed.

•

Draw a sketch of the GDF layout. Include:

The location of the vent risers

Tank pad

Dispensers

Building with the electrical panel location

Property lines

Any existing conduits near the proposed GREEN MACHINE location.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 38

Figure 1-5: Example of a GDF Layout

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 39

Figure 1-6: Example of a GREEN MACHINE with Vapor Piping Layout

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 40

1.16 Sample Sketch

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 41

1.16.1 Your Sketch

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 1: GREEN MACHINE™ Installation Instructions Page 42

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 43

Chapter 2: Vapor Piping Installation

2 Vapor Piping Installation Overview

•

There are 3 piping connections to be made to the GREEN MACHINE. See Figures 2-1 & 2-2:

•

Vapor Inlet (supply) from the UST’s

•

Vapor (concentrate) Return to the UST’s

•

Air Outlet to atmosphere

•

All the GREEN MACHINE piping connections are 1” diameter National Pipe Thread (NPT).

2.1 General Notes

•

The piping contractor is responsible for providing all necessary piping, non-hardening pipejoint compound, and pipe fittings.

•

Make sure the gasoline UST tanks vapor piping is manifolded either above ground or below ground.

•

Locks must be installed on the valves to prevent unauthorized tampering of the equipment.

•

Under normal operation, the valves must be locked in the OPEN position.

•

VST requires a minimum slope of 1/4” per foot on all vapor-piping away from the GREEN MACHINE to the vent risers or to any other UST piping connection.

•

The ¼” diameter drain line with the supplied adapter must be installed per Figure 2-1.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 44

Figure 2-1: Vapor Piping Overview

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 45

2.2 Flexible Piping

•

If flexible piping is required by the local authority to meet seismic requirements, install the flexible piping between the GREEN MACHINE locking ball valve and the vent riser(s).

•

The flexible connector must be approved for a service station above-ground application.

•

Support the flexible piping per manufacturer’s recommendation.

•

The slope of the flex connection from the GREEN MACHINE back to the vent riser must be a minimum of 1/4” per foot slope.

•

Liquid traps are not allowed.

Figure 2-2: GREEN MACHINE Connections

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 46

2.3 Vapor Inlet and Vapor Return Piping Installation

•

Install a 1” vapor inlet pipe and a 1” vapor return pipe as shown in Figure 2-1 from the vapor inlet and vapor return connections on the GREEN MACHINE to an existing vent riser.

•

An existing vent riser that connects to the GREEN MACHINE must be modified by:

•

Adding the first tee (near the bottom of the vent riser) for connecting the 1” vapor

return pipe. The first tee must be installed to allow the vapor return to slope away from the GREEN MACHINE.

•

Adding a second tee/cross (just below the P/V valve) for connecting the 1” vapor inlet

pipe. The second tee/cross must be installed at the top of the vent riser, but below the P/V valve.

•

Both the vapor inlet and the vapor return lines have: a 1” union, a 1” locking ball valve, and a 1” tees/caps, and any other piping fittings to complete the installation.

•

The 1” vapor return pipe connecting to the bottom of the vent riser MUST BE INSTALLED below the 1” vapor inlet pipe that connects to the top of the vent riser.

•

A ¼” drain line MUST BE INSTALLED between the vapor inlet and the vapor return so any condensate from the vapor inlet line can drain into the vapor return line. VST is supplying a ¼” NPT x ¼” NPT adapter with a 0.063 orifice. The orifice will eliminate any vapor flow between

the vapor inlet line and the vapor return line.

•

Install a tee into the vent riser that will connect to the GREEN MACHINE Vapor Inlet using 1” NPT pipe.

•

The new tee must be installed to allow for slope away from the GREEN MACHINE to the vent riser.

•

If there are multiple-grade UST’s and multiple vent risers, VST recommends connecting the GREEN MACHINE to the lowest octane vent riser.

•

From the vent riser, install the 1” locking ball valve, then the 1” union, then the 1” tee. See Figure 2-1.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 47

2.4 Air Outlet Piping Installation

•

Install a new vent riser next to an existing vent riser (if possible).

•

The 1” piping must slope away from the GREEN MACHINE a minimum of ¼” per foot. See Figure 2-1.

•

Install the new dedicated vent riser so that the discharge opening is at least as high as the existing riser and a minimum of 1” diameter.

•

Install a tee with a cap at the bottom of the new air outlet vent riser to provide for manual drainage, if required.

•

Make sure the ¼” drain line is installed between the vapor inlet and the vapor return lines.

•

Install piping from the 1” NPT Air Outlet fitting on the GREEN MACHINE to the new vent riser.

•

From the vent riser, install the 1” locking ball valve, then the 1” union, then the 1” tee as

shown in Figure 2-1.

•

A rain cap or equivalent must be installed on the new air outlet vent riser.

•

If a PV vent valve is used, the internal components must be removed to allow open venting to the atmosphere.

2.5 Vapor Piping Post-Installation

•

After all the piping has been installed, make sure the 3 lockable ball valves are locked and in the OPEN position.

•

Make sure all the pipe connections are tight.

•

Make sure the slope is a minimum 1/4” per foot away from the GREEN MACHINE to the vent risers.

•

Make sure there are no traps between the GREEN MACHINE and the vent risers.

•

If flex piping is used, make sure the flexible piping is adequately supported.

•

Make sure the ball valve below the Pressure Sensor is OPEN, or the handle is vertical. See Figure 2-3.

•

The ¼” diameter drain line with the supplied adapter must be installed per Figure 2-1.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 48

Figure 2-3: Pressure Sensor w/ 3-Way Isolation Valve Open

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 49

2.6 Vapor Piping Bill of Material

Contractor Supplied

1” diameter straight tees with caps

1” diameter unions

Straight tee (sized to match existing vent riser)

Straight tee with cap (sized to match new vent riser)

Rain cap (on the new air outlet vent riser)

1” diameter pipe, elbows, and misc. pipe fittings

Vent Stack pipe supports and hardware (as required)

¼” NPT Compression Fittings (2 each)

1” x ¼” NPT Reducer Bushing

¼” Diameter Copper Tubing

Vapor Systems Technologies Supplied

¼” x ¼” NPT Brass Adapter, with a 0.063” diameter orifice

(6) Locks (3-Ball Valves, 2-Cover, and 1-ON/OFF Safety Switch)

(3) 1” Brass Full Port Ball Valves, Locking

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 2: Vapor Piping Installation Page 50

This page left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 51

Chapter 3: Electrical Installation

3 Electrical Safety

• The GREEN MACHINE uses lethal voltages and operates in areas where

gasoline vapor may be present.

• Serious injury or death from electrical shock, fire, or explosion may result

if the power is ON during installation, testing, or maintenance.

• Be sure to use Lock-Out/Tag-Out procedures when working on or

installing the GREEN MACHINE or while working on electrical components.

• When performing maintenance, always power OFF electrical components

connected to the GREEN MACHINE. The GREEN MACHINE can start automatically.

• Do not use tools that can generate sparks if there is risk of flammable or

explosive vapors being present.

• Read and understand all materials related to installing, testing, and

operating the GREEN MACHINE prior to installation.

3.1 Electrical Requirements

*Note 1: The 8.8 amp listed is only for the ½ HP, 115 VAC, 1-Phase, 60-Hz Leeson Motor.

Table 1: VST Control Panel Power Requirements

VST Control Panel Power Requirements

VST CONTROL PANEL – POWER SOURCES

Option 1: Main power

1-Phase

115VAC

60-Hz

20-amp breaker

Electrical

Panel

Option 2: ESO Relay

power

1-Phase

115VAC

60-Hz

20-amp relay

Emergency

Shut-Off

Equipment

Phase

Voltage

Amperage

Frequency

Fuse/Breaker

Size

Location

Vacuum Pump Motor

1-Phase

115VAC

8.8

*(See note 1)

60-Hz

15-amp breaker

VST

Control

Panel

Control Valves

1-Phase

115VAC

1.0

60-Hz

5-amp fuse

(3 each)

24VDC Power supply

1-Phase

115VAC

4.0

60-Hz

4-amp fuse

Pressure Sensor

24VDC

Protected by

24VDC power

supply

GREEN MACHINE

Controller

24VDC

Protected by

24VDC power

supply

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 52

3.2 Electrical Installation

•

The VST Control Panel and the GREEN MACHINE Internal Junction Box arrive from the factory pre-wired and completely tested.

•

The Electrical Contractor is responsible for supplying all additional wires, conduits, fittings, seal-offs, outlets, and the Safety Disconnect Switch required to install the GREEN MACHINE and meet regulation requirements and standards.

•

All wiring must be gasoline and oil resistant.

•

A LOCKABLE SAFETY DISCONNECT-SWITCH MUST BE INSTALLED BY THE GREEN MACHINE:

•

Must be wired per included drawings.

•

Should be installed within eye-sight of the GREEN MACHINE for safety reasons.

•

Must not be installed within 3 feet of the GREEN MACHINE.

•

Consult the NEC for restrictions, location, and type of disconnect.

•

The GREEN MACHINE is installed in a Class I, Division 2 hazardous location and therefore requires electrical seal-offs when connecting to ordinary, non-hazardous electrical locations. Consult the NEC and NFPA for installation instructions.

•

All wiring (115 VAC and 24 VDC) to be TFFN or THHN with 600V insulation.

•

The contractor is responsible for sizing the wire, cable, and conduit according to the NEC.

•

All power (115 VAC and 24 VDC), the neutral, and the ground wires connected to the GREEN MACHINE will be disconnected when:

•

The Power Switch on the front of the VST Control Panel is turned OFF.

•

The station Emergency Shut-Off is activated.

•

The Safety Disconnect Switch at the GREEN MACHINE is opened.

•

Power is turned OFF to the VST Control Panel at the electrical distribution panel.

•

CAUTION: SAFETY PRECAUTION

•

BE SURE THE BREAKER INSIDE THE PANEL IS LOCKED OUT/TAGGED OUT PRIOR TO THE INSTALLATION.

3.3 Electrical Installation Code Requirements

•

According to NFPA 30:

•

“Electrical wiring and electrical utilization equipment shall be a type specified by and be installed in accordance with NFPA 70. Electrical wiring and electrical utilization equipment shall be approved for the locations in which they are installed.”

•

All electrical wiring and electrical utilization equipment must be installed to meet federal, state, and local codes.

•

Flexible electrical conduit connections to the GREEN MACHINE may be required by local jurisdictions to meet code requirements.

•

Following such procedures may be required by local, state, and national authorities.

•

You must install the GREEN MACHINE in accordance with the National Electric Code (NEC), NFPA 70, and with the Automotive and Marine Service Station Code (NFPA 30A).

•

According to NFPA 30A: “Electrically energized vapor-recovery equipment shall be directly connected to and controlled by the emergency pump shut off in Section 5202.4.7.”

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 53

3.4 Electrical Components

Table 2: Table of Electrical Components

3.5 Electrical Wiring Installation

SAFETY PRECAUTION: PRIOR TO STARTING ANY ELECTRICAL WORK, BE SURE TO US LOCK OUT / TAG OUT PROCEDURES.

Wires Required to install the GREEN MACHINE: 9-WIRES AND 1-CABLE FROM THE VST CONTROL PANEL TO THE GREEN MACHINE INTERNAL JUNCTION BOX

1-Vacuum Pump 115 VAC Hot

1-Common Neutral

1-Common Ground

1-Control Valve V1 115 VAC Hot

1-Control Valve V2 115 VAC Hot

1-Control Valve V5 115 VAC Hot

1-Safety Switch 115 VAC Hot

1-Safety Switch Neutral

1-Safety Switch Ground

10.

1-Cable, 3 conductors, 18 AWG, twisted pair, shielded ground

IN ADDITION, THERE ARE 3-WIRES FOR THE 115 VAC OUTLET FROM THE ELECTRICAL DISTRIBUTION PANEL

1-Outlet 115 VAC Hot

1-Outlet Neutral

1-Outlet Ground

3.5.1 INSTALLING THE VST CONTROL PANEL:

•

The contractor must drill holes in the VST Control Panel for all wiring connections.

•

Install the VST Control Panel only inside the GDF. The location may vary within the GDF given the allowable space.

• When possible, place the VST Control Panel as close to the Fuel Management System as

possible.

•

After the Control Panel is installed and power applied to the panel, Figure 3-1 shows the Main Screen with the GM DISABLED – ENTER CODE label, which will be discussed later in this Chapter.

Existing Components

VST Supplied Components

Contractor Supplied Components

115V Main Electrical Panel

Fuel Management System (TLS-350/450) or other

Overfill Alarm Output Relay (4-Relay Module)

Emergency Shut-Off (ESO)

Pre-wired VST Control Panel

Pre-wired GREEN MACHINE Internal Junction Box

115V Outlet (For maintenance and testing)

Lockable Safety DisconnectSwitch

All conduit, wire, cable, fittings, and seal-offs, and any other electrical material to complete the electrical installation

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 54

3.5.2 OPTION 1: POWER TO THE VST CONTROL PANEL FROM THE MAIN ELECTRICAL

DISTRIBUTION PANEL.

Figure 3-2: Is an Electrical Overview Drawing for Reference for Option 1.

Figure 3-3: Wiring the Supply Power to the GREEN MACHINE from a Main Electrical Distribution Panel:

1. Make sure the 20-amp breaker used for the GREEN MACHINE inside the distribution panel is

turned OFF and follow Lockout-Tagout safety procedures.

2. Install the 115 VAC power, the neutral, and the ground wires from the main distribution panel to the

VST Control Panel.

3. Wiring:

• L1 115 VAC Hot to Wire Number 02011

• N Neutral to Wire Number 02012

• Ground to Ground

Wiring the VST Control Panel to the ESO Relay:

1. When activated, the ESO will turn OFF and disconnect power, the neutral, and ground from the

GREEN MACHINE.

2. Two wires MUST BE INSTALLED from the VST Control Panel to the ESO relay or control system. The

technician making these connections MUST BE CERTIFIED to work on this system.

3. Reference the ESO terminal block wire numbers.

4. Wiring:

• 115 VAC to Wire Number 02011

• 115 VAC Switch Leg to Wire Number 02032

3.5.3 OPTION 2: POWER THE VST CONTROL PANEL FROM THE STATION EMERGENCY SHUT-

OFF (ESO) RELAY.

Figure 3-4: Is an Electrical Overview Drawing for Reference for Option 2.

Figure 3-5: Supply Power to the GREEN MACHINE from the ESO Relay:

1. Make sure the ESO Relay is 20A or higher.

2. Install the 115VAC power, the neutral, and the ground wires from the ESO Relay to the VST Control

Panel.

• ESO L1 115 VAC Hot to Wire Number 02011

• ESO N Neutral to Wire Number 02012

• ESO Ground to Ground

Wiring the VST Control Panel ESO Relay Jumper:

1. Since the VST Control Panel power is wired to the station ESO Relay, a jumper MUST be

installed inside the panel.

2. Install the jumper wire inside the VST Control Panel.

• Wire Number 02011

• To Wire Number 02032

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 55

3.5.4 Wiring the Electrical Components at the GREEN MACHINE Location.

Figure 3-6: Shows the Field Wiring from the VST Control Panel to the GREEN MACHINE Internal Junction

Box: Vacuum Pump Motor, Pressure Sensor, Safety Power Switch

1. Wiring the Internal Junction Box a. Install 6 wires from the VST Control Panel to the junction box

a. Vacuum Pump 115 VAC to wire number 02052 b. Vacuum Pump Neutral to wire number 02042 c. Control Valve V1 115 VAC to wire number 02062 d. Control Valve V2 115 VAC to wire number 02072 e. Control Valve V5 115 VAC to wire number 02074 f. Ground to Ground

2. Pressure Sensor Cable a. Install 1-Pressure Sensor Cable from the VST Control Panel to the Internal Junction Box b. The cable is supplied by the contractor c. The cable must be 3-conductor, 18 AWG, twisted and shielded

• 24 VDC (+) to wire number 02092

• 4-20 mA SIGNAL to wire number 04052

• Shielded ground (Lead wire is a bare ground)

3. Safety Disconnect Switch

a. Install 2 wires from the VST Control Panel to the Safety Disconnect Switch

• 115 VAC to wire number 02032

• 115 VAC switch leg to wire number 02023

• Ground to Ground

3.5.5 Wiring the Overfill Alarm Field Wiring

Figure 3-6: Shows the Overfill Alarm Field Wiring from the VST Control Panel to the Fuel Management

System

1. The VST Control Panel supplies 24 VDC to an overfill alarm relay.

2. The overfill alarm output relay is a “dry” relay (N.O.) that shuts down the GREEN MACHINE

when a UST reaches the Overfill Level volume during a fuel drop.

3. Install two wires from the VST Control Panel to the Fuel Management System Overfill Alarm

(N.O.) output relay. (Refer to the Fuel Management System Installation Manual for connecting and configurating the correct relay. Programming of the Overfill Relay will be completed by other.)

a. TLS-350 or equivalent Overfill Alarm Relay Circuit. b. Connect to the COMM Bay, 4-Relay Module

• 24 VDC (+) to wire number 02092

• 24 VDC (0) to wire number 04051

c. TLS-450 PLUS or equivalent Overfill Alarm Relay Circuit d. Connect to the Module Bay, I/O Module

• 24 VDC (+) to wire number 02092

• 24 VDC (0) to wire number 04051

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 56

3.5.6 Wiring the VST Control Panel to the GREEN MACHINE

Figure 3-7: Wires from the VST Control Panel to the GREEN MACHINE Internal Junction Box Wiring

Diagram.

1. This drawing is used for wiring from the VST Control Panel to the Internal Junction Box for

the Vacuum Pump Motor, the 5-control valves, and the Pressure Sensor. For Reference.

3.5.7 Wiring the Pressure Sensor

Figure 3-8: Wiring Diagram of the Pressure Sensor.

1. This drawing is used for wiring from the Internal Junction Box to the Pressure Sensor located

inside the GREEN MACHINE cover.

3.5.8 Vacuum Pump Motor Wiring Diagram

Figure 3-9: Wiring Diagram of the Vacuum Pump Motor, 115 VAC, 1-phase, 50-Hz, 1725 rpm.

1. This is the vacuum pump motor wiring diagram and is used to reverse the motor direction if

required.

3.5.9 Applying Power to the VST Control Panel

After all the wiring connections listed below are completed and checked, power can be turned ON at the VST Control Panel. The following items have been installed and wired:

1. VST Control Panel

2. Emergency shut‐Off Relay

3. Overfill Alarm Relay

4. GREEN MACHINE Internal Junction Box

5. Pressure Sensor

6. Safety Disconnect Switch

7. Outlet

After power is turned ON to the VST Control Panel, the Main Screen will show

GM DISABLED – ENTER CODE. This means:

1. The VST Control Panel has power through the Distribution Panel or the ESO Relay.

2. The GREEN MACHINE cannot operate because Testing & Start‐Up has not been completed.

3. The GREEN MACHINE cannot be started by the Electrical Contractor.

4. See Figure 3‐1: VST Control Panel – GM Disabled – Enter CODE Main Screen

Before turning OFF power the VST Control Panel, check to make sure there are no GREEN MACHINE Alarms.

1. On the Main Screen, push the Faults & Alarms soft button. This will bring up the Alarms Screen.

2. All the items on the screen should be Green, indicating there are no alarms present. a. Pressure Sensor Alarm b. Vacuum Pump Alarm c. Maint. Switch Alarm (Make sure the Maint. Switch on the front of the Control Panel is turned

ON)

d. Overfill Alarm e. SD Card Alarm

3. If an Alarm is present, call Vapor Systems Technologies at 937-704-9333 for instructions.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 57

CAUTION: TURN OFF POWER TO THE VST CONTROL

PANEL AT THIS TIME.

The power to the VST Control Panel will be turned

ON AGAIN during the GREEN MACHINE

Post Installation Start-Up.

Figure 3-1: VST Control Panel - GM Disabled - Enter CODE Main Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 58

Figure 3-2: GREEN MACHINE Installation Overview Option 1

Option 1

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 59

Figure 3-3: The Control Panel Power and ESO Connections Option 1

Option 1

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 60

Figure 3-4: The GREEN MACHINE Installation Overview Option 2

Option 2

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 61

Figure 3-5: The Control Panel Power Connection Option 2

Option 2

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 62

Figure 3-6: The VST Control Panel Field Wiring

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 63

Figure 3-7: GREEN MACHINE Internal Junction Box Field Wiring

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 64

Figure 3-8: Pressure Sensor Wiring Diagram

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 65

Figure 3-9: Vacuum Pump Motor Wiring Diagram

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 3: Electrical Page 66

This page left intentionally blank.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 67

Chapter 4: Control Panel

4 VST Control Panel Overview

•

The VST Control Panel is designed to manage the operations of the GREEN MACHINE based on UST vapor pressure. Figure 4-1 shows the front of the Control Panel with the following items:

•

The VST Control Panel is what controls the GREEN MACHINE.

•

The GREEN MACHINE will turn ON if the UST pressure is above 0.20 IWC.

•

The GREEN MACHINE will operate until the UST pressure falls below 0.20 IWC.

•

The Power Switch (Lockable):

•

Provides a means to disconnect ALL power from the VST Control Panel and ALL power to the GREEN MACHINE.

•

The Power Switch can be locked in the OPEN or CLOSED position. (Use lock-out/tag-out procedures.)

•

The Maintenance Switch (Lockable)

•

Turning the Maint. Switch OFF will disconnect ALL power from the GREEN MACHINE.

•

Turning the Maint. Switch OFF will keep power ON to the VST Control Panel and to the GREEN MACHINE Controller.

•

Turn the Maint. Switch ON for normal GREEN MACHINE Operation.

Figure 4-1: VST North America Control Panel, Front View

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 68

4.1 Main Screen Overview

• The Control Panel PLC will always power up in the Main Screen. See Figure 4-2.

• The GREEN MACHINE will always be in the Normal Operating mode when the Main

Screen is showing on the PLC, unless there is an Alarm Condition.

• GM Status:

•

Normal (Green Box) indicates the GREEN MACHINE is operating normally (no active Alarms).

•

Alarm (Red Box) indicates an Alarm is active.

• Date and Time:

•

Push the Date and Time soft button to change the Date and Time.

• Maintenance Screen and an Alarm Screen:

•

Push the Maintenance Screen soft button to access the Maintenance Screen.

•

A password (878) is required to access the Maintenance Screen.

•

Push the Alarm Screen soft button to access the Alarm Screen.

Figure 4-2: Main Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 69

GREEN MACHINE Messages:

GREEN MACHINE – Running:

Due to the UST pressure being greater than 0.20 IWC (Blue Text Box).

GREEN MACHINE – Idle:

Due to the UST pressure being less than 0.20 IWC (Blue Text Box).

GREEN MACHINE – Alarm:

Go to the Alarm Screen to identify the Alarm: An Alarm has activated. (Red Text Box) See the Operator Instruction Sheet for directions.

Displayed Data:

UST Pressure (IWC):

Displays the UST pressure in real-time.

Run Cycles:

Displays the number of GREEN MACHINE completed cycles.

Date and Time

Date (MM/DD/YY) and 24-Hour Clock (HH:MM:SS).

4.2 Maintenance Screen Overview

Figure 4-3: Maintenance Screen Overview

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 70

Maintenance Screen, continued…

•

When the Maintenance Screen is shown, the GREEN MACHINE will always be in the OFF mode (unless the Manual ON button is pushed or testing is being conducted). See Figure 4-3.

•

The UST Pressure is displayed as Inches of Water (IWC).

•

The GREEN MACHINE can be placed in the Manual ON or Manual OFF mode only in the Maintenance Screen.

•

This feature is used when conducting maintenance on the GREEN MACHINE.

•

Vac Pump Bump is used to check the vacuum pump motor rotation during start-up or after performing maintenance on the vacuum pump motor.

•

The Reset Motor Alarm is used when the Vacuum Pump is in Alarm.

•

Function Button labels are shown at the bottom of the screen.

•

The F1, F2, F3, F4 Function buttons and the ESC button are accessible

•

F1: Start a Leak Test

•

F2: Start a Functionality Test

•

F3: NOT USED

•

F4: Stops all testing and returns to the Maintenance Screen in the OFF Mode.

•

Pushing the ESC button stops all testing and returns to the Main Screen to the Normal Operating Mode.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 71

4.3 Alarm Screen Overview

Figure 4-4: Pressure Sensor Alarm shown on the Alarm Screen

The Alarm Screen shows the following - See Figure 4-4:

•

GM Status

•

Normal (Green Box) indicates the GREEN MACHINE is operating normally (no active Alarms).

•

Alarm (Red Box) indicates an Alarm is active. When an Alarm is active, see Chapter 10, the Operator Instruction Sheet, for directions.

•

Pressure Sensor Alarm:

•

An Alarm will occur:

•

When the Pressure Sensor is not connected to the Control Panel.

•

When the Pressure Sensor is not wired properly at the Control Panel or at the GREEN MACHINE Internal Junction Box.

•

The GREEN MACHINE will NOT operate during this Alarm.

•

Vacuum Pump Alarm:

•

An Alarm will occur:

•

When there is a problem with the vacuum pump, motor, or circuit.

•

The GREEN MACHINE will NOT operate during this Alarm.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 4: Control Panel Page 72

Alarm Screen, continued…

•

Maintenance Switch Alarm:

•

The Maintenance Switch is used when we want power to the VST Control Panel, but do not want the GREEN MACHINE to operate.

•

The GREEN MACHINE will not operate during this alarm.

•

The Maintenance Switch Alarm will occur:

•

When the Maintenance Switch is turned OFF, the GREEN MACHINE will not operate and the switch will show as an active alarm.

•

To remove the Maintenance Switch Alarm, turn the switch to ON.

•

Overfill Alarm:

•

An Alarm will occur:

•

Whenever there is a UST gasoline overfill at the station, the VST Control Panel is configured to alarm.

•

If an overfill alarm activates while a test is running:

•

The test will terminate.

•

The Alarm will display RED, OVERFILL ACTIVE.

•

The GREEN MACHINE will NOT operate during this Alarm.

•

SD Micro Card Alarm:

•

An Alarm will occur:

•

If the card is not installed or installed incorrectly.

•

After the card is installed, the Alarm will clear and Normal (Green).

•

The GREEN MACHINE will operate during this Alarm.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 5: Intentionally Blank Page 73

Chapter 5: OPEN: NO CONTENT

5 Left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 5: Intentionally Blank Page 74

Left intentionally blank

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing & Startup Page 75

Chapter 6: Testing & Start-Up

6 Post-Installation GREEN MACHINE Testing & Start Up

6.1 VST Control Panel Initial Start-Up Power:

When the power is turned ON to the VST Control Panel, the Main Screen will show on the PLC with the label GM DISABLED – ENTER CODE. See Figure 6-1. The CODE was initiated to prevent the electrical contractor from starting the GREEN MACHINE before the Start-Up was completed. The Start-Up can be completed with the GM DISABLED. The CODE to the VST Control Panel must be entered before the GREEN MACHINE can become operational. The CODE will be supplied to the Start-Up Contractor via e-mail after Appendix B is submitted online.

Figure 6-1: Main Screen with the GM DISABLED – ENTER CODE

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing & Startup Page 76

6.2 Before beginning the Testing and Start-Up procedures

Follow the steps below to prepare the GREEN MACHINE and VST Control Panel for Testing & Start-Up

STEPS

DESCRIPTION

Unlock the hasps and remove the cover on the GREEN MACHINE.

Close the 3-way valve below the Pressure Sensor (the handle is horizontal).

Close the three (3) ball valves between the GREEN MACHINE and the vent risers. Reference Figure 6-2.

Remove the caps from the 3 tees. Reference Figure 6-2.

Turn ON the GREEN MACHINE breaker at the Main Distribution Panel OR power is provided by the ESO Relay.

Turn the Power Switch to the “ON” position located on the front of the Control Panel.

At the PLC Main Screen, push the Maintenance Screen button to access the Password Screen.

Enter 878 at the Password Screen to access the Maintenance Screen. (The GREEN MACHINE will now be in the Manual OFF mode.)

Make sure the Maintenance Switch is ON at the VST Control Panel. (The GREEN MACHINE cannot operate in the Automatic Mode when the Maintenance Screen is showing regardless of the UST pressure.)

6.3 Post Installation Start-Up Tests

During post-installation testing, the GREEN MACHINE will use outside air (no gasoline vapor from the USTs) to conduct these tests.

The following tests must be conducted in the order shown below to avoid damage to the equipment.

6.4 Bump Test

6.5 Functionality Test

6.6 Programming the Fuel Management System for the GREEN MACHINE Overfill Alarm

Relay

6.7 Test the Overfill Alarm on the GREEN MACHINE VST Control Panel:

6.7.1 The TLS-350 Overfill Alarm Connection

6.7.2 The TLS-450 Overfill Alarm Connection

6.7.3 The TLS-450 PLUS Overfill Alarm Connection

6.8 Changing the Date and Time Procedure

6.9 Submitting Appendix B and Verification CODE Retrieval

The final step in the installation process is to start up the GREEN MACHINE and get it field commission ready. This final commissioning process requires a verification code that will be entered into the PLC.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing & Startup Page 77

How to get a verification code:

Go to www.vsthose.com

Click on VST Education

Under “North America GREEN MACHINE,” Click on “Supporting Documents and Instructional Video”

Click on “Start-Up/Commissioning Contractor.”

Click on “Appendix B – Start-Up Contractor Check Out Form.”

Fill out and submit Appendix B with the required photos.

Receive an email from VST with the Verification CODE and a copy of the filled out Appendix B

These items are to be checked in Appendix B as they are completed.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 78

Figure 6-2: Vapor Piping Overview

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 79

6.4 Bump Test

6.4.1 Purpose of the Bump Test

The purpose of the Bump Test is to ensure that the Vacuum Pump Motor is rotating in the correct direction when the GREEN MACHINE is running.

•

Damage will occur to the vacuum pump if it rotates in the wrong direction.

6.4.2 Preparation for the Bump Test

Make sure the Maintenance Screen is showing on the PLC. See Figure 6-3. (The GREEN MACHINE is now in the Manual OFF mode and will not operate.)

If the PLC is not in the Maintenance Screen: At the Main Screen, push the Maintenance Screen button to access the Password Screen then enter the password to access the Maintenance Screen: Password is 878.

One person needs to be at the VST Control Panel to begin the Bump Test.

A second person needs to be at the GREEN MACHINE when the Motor Bump Test begins.

After the test is started, the motor will rotate for 5-seconds, which will allow the person at the GREEN MACHINE to check the rotation of the motor.

Figure 6-3: Maintenance Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 80

6.4.3 Bump Test Procedure

At the Maintenance Screen, push the Vac Pump Bump button to go to the Bump Motor Confirmation Screen. See Figure 6-3.

At the Bump Motor Confirmation Screen, push the red Confirm Motor Bump button to start the vacuum pump motor rotation. Then cancel the Bump Motor; push the green button to return to the previous screen. See Figure 6-4.

The Vacuum Pump Motor will rotate for 5-seconds, which is just enough time for the second person at the GREEN MACHINE to check the motor rotation. The motor rotation is indicated by a directional arrow on the pump.

If the motor is rotating in the correct direction, the test is completed.

If the motor is not rotating in the correct direction, switch two of the motor wires, T5 and T8, at the Vacuum Pump Motor Junction Box. See Figure 6-5.

After changing the motor leads, run the Bump Test again to make sure the Vacuum Pump Motor is rotating in the correct direction.

When the test is completed, the PLC will show the Main Screen.

Figure 6-4: Bump Confirmation Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 81

Figure 6-5: Vacuum Pump Motor Wiring Diagram

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 82

6.5 Functionality Test

6.5.1 The Purpose of the Functionality Test

The purpose of the Functionality Test is to verify that the Control Panel, Vacuum Pump, and the Control Valves are working properly.

6.5.2 Preparation for the Functionality Test

At the VST Control Panel, make sure the Maintenance Screen is showing on the PLC. See Figure 6-6. (The GREEN MACHINE is now in the Manual OFF mode and will not operate.)

If the PLC is not in the Maintenance Screen: At the Main Screen, push the Maintenance Screen button to access the Password Screen, then enter the password to access the Maintenance Screen: Password is 878.

At the GREEN MACHINE, make sure the locks from the three ball valves have been removed, all three valves are closed, and the caps from the three tees have been removed. See Figure 6-7.

Unlock the hasp and remove the cover from the GREEN MACHINE.

Close the 3-way valve below the Pressure Sensor so the handle is turned HORIZONTAL (OFF or Closed). Leaving the valve ON or Open during this test may damage the Pressure Sensor.

Figure 6-6: Maintenance Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 83

Figure 6-7: GREEN MACHINE Vapor Piping Layout

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 84

6.5.3 Functionality Test Procedures

Push the F2 button to access the Functionality Test Screen. See Figure 6-8.

To start the Functionality Test, push the Start Button.

Push the Confirm Functionality Test Button to confirm you would like to start the Functionality Test. See Figure 6-9.

The GREEN MACHINE will Run for 60-seconds then Purge for 60-seconds (this is one cycle).

The GREEN MACHINE will continue to cycle 5-times or until the F4 button is pushed to end the test.

• There are 5-cycles to provide enough time to conduct the test.

• Pushing the F4 button will return the system to the Maintenance Screen and the

GREEN MACHINE will be in the OFF mode.

When the test has ended, the VST Control Panel PLC will display GREEN MACHINE OFF.

During the 60-second Run mode: See Figure 6-10.

• Place your hand over the tee opening at the Vapor Inlet and feel for suction.

• Next, place you hand over the tee opening at the Vapor Return and feel for zero

airflow.

• Next, place your hand over the tee opening at the Air Outlet and feel for air blowing.

During the Run cycle:

Suction at the Vapor inlet:

NORMAL

Air blowing out the Air Outlet:

NORMAL

No air blowing/suction at the Vapor Return:

NORMAL

All other blowing or suction conditions at each location, check the following items:

•

Make sure the Vacuum Pump is not in alarm. If so, see Chapter 8: Troubleshooting, Section 8.6.

•

Check the Control Valves to make sure they are all operational. See Chapter 8: Troubleshooting, Section 8.6.1, Step 5:

•

Make sure there is no debris in the valve seat. Clean the valves as shown in Section 7.5: Cleaning the Control Valves.

•

Make sure the flare nuts are tight. Check each 45° flare nut to make sure they are snug but not over tightened.

During the 60-second Purge cycle: See Figure 6-10.

• After the Purge cycle has begun, place your hand over the tee opening at the Vapor

Return and feel for air blowing. The blowing air will reduce to zero flow soon after the Purge cycle begins.

• Next, place your hand over the tee opening at the Vapor Inlet and feel for zero

airflow.

• Next, place your hand over the tee opening at the Air Outlet and feel for zero

airflow.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 85

Functionality Test, continued…

10.

During the Purge cycle:

No air blowing/suction at the Vapor Inlet:

NORMAL

No air blowing/suction at the Air Outlet:

NORMAL

Momentary blowing at the Vapor Return:

NORMAL

All other blowing or suction condition at each location:

•

Make sure the Vacuum Pump is not in alarm. If so, see Chapter 8: Troubleshooting.

•

Check the Control Valves to make sure they are all operational. See Chapter 8: Troubleshooting:

•

Make sure there is no debris in the valve seat. Clean the valves as shown in Chapter 7: Maintenance.

•

Make sure the flare nuts are tight. Check each 45° flare nut to make sure they are snug but not over tightened.

11.

After the Functionality Test has ended:

• The PLC will automatically go back to the Maintenance Screen and will remain in the

OFF mode.

• Lock open the three ball valves between the GREEN MACHINE and the Vent Risers,

and replace the caps on the three tees.

• CAUTION: Make sure the 3-way valve below the Pressure Sensor is turned

VERTICAL (ON or Open). Leaving the valve turned OFF at the Pressure Sensor will not allow the GREEN MACHINE to operate in the Normal Operating Mode.

• At the PLC, push the ESC button to return to the Main Screen.

Figure 6-8: Functionality Test Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 86

Figure 6-9: Functionality Test Confirmation Button

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 87

Figure 6-10: GREEN MACHINE Operation Diagram

6.6 Programming the Fuel Management System Overfill Alarm Relay for the

GREEN MACHINE

OVERFILL ALARM RELAY CIRCUIT

•

The Electrical Contractor has installed the Overfill Alarm signal wiring from the VST Control Panel to the “Fuel Management System Overfill Alarm” output module.

•

The VST Control Panel supplies 24 VDC to the Overfill Alarm relay.

•

The Overfill Alarm output “dry” relay (N.O.) shuts down the GREEN MACHINE when a UST reaches the Overfill Level (90%) during a fuel drop.

•

Label the Overfill relay “GM Overfill Alarm.”

•

The wiring from the VST Control Panel to the Fuel Management System MUST be installed before the Start-Up of the GREEN MACHINE can be complete.

•

Reference Overfill terminal block wire numbers:

• 24 VDC (+) – (Wire Number 02092)

• 24 VDC (0) – (Wire Number 04051)

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 88

6.7 Testing the Overfill Alarm on the GREEN MACHINE VST Control Panel

6.7.1 TLS-350 Overfill Alarm Test

•

This procedure will test the connection from the TLS-350 to the VST Control Panel.

•

The VST Control Panel may or may not be wired/connected to the TLS-350 Overfill Alarm relay as outlined Chapter 3: Electrical Installation.

•

When an Overfill occurs, the Overfill relay closes which completes a 24 VDC circuit to the VST Control Panel. The GREEN MACHINE will remain OFF two hours after the Overfill Alarm clears.

Procedures:

At the TLS-350, Press MODE until the screen reads SETUP MODE.

Press FUNCTION until the screen reads OUTPUT RELAY SETUP.

Press the PRINT button to print a list of output relays, then read the printout and identify the relay number associated with the OVERFILL for the GREEN MACHINE.

Figure 6-11 shows the GREEN MACHINE OVERFILL relay as relay number 2.

Press MODE to return to ALL FUNCTIONS NORMAL screen.

At the ALL FUNCTIONS NORMAL screen, press FUNCTION until the screen reads TEST OUTPUT RELAYS.

Press the STEP button until the screen reads TEST OUTPUT RELAYS ENTER RELAY NUMBER 0.

Press the number on the keypad that corresponds to the relay assigned to the GREEN MACHINE output relay, then push ENTER.

The screen should read R X: GM OVERFILL PUSH ALARM/TEST KEY.

10.

Press RED ALARM/TEST button to activate the GREEN MACHINE Overfill relay.

11.

If the Overfill Alarm is active, the wiring of the Overfill Relay and the Overfill programming is correct. After two hours, the Overfill Alarm will clear.

12.

If the Overfill Alarm is NOT active, contact the General Contractor or the electrical contractor to correct the wiring from the VST Control Panel to the TLS-350 Overfill relay, then conduct the test again until the test passes and the Overfill Alarm is active on the VST Control Panel PLC.

13.

After the test is concluded, press the MODE button at the TLS-350 until the screen reads ALL FUNCTIONS NORMAL.

14.

The Test has passed and is concluded. The GREEN MACHINE will remain OFF for two hours after the test is completed.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 89

6.7.2 TLS-450 Overfill Alarm Test

•

The Overfill Relay and VST Control Panel Check is used to test the TLS-450 Overfill Relay as it is connected to the VST Control Panel. When the Overfill relay is active, the VST Control Panel will not allow the unit to operate.

•

This test sets selected relays to INACTIVE for two seconds and then sets them to ACTIVE for two seconds. When the test is complete the relays are automatically reset to their original state.

Procedures:

At the TLS-450 Home Screen, select the Diagnostic button to access the Diagnostic Screen.

At the TLS-450 Diagnostic Home Screen, select the Relay and Input button to access the Relay & Input Screen.

At the Relay & Input Screen, select the Test Relay to conduct the Sequential Testing Procedure.

Check the box for the Overfill relay connected to the VST Control Panel.

For the selected relay the system will perform the following sequence:

5.1

Save State: The current relay state will be saved before a test is run on the specific relay.

5.2

Highlight Relay: For the relay being tested, the screen will highlight that relay during its test.

Figure 6-11: Output Relay Setup

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 90

TLS 450 Overfill Alarm Test, continued…

5.3

Deactivate Relay: The relay being tested will be put in an Active state for two seconds and the status of the relay on the screen will be set to Sw Test.

5.4

Activate Relay: The relay being tested will be put in an Active state for two seconds and the status of the relay on the screen will be set to Sw Test.

5.5

Reset Relay: Once the test is complete, the relay will be returned to its original status which was saved at the beginning of the test and will no longer be highlighted.

5.6

Test Completion: Touch the selected Overfill Relay to deselect it or close the screen.

After the test is complete, check the VST Control Panel PLC to make sure the Overfill Alarm is active.

If the Overfill Alarm is active, the wiring of the Overfill Relay and the Overfill programming is correct. After two hours, the Overfill Alarm will clear.

If the Overfill Alarm is NOT active, contact the General Contractor or the electrical contractor to correct the wiring from the VST Control Panel to the TLS-450 Overfill relay, then conduct the test again until the test passes and the Overfill Alarm is active on the VST Control Panel PLC.

6.7.3 TLS 450 Plus Overfill Alarm Test

Procedures:

At the TLS-450 Plus Home Screen, select the Diagnostic button to access the Diagnostic Screen.

At the Diagnostic Screen, select the Relay and Input button to access the Relay & Input Screen.

At the Relay & Input Screen, select the Relay button to access the Relay Diagnostics Screen.

Check the Relay number that is connected to the VST Control Panel.

Push the Action button, then push the Activate Relays buttons. After the Activation button is pushed, the Relay Screen will show again.

If the Overfill Alarm is active, the wiring of the Overfill Relay and the Overfill programming is correct. After two hours, the Overfill Alarm will clear.

If the Overfill Alarm is NOT active, contact the General Contractor or the electrical contractor to correct the wiring from the VST Control Panel to the TLS-450 Plus Overfill relay, then conduct the test again until the test passes and the Overfill Alarm is active on the VST Control Panel PLC.

At the TLS, push the Action button, then push Finish Test.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 91

TLS 450 Plus Overfill Alarm Test, continued…

Deselect the Relay # □ that is connected to the VST Control Panel.

10.

Push the Home button to conclude the Overfill Alarm Test

6.8 Changing the Date and Time Procedure

6.8.1 Changing the Date and Time Procedure

From the Main Screen, push the Date and Time soft button. This will bring up the Date and Time Interface Screen. See Figure 6-12.

On the Date and Time Interface Screen, insert the Date: (MM/DD/YY) then the Time: (HH:MM:SS). Use the ARROW keys to move from left or right if a number is not correct. The Time is a 24-hour format so 1:00 PM is set at 13:00 hours. See Figure 6-13.

After the Date and/or Time has been set, push Return button to accept the change(s) and return to the Main Screen.

After returning to the Main Screen, check to see if the Date and Time are correct.

Figure 6-12: Main Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 92

Figure 6-13: Time & Date

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 93

6.9 Submitting Appendix B to VST for the Verification CODE

6.9.1 Start Up of the GREEN MACHINE

Go to www.vsthose.com

Click on VST Education

Under “North America GREEN MACHINE,” Click on “Supporting Documents and Instructional Video”

Click on “Start-Up/Commissioning Contractor.”

Click on “Appendix B – Start-Up Contractor Check Out Form.”

Fill out and submit Appendix B with the required photos.

Receive an email from VST with the Verification CODE and a copy of the filled-out Appendix B

6.9.2 Procedures

Apply power to the VST Control Panel

The PLC starts up in the Main Screen where the GREEN MACHINE is shown to be DISABLED. See Figure 6-1.

Push the Maintenance button, then enter 878 on the Password Screen to go to the Maintenance Screen.

Using Chapter 6: Testing and Start-Up, complete the following sections:

Chapter 6 Sections for Reference:

Section

Title

6.4

Conduct the Bump Test

6.5

Conduct the Functionality Test

6.6

Programming the Fuel Management System Overfill Relay for the GM Overfill Alarm

6.7

Conduct the Overfill Alarm Test

6.8

Change the Date/Time per the time-zone

6.9

How to submit Appendix B to VST to obtain the Verification CODE

Complete Appendix B Checklist Form, then push the SUBMIT button. (All the fields contained in Appendix B MUST BE CHECKED OR FILLED OUT, INCLUDING PICTURES.

An email with the Verification CODE is sent to the person conducting the Start-Up after Appendix B is SUBMITTED to VST.

On the Maintenance Screen, push the Function Buttons F1 & F2 at the same time to bring up the Password Screen to enter the Verification CODE.

Push the large button with 000000 showing. See Figure 6-14.

At the Verification CODE Screen, enter the CODE that was received in the email, then push ENTER.

See Figure 6-15.

If the correct CODE was entered, the PLC will show the Main Screen and the GREEN MACHINE will now be operational.

10.

If the incorrect CODE is entered, the Verification CODE Screen will show WRONG! Push the large button again and enter the correct Verification CODE.

11.

Once the correct Verification CODE is entered, the PLC returns to the Main Screen and the GREEN MACHINE is now fully operational.

12.

Function Buttons F1 & F2 will no longer work

13.

At the Main Screen, the GREEN MACHINE will turn ON if the UST pressure is at or above 0.20 IWC, or remain OFF if the UST pressure is below 0.20 IWC.

14.

The GREEN MACHINE:

• Is Operational

• Start-Up is complete and verified

• The Overfill protection is installed and tested

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 6: Testing and Startup Page 94

Figure 6-14: VERIFICATION CODE screen

Figure 6-15: Enter the Verification CODE screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 95

Chapter 7: Maintenance Procedures

7 Maintenance Overview

• VST recommends conducting Maintenance on the GREEN MACHINE annually to make sure all

the components are in good working order. If the annual maintenance is not conducted, there is a possibility the GREEN MACHINE may not be operating properly.

• The Vacuum Pump and Control Valves are the only components with moving parts in the GREEN

MACHINE; therefore, it requires very little maintenance.

• All replacement parts must be from VST’s recommended replacement parts list located in

Chapter 9: Replacement Procedures Section.

• If the GREEN MACHINE is not functioning properly consult Chapter 8: Troubleshooting Section to

determine which component may need to be repaired or replaced.

• Sections that will be covered in this Chapter:

7.1

Maintenance Procedures

7.2

Recommended Replacement Parts

7.3

Functionality Test

7.4

Pressure Sensor Verification Test

7.5

Rubber Flange Sleeve Replacement

7.6

Cleaning the Control Valves

7.7

Check the Air Outlet for Liquid Condensation

7.8

Separator Check Procedure

7.1 Maintenance Procedures

At the VST Control Panel Main Screen, check to make sure there are no alarms. See Figure 7-1.

If there are alarms, repair the item causing the alarm (See Chapter 8: Troubleshooting) before proceeding.

VST has recommended spare parts that might be needed when conducting Maintenance. See Section 7.2.

Conduct a Functionality Test: See Section 7.3. The Functionality Test will verify the GREEN MACHINE is operating properly.

• If the Functionality Test Passes, go to Step 3.

• If the Functionality Test does not Pass (See Chapter 8: Troubleshooting Procedures)

Conduct a Pressure Sensor Verification Test: See Section 7.4.

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 96

Maintenance Procedures, continued…

Rubber Flange Sleeve Replacement Procedure: See Section 7.5. To keep the GREEN MACHINE operational, replace the rubber flange sleeve yearly.

Cleaning the Control Valves: See Section 7.6. Cleaning the control valves will reduce valve noise. Check the valve components for wear and damage and keep the valves operational for a longer period of time.

Check the Air Outlet for Liquid Condensate: See Section 7.7. Check annually for liquid condensate in the air outlet pipe.

Check the Separator for debris: See Section 7.8.

Figure 7-1: VST PLC Main Screen w/no alarms

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 97

7.2 Recommended Replacement Parts

VST recommends the ASC bring the parts shown in the table below for replacement parts. The entire list of GREEN MACHINE replacement parts can be found in Chapter 9: Replacement Procedures.

Ref. #

Description

Part No.

Quantity

Manuf.

VACUUM PUMP MOTOR (ONLY), 115VAC, SINGLE-PHASE

GM-027

VST

MODEL 2 VACUUM PUMP (ONLY)

GM-022

1 3 RUBBER FLANGE SLEEVE

GM-004

1 4 CONTROL VALVES – CORE REBUILD KIT

GM-006

5 5 PRESSURE SENSOR

GM-015

1 6 SEPARATOR

GM-049

Figure 7-2: Maintenance Replacement Parts

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 98

7.3 Functionality Test

7.3.1 The Purpose of the Functionality Test

The purpose of the Functionality Test is to verify that the Control Panel, Vacuum Pump, and the Control Valves are working properly.

7.3.2 Preparation for the Functionality Test

At the VST Control Panel, make sure the Maintenance Screen is showing on the PLC. See Figure 7-3. (The GREEN MACHINE is now in the Manual OFF mode and will not operate.)

At the GREEN MACHINE, make sure the locks from the three ball valves have been removed, all three valves are closed, and the caps from the three tees have been removed. See Figure 7-4.

Unlock the hasp and remove the cover from the GREEN MACHINE.

Close the 3-way valve below the Pressure Sensor so the handle is turned HORIZONTAL (OFF or Closed). Leaving the valve ON or Open during this test may damage the Pressure Sensor.

Figure 7-3: Maintenance Screen

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 99

Figure 7-4: GREEN MACHINE Vapor Piping Layout

4.5 - GREEN MACHINE™ - North America - Installation, Operation, Maintenance, & Troubleshooting Manual

Chapter 7: Maintenance Procedures Page 100

7.3.3 Functionality Test Procedures

Push the F2 button to access the Functionality Test Screen. See Figure 7-5.

To start the Functionality Test, push the Start Button.

Push the Confirm Functionality Test Button to confirm you would like to start the Functionality Test. See Figure 7-6.

The GREEN MACHINE will Run for 60-seconds then Purge for 60-seconds (this is one cycle).

The GREEN MACHINE will continue to cycle 5-times or until the F4 button is pushed to end the test.

• There are 5-cycles to provide enough time to conduct the test.

• Pushing the F4 button will return the system to the Maintenance Screen and the

GREEN MACHINE will be in the OFF mode.

When the test has ended, the VST Control Panel PLC will display GREEN MACHINE OFF.

During the 60-second Run mode: See Figure 7-7.

• Place your hand over the tee opening at the Vapor Inlet and feel for suction.

• Next, place you hand over the tee opening at the Vapor Return and feel for zero

airflow.

• Next, place your hand over the tee opening at the Air Outlet and feel for air blowing.

During the Run cycle:

Suction at the Vapor inlet:

NORMAL

Air blowing out the Air Outlet:

NORMAL

No air blowing/suction at the Vapor Return:

NORMAL

All other blowing or suction conditions at each location, check the following items:

•

Make sure the Vacuum Pump is not in alarm. If so, see Chapter 8: Troubleshooting, Section 8.6.

•

Check the Control Valves to make sure they are all operational. See Chapter 8: Troubleshooting, Section 8.6.1, Step 5:

•

Make sure there is no debris in the valve seat. Clean the valves as shown in Section 7.5: Cleaning the Control Valves.

•

Make sure the flare nuts are tight. Check each 45° flare nut to make sure they are snug but not over tightened.

During the 60-second Purge cycle: See Figure 7-7.

• After the Purge cycle has begun, place your hand over the tee opening at the Vapor

Return and feel for air blowing. The blowing air will reduce to zero flow soon after the Purge cycle begins.

• Next, place your hand over the tee opening at the Vapor Inlet and feel for zero

airflow.

• Next, place your hand over the tee opening at the Air Outlet and feel for zero

airflow.

VST GREEN MACHINE VST-GM-CS2-101 Installation, Operation, Maintenance, & Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual